GENERIC METHODOLOGY FOR

ERECTION &INSTALLATION OF SUGAR

FACTORY

METEC
DATE
19/2/2012

PREPARED BY
CORPORATE PROJECT MANAGEMENT-

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1. CONSTRUCTION METHODOLOGY OF CIVIL WORKS
1.1. INTRODUCTION
1.2. CIVIL WORK METHODOLOGY
1.2.1. SITE CLEARANCE
1.2.2. EXCAVATION
1.2.2.1. BULK EXCAVTION
1.2.2.2. PIT EXCAVTION
1.2.3. BACKFILINIG WORK
1.2.4. STONE MASONRY FOUNDATION
1.2.5. STRUCTURAL STEEL (REINFORCEMENT ) WORK :
1.2.6. CONCRETE AND ALLID WORKS FOR SUB-STRUCTURE
2. ELECTRO MECHANICAL INSTALLATION METHEDOLGY
2.1. MECHANICAL EQUIPMENT INSTALLATION
2.1.1. INTRODUCTION
2.1.2. GENERAL GUIDELINE FOR EQUIPMENT INSTALATION
2.1.3. PLANT COMMISSIONING PROGRAM
2.1.3.1. METHOD FOR DEFING COMMISSIONING TEST
2.1.3.2. SCOPE OF PLANT COMMISSIONING PROGRAM
2.1.3.2.1. PRE- OPERATIONAL TEST
2.1.3.2.2. INITIAL START -UP TEST
2.2. ELECTRICAL SYSTEM INSTALLATION
2.2.1. Introduction
2.2.2. Objective
2.2.3. Codes &standards
2.2.4. Scope
2.2.5. Planning &Scheduling of the projected
2.2.6. Material Handling Methodology
2.2.7. Project Team Preparation
2.2.8. Material Transportation And Delivery
2.2.9. Mobilization of Project Team And Machinery

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2.2.10. General Safety
2.2.11. Installation of HV/LV system
2.2.11.1. Installation of high voltage (HV) system
2.2.11.2. Installation of high voltage (LV) system
2.2.12. Methodology for Electrical Equipments
2.2.13. Generator Assembling /Erection Procedures
2.2.13.1. Installation of Turbine & Generator System
2.2.13.2. Installation of Water and Steam Line System
2.2.13.3. Connecting Electrically /Pneumatically Activated Controls
2.2.14. Substation (Switch Yard ) Erection
2.2.15. Installation of protection
2.2.15.1. Fire alarm system installation
2.2.15.2. Earthling System Installation
2.2.15.3. Lightening Protection System Installation
2.2.16. Testing And Commissioning
2.2.17. Project Energizing And Site Hand Over

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 1.1. INTRODUCTION
Construction Methodology: in these section only the methodology of civil works are covered and sub
divided as follows:

Site clearance
Earth Work (Including Borrow Production )
Concrete And Allied Works For Sub- Structure
Structural Steel (Reinforcement ) Work :

SCOPE

This Construction Methodology describes the methods. Equipment and labor resources the contractor
intends to employ, as well as the duration of the resources utilization, for the execution of the major
activities. The methodology is expected to provide a summary and explanation that would be taken to
smoothly execute the project.

General description of the major project activities within the above major sections are covered by Work
Methodology.

MOBILIZATION AND SITE ESTABLISHMENTS

During mobilization period, the task of acquiring of unrestricted access to site and selection of
camp site is to be carried out. The project management staff consisting of project manager,
office engineer, material engineer, laboratory technician, surveyor, and site superintendent will
mobilize soon after issuance of notice to commence.

All necessary machineries and equipment will be mobilized during the mobilization period.

It is planned to establish temporary facilities in the vicinity of the project area. Layout of the
camp drawings for the various blocks shall be prepared and submitted to the client for
approval.

The surveying crew, together with the consultant surveyor, will be engaged in identify in
benchmarks and control points. After confirmation of existence and condition of GPS and BM
points by joint condition survey, handing over of these points will be held .then re-
establishment of bench marks which are damaged or which are in the construction limit will be
done to start main surveying work.

Material engineer and laboratory technicians will be engaged in search of borrow and quarry
sites for local construction material.

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1.2. CIVIL WORKS METHODOLOGY
1.2.1. SITE CLEARANCE

Any obstacles, including the stumps of trees to a minimum of 60cm below ground
level or 150 cm below foundation level whichever is lower, shall be removed. The
area shall be cleared of fences, trees, plants ,logs , stumps, bush ,vegetation ,
rubbish , slush , etc and other objectionable matter. The pits formed due to removal
of uprooted trees shall be bake filled with selected earth material and well
compacted .The materials so removed shall be burnt or disposed off as directed by
the Engineer.

Well ahead of commencement of clearing and grubbing activities, the following

operations will be undertaken under the supervision of the Engineer:

Resurveying of the plant area.

Identification of corners of each block
Getting approval of limit for clearing and grubbing
Arranging disposal site for unsuitable cleared and grubbed materials

The methodology we follow for Site Clearing work shall be the following

1. means of taking the elevation ,angle , alignment of the profile boards ;

Can be achieved by one or combination of: total station. Theodolite,
leveling etc.
2. method of investing physical obstruction ;
This will be achieved together with the material engineer`s consultation.
3. Means of top soil removal ;
This can be achieved by using a bull dozer of required capacity based
the soil property
4. The beginning and ending time of the activity ;
Based on the volume of work we will determine the ending time of the
clearance work after we know the commencement of work.
5. Instant remedy /immediate action to be taken if ,during execution ,unwanted
quality or destruction effect or over looked items , the leveling etc. encountered

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1.2.2. Excavation
All excavation shall be carried out by mechanical excavation unless ,in opinion of
engineer , the work involved and time schedule permit manual work .

Excavation for permanent work shall be carried out to such widths, lengths, and
depths as are shown on the drawing or such other lines and grades as specified by
engineer.

1.2.2.1. Bulk Excavation

The methodology we follow for bulk excavation work is the following :

1. Method of investigating underground physical obstruction ;

This will be achieved together with the material engineer`s
consultation.
2. Disposal distance of the excavated material ;
It is the responsibility of the main contractor to allocate the
area for the spoil.
3. Equipment to be applied for this activity;
Back Hue excavators will be used for bulk excavations
generally
4. The beginning and ending time of the activity;
Based on the volume of work we will determine the ending
time of the bulk excavation work after we know the
commencement of work.
5. Instance remedy /immediate action to be taken if, during excavation,
unwanted quality or destruction effect or over looked items, the
leveling etc. encountered

1.2.2.2. PIT EXCATION WORK

The methodology we follow for Pit Exaction Work shall be the following

1. Method of side wall of pits form falling in:

It is to provide protection to the adjacent structures when excavating to
any appreciable depth.
2. Equipment to be applied for this activity;
Bake hue excavators will be used for bulk excavations generally.

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 3. Beginning of producing appropriate size and quality of concrete
spacers;
Concrete spacers that will be used for footing pads according to the
cover provided on the drawing will be prepared.
4. Method of investing underground physical obstruction
This will be achieved together with the material engineer`s consultation.
5. Way of pre excavation reading:
Can be achieved by one or combination of: total station, Theodolite,
leveling etc.
6. The beginning and ending time of the activity;
Based on the volume of work we will determine the ending time of the
pit execution work after we know the commencement of work and plan
together with the master schedule.
Instant remedy/immediate action to be taken if, during execution,
unwanted quality or destruction effect or over looked items, the leveling
etc. encountered.
1.2.3. BACK FILLING WORK:

In placing backfill and fill, the following precautions and methods will be employed:-

Excavated areas around structures will be backfilled with approved

material in horizontal layers, not exceeding 200mm in depth after
compaction, to the level of the original ground surfaces. Each layer
will be moistened or dried to optimum moisture content for the
material and compacted to a density to a density to the satisfaction
of the Engineer.

The mythology we follow for Back Filling Work shall be the following:
1. Specifying the Back fill material;
The material engineer shall specify the material for backfilling according to the
specification to be followed.
2. Volume of back filling materials;
It is the obligation of the quantity surveyor to determine the volume of material
required for backfill.
3. Method of re checking the reduced level reading;
Can be achieved by one or combination of; total station, the dolente, leveling
etc.
4. Method of sprinkling water;
This can be achieved by using water trucks .

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5. Method of spreading Selected material;
This can be achieved by grader, loader together with man power .
6. Method to protect Sanitary and Electrical pipes during compaction (preferably to be
executed after back filling);
The engineer shall make due notice where sanitary and electrical pipes are
located, and give order to protect them.
7. Compaction Test schedule;
We engineer shall part by part density test on partly completed sections together
with the consultation of the Engineer.
8. The beginning and end of the activity;
Based on the volume of work we will determine the ending time of the backfill
work together with the master schedule.
9. Instant remedy/immediate action to be taken if, during execution, unwanted quality or
destruction effect or over looked items, correction to be made if density tests fail to meet
the requirement of the specification and retaking of the test will be made etc. encountered.

1.2.4. STONE MASONRY FOUNDATION:

The Methodology we follow for Stone Masonry Foundation is as follows:

1. The contractor shall be provided with approved final working drawings
2. Means of protecting trench wall from falling in;
Braced walls using walls &struts
3. Bedding material preferred;
The bedding material shall be as the provision of the working drawing .
4. Method of placing each course to Battered Stone Masonry and to Masonry thicker
than 50 cm.;
5. The proportioning of the courses uniformly throughout the height.
6. Program to take cube tests
The contractor shall cast test cubes every time for new works or for any material
change (either cement or sand) or any time by the order of the engineer.
7. Quality and quantity of mixers;
It`s the duty of the contractor to use qualified mixers both in quality and quantity,
and the engineer should check as the mixer used is according to the specification.
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 8. Submittal of scaffolding design (if needed);
The contractor shall submit scaffolding design for approval if requird.

1.2.5. STRUCTURAL STEEL (REINFORCEMENT) WORK

The methodology we follow STRUCTURAL STEEL (Reinforcement)work, is as follows:

Reinforcement will be bent in accordance with schedules of bars and specified conditions
prior to fixing in position .

Reinforcement bar shall be tested for all requirement (as cleanliness of the bar ,tensile
strength test )
Submittal of form work design;
Check the conformity with approved formwork design i.e. dimension,
Submittal of shop drawing showing Diameter, Spacing, number, length, shape,
method of tying and bending dimension of main reinforcement bar in accordance with
the drawing;
The form work we use shall be mild steel and shall be clean &smooth.
The Method we use to treat the formwork for preventing adherence of concrete
/coating with oil or any other release agent /
Usage of top form work for casting concrete on surface steeper than 20 from
horizontal to enable the concrete to be properly compacted;
During placing and fixing of reinforcement:-

Reinforcement will be placed as shown on the Drawings securely against

displacement during the placement and compaction of the concrete.
Projecting ends of ties or clips will be restrained of encroaching into the concrete
cover.
Where protruding bars are exposed to the elements for an indefinite period the
bars shall be adequately protected against corrosion and damage and shall be
properly cleaned before being permanently encased in concrete.

1.2.6. CONCRETE FOR STRUCTURES

This work covers the manufacture, transport, placing, and testing of concrete used in the
Work.

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The metrology we follow for concrete works is as follows:
1. The contractor shall make sure the availability of aggregate, cement & equipment
for producing the required volume of concrete.
2. The engineer shall submit mix proportion for the mix design, maximum size of
aggregated allowed in the mix, specify the type of admixture in the mix design.
3. Quality of cement
The quality of cement shall be tested before any work is to begin.
4. Units for measuring aggregates
As specified in the mix design. (e.g. either in volume or weight basis).
5. The water we use for concrete mixing should be free of any contamination.
Protection of water from contamination
6. It`s the engineer`s responsibility to check availability of enough number of mixer
& vibrator for ensuring continues supply &compaction of concert ,and the
contractor should ensure this .
7. Method of placing concrete ;
Before placement of concrete, forms and reinforcement shall be inspected
and approved by the engineer`s representative.
Then the placing will be achieved by using one of the following; concrete
pump, by using concrete chute or directly pouring from the mixer truck to its
final position.
8. Workability of concrete for ensuring proper handling and placing of concrete
without segregation /low, medium, high/
The concrete shall by the order of the engineer take slump test on site
&make sure the water /cement ration of freshly mixed concrete is the limit
of the mix design.
9. Casting test cubes
The contractor shall cast test cubes any time by the order of the engineer.

2. ELECTOR MECHANICAL WORKS

2.1. Mechanical Equipment installation
2.1.1. Introduction
This guideline given an Into how mechanical equipment is installed and
commissioned also is been developed for correct installation, and handover
of equipment in order for preventing its failure at a later date.

Scope: This installation covers installation; commissioning and handover

equipment is installation in general.

Purpose: It provides a general instruction on how correctly to install,

commission and handover a range of mechanical and electrical
engineering system and also it establishes equipment installation

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 minimum requirements for Receiving equipments, Equipment
foundation construction, installation, equipment commissioning and
integration up to final certificate/handover.

Applicability: it is compulsory for all planed sugar factory construction and

future other industries.

Major activates on mechanical equipment installation

Receiving machine or parts

1. Receive machine
2. Temporary storage
3. Site construction
4. Assembling and Installation
5. Commissioning Temporary Storage
6. System Integration
7. Defect liability period
8. Machine handover
Foundation construction

Yes
No
Assembling and Installation

Commissioning
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System integration?
 2.1.2. General guideline for Equipment Installation
1. Receive machine/parts from supplier/ Manufacturer either assembled or disassembled
with its full documentation.

The documentation should minimum include the below listed manuals.

A. Operation Manual

B. Erection and Installation manual (Mechanical and Electrical)

C. Spare part list manual

D. Civil Drawing, Mechanical drawing and Architectural drawing

Ref. Equipment list

S/N Equipment Description U/M Qty. Origin Status Remark

Name

1 Diffuser Type=Electric variable Parts/disassembled

speed type
Set 1 Foreign

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 Length= 65.9m

Width=9.1m

Height=11.3m etc..

2 Pump Type=End suction Set 10 foreign Assembled

process

Capacity= 750m3/hr

Head=150m etc

3 clarifier Set 2 Local Parts/disassembled

Tab le 1.1 Sample Equipment list format.

N.B The equipment list should minimum complete the above listed information.

2. Temporarily storing the machine/parts

After receiving the equipments/parts should be handled with maximum care with the supplier
recommendation.

During temporary storing make sure:

Appropriate material handling mechanisms are followed during loading and unloading
of the equipments.
All the equipments are stored in appropriate place in order to avoid rust, material
damage, material exposed to outside temperature etc.
All the equipments are in their protective casing.
All the identification card is available on the equipment.

Ref. Operation manual, erection and installation manual for safety machine handling and
proper material handling.

3. Foundation construction

Site Construction is where all construction for equipment, steel structure, office building and
all supportive systems are included

During the foundation construction make sure:

The machine lay out is correct

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 The machine foundation is as per the design ( respective of each machine)
The spacing between consecutive machine and the neighboring machine
Enough working space is provided
All underground electrical and sanitary constructions are provided (as per the
design)
Finally confirm for the foundation construction is capable for installation or not.

Ref. Civil drawing, Mechanical drawing, erection and installation manual for respective of
each machine/equipment

4. Start assembling/Installation process

Before starting the assembling process make sure:

To create awareness of basic safety procedures to be followed in all assembling

process. All the material handling mechanisms are available, the tools used for
assembling process are available (respective of each machine), weather you have
enough available space/area for assembling and finally follow the installation
steps for correct assembly.
Pre-installation activates e.g. site accessibility, utilities availability, installation
consumables, documentation availability
Installation activities e.g. adhering to risk assessment ,other relevant safety
standard ,authority to carry out activity to carry out the installation activities,
providing of safe access and working arrangements, safe isolation of services
,disposing of waste items in a safe and environmentally acceptable manner,
leaving the work area in a safe condition.
Methods and techniques e.g. slings, cranes, fork lift, portable lifting devices,
block and tackle ,rollers , hoists, jacks
Making connections e.g. mechanical, electrical wired, fluid, power, utility service
Testing that the installation works
Checking and testing activities and testing activities e.g. input to- output ,
functional testing ,self- diagnostics , emergent problem sequence ,injection and
sampling, unit substitution
Completing relevant paper work e.g. installation records, company specific
paperwork, job card

Ref. operation manual, erection and installation manual for each machine.

5. Equipment Commissioning

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Commissioning tests serve as a progressive transition between the erection , installation and the
start of normal operation of the various plant systems.

These tests may take place in-factory, on specific test facilities or on-site. The choice depends on the
type of equipment, on the level of a systems integration that can be simulated off-site and on the ability
to obtain specific conditions on- site. plant commissioning tests cover all operations performed on
equipment, systems and structures in order to ensure that they behave as specified in the design
requirements.

It also ensures new equipment is ready for occupancy and use,i.e. fit for purpose, train
staff in the operation of new equipment and safety procedures, identify any minor
defects which require rectification, receive all warranties and procedure manuals.
Principles of The Method
Since the main purpose of commissioning tests is to ensure that plant systems will perform
according to their design, the analy0sis is based on reference documents that define and
describe the system-related functional aspects and specification. This reference material is
mostly obtained from plant system manuals and from specification in plant equipment lists.
2.1.3.2 SCOPE OF THE PLANT COMMISSIONING PROGRAMME
The plant commissioning phase ranges from installation to commercial operation.It is organized
into tow test categories:
A. Pre-operational tests and
B. Initial start-up tests (operation tests).
Pre-operational tests
Pre- operational testing begins after completion of the erection and installation phase and it
is normally completed before the initial core is loaded.
Pre- operational tests are conducted using specific test procedures as well as operating
procedures according to designers/ manufactures manual.
The tests are organized by sequences so that the satisfactory completion of one test
ensures the safe performance of subsequent tests
(Conditional) Moreover, when a pre- operational test can not normally be completed before
initial core loading, due to unavailability of associated equipment and/ or systems or when
its results are deemed unsatisfactory, then the test may exceptionally be carried out or
repeated after loading has taken place. However, neither test performance nor lack of test
rest results may in any way conflict with the safety requirements.
Initial start-up test (operational test)
Operational tests are carried out under actual operating conditions. The operational test
programmed is designed to meet the following major objectives:
1. Demonstrate that the plant unit operates in accordance with design bases,
specifically with regard to safety requirements.
2. Show that the plant is capable of delivering output required under the specified
operating conditions,
3. Provide measured data for use as a reference in subsequent plant operation during
plant-life.

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 The Plant Commissioning Programmed is carried out in three main phases:
Pre-operational test program
Phase I: includes the preliminary tests and controls, the first start-up of equipment, functions or
group of functions, without any interaction.
Phase II: includes functional tests with supplementary equipment e.g. ambition water, steam
etc.initial start-up test program me
Phase III: includes actual start up, including a Demonstration Run, up to Commercial
Operation Date.

Commissioning procedure:

Pre- start up e.g. checking for damage, correct positioning, correctly secured, utilities
operative, appropriate fluid levels, clear of obstructions, correct labeling, guards,
fences and systems operative
Methods, techniques and procedures e.g. running system (low speed), checking for
leaks, sensory checks, incrementally load, conducting trial run, monitoring and
recording measurements, shutting down and isolating
Using instruments e.g. devices (such as alignment, measuring), testing, electrical
measurement
Completing relevant paperwork e.g. commissioning log/ report, corrective action
report, job sheet, customer- specific documentation, handover report

Ref. Operation and erection and installation manual

6. Equipment integration

When the equipment is commissioned, the process element needs to be connected to the
system and integrated to become a functional part of the process.

Ref. operation and erection and installation manual

7. Maintenance during defects liability period

The defects liability period is__________ (specify time). During the defects liability period the
maintenance procedure should be established to include:

Maintenance monitoring through maintenance records incorporating all comments,

rectification works and any new defects.
Each_________ (specify time )the superintendent is to provide a report to the principal
indicating:
Maintenance is required
Maintenance has been undertaken
Defects have been completed/ rectified
New faults have been discovered
Any recommendations, suggestions, comments or any other relevant issues
needing attention or action

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 The reports are to be incorporated in to and the maintenance manuals as part of
the quality assurance, recording and tracking of asset conditions.

8. Machine handover

Prior to the end of the defects liability period, all the responsible personnel/ department in conjunction
with the principal`s reprehensive and the principal consultant ensure that all final defects have been
addressed and full operation is approved.

Handover procedures:

Run the installation

Confirm all safety procedures are working
Give instructions e.g. modifications, unusual features, operating instructions, service/
maintenance requirements
Handover documentation
People involved e.g. commissioning engineer, maintenance supervisor, production/
process supervisor
Compete all relevant paperwork e.g. job card, installation and commissioning report,
handover
Paperwork
Confirm handover of responsibility for the equipment.

2.2 Generic methodology of electrical system

installation
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2.2.1. Introduction
A sugar factory is an area where different equipments with different capacity, power
requirement, and way of installation, protection system, and control system is going to be
performed. In order to properly manage and execute the required installation work, this
methodology is by considering the major tasks expected to be done,
2.2.2 Objective
The main objectives of this methodology can be summarized as to adopt or set:
Safe, economical and harmonious working condition
Time & cost effective project
Ease installation work
Reliable & quality system that meet the required standard

2.2.3. Codes & standards

All codes and standards would be referred from EBCS -10

2.2.4. Scope
This methodology is prepared as a guide line for the installation of the following
main tasks. But methodology of some activities like equipment calibration,
equipment setting, and modification works will not be included.
High & low voltage system installation
Equipment installation
Telephone & data system installation
Safety & security system installation
Generator erection & installation and
Test and commissioning
2.2.5. Planning & scheduling of the projected
Period to start the installation work, it is mandatory to give answer for questions like
what is the type of project, where is the location of the project, what major tasks of work of work
are going to be done, what resources are required for accomplishing the work, how the work can
be conducted, etc and how long it take to complete the project work, should be answered by the
contractor.
Man power required /human resource/.
Materials and equipments required
Time required /starting & completion date/.
Financial & capital budget.
Possible risks & their mitigation method.
2.2.6. Material handling methodology
Diversified types of electrical materials are supposed to be installed in
factory (sugar factory), so during storing of these materials at site, means
of storing or handling of these materials should be with consideration of
the following steps.
Identifying materials that can be stored indoor & out door

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 Identify materials requiring special care of handling due to adverse
weather conditions like strong sun light, humidity , & cold weather and
store accordingly.
2.2.7. Project team preparation
For the execution of the demanded electrical system installation, the project
manager allocates manpower with consideration of skill required to meet desired
quality and finish the work within the allocated time schedule. Some of the main
and common manpower required for electrical system installation are:
Daily laborer
Technicians or electricians
Forman
Supervisor
Engineer
Project manager
Guard
Clerk
Administrator
2.2.8. Material transportation and Delivery
Diversified types of electrical materials are supposed to be installed in a factory
(sugar factory), so during supplying of these materials, means of transportation of
these materials, means of transportation of these materials should be with
consideration of the following steps.

Identifying construction order

Identifying materials which need special care of transportation and
transporting accordingly
Check the materials arrived at site and cross check with the supplier
material list
Conduct possible test and inspection
Write comment and record the result
2.2.9. Mobilization of project team and machinery
Untimely mobilizing of the project resource (manpower, machinery)
incurs the contractor cost of construction. Therefore a contractor should
follow some of the following major steps when mobilizing of manpower,
machinery, and other materials to site.
Referring construction schedule
Determine necessary resource for each task
Prepare temporary accommodation(camp) for workers
Mobilization of workers
Preparing daily, weekly and monthly work progress format in
collaboration with the client
Preparing payment requisition format
Preparing site diary format
2.2.10. General safety
This section sets requirements for electrical safety. It specifically addresses
working in restricted areas; working near exposed energized overhead lines or

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 parts; working on electrical equipment and systems; personal protective
grounding; temporary wiring; disconnect and over current protection; ground-
fault protection; hazardous locations; and wet locations
Follow all electrical safety rules during the process of all installation work
Identify electrical system that is potential of hazard (step potential, touch
potential, bare live conductors, improperly/ not grounded equipments
metal body etc.)
Awareness creation for non-electrical personnel (operators, welding
technicians, truck drives etc) also the basic safety rules.
Follow necessary safety procedures during installation of electrical devices
like motors, control panels, distribution boards, generator etc to avoid
cause of damage.
When installing special hazardous areas like garages, fuel and other
flammable material stores, battery rooms etc, follow the necessary safety
rules.
Make sure that any power carrying conductor is disconnected and
grounded properly during installation work.
2.2.11. Installation of HV/LV system
According to statutory (national) regulation, high voltage(HV) system is installed by
the electric supplying authority (EEPCo).but in a sugar factory it very practical to
generate electrical power that can satisfy the factorys consumption and even for
sale for other consumers.Soit is important to set a working methodology for the
betterment of the mentioned objectives.
2.2.11.1. Installation of high voltage (HV) system
Voltage above 1000V is classified as high voltage and needs guide line for safe
(even it can cause fatal shock or death to a person who may step close to it) and
good work practice.
Disconnect & make sure that the system under installation is properly
grounded before starting the installation work.
Keep the recommended clearance distance (between conductors,
between conductors and metallic structures, between conductors and
body frames)during the installation work
Measure the termination span (from one pole to another for over hand
system or from one terminal point to another for underground system)
and prepare wire for installation accordingly.
Prepare all the necessary materials and fittings of transformer and
perform fitting
Install the porcelain insulators to the transformer.
Prepare the disconnecting mechanism (disconnector) & install it.

Conduct the cabling installation system

Provide all the recommended protection system (earthling, lightning

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 Protection, safety guard, fire protection, cooling system)
Inspect & test the system procedurally
Write comment report for the concerned body
2.2.11.2. Installation of low voltage (LV) system
Disconnect & make sure that the system under installation is properly
grounded before starting the installation work.
Keep the recommended clearance distance (between conductors,
between conductors and metallic structures, between conductors and
body frames)during the installation work
Measure the termination span (from one pole to another for over hand
system or from one terminal point to another for underground system)
and prepare wire for installation accordingly.
Prepare the disconnecting mechanism (disconnector)& perform the
installation work.
Provide all the recommended protection system(earthing, lightning
protection, safety guard, fire protection,)
Inspect & test the system procedurally
Keeping the national standards and codes ofinsttallation of low voltage
system for different purpose, install lighting system (indoor
&outdoor),&receptacles(three phase & single phase),install equipments
(motors, lathe machines, welding machines etc)
Write comment report for the concerned body
2.2.12. Methodology for Electrical Equipments
in sugar factory some of the main equipments require electrical installation are
feed table, knife machine, shredder, conveyor belts milling machines, water and
juice pump motors, centrifugal machine, sensors and control systems incorporated
with all these machines. So this methodology is to offer guide line for proper and
correct way of installing these equipments and attaining desired slandered &
advantages.
Identifying the type of equipments
Preparation appropriate cable size
Preparation of appropriate control and protestation components
Design and manufacturers equipment installation manual
Prepare working area
Preparing necessary installation materials
Follow all the recommended safety rules
Installing the equipments procedurally
Test and inspection
2.2.13. Generator assembling/ erection procedure
All continuous process plants like sugar mills, paper manufacturing units, etc always require an
uninterrupted input of energy in the form of electric power and steam to
sustain the critical production process. In steam turbine based
cogeneration system, the steam so produced is then expanded through a
steam turbine to produce mechanical power/ electricity and a low-
pressure steam. This installation manual is designed as a procedural guide
for all steam generators.

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2.2.13.1. Installation of turbine& generator system
Transportation, temporary storage
Unpacking of the parts &checking/examining
Placing of foundation bolts.
Assembly of laminated rim.
Stator assembly
Pole assembly
Field coil assembly
Rotor assembly
Turbine assembly
Turbine shaft assembly
Assembly of turbine coupling
Assembly of trust bearing
Bolting of spider shaft
Assembly of guide bearings
Installation of lubrication system
Installation of rotor bearing
Installation of Generator control system
Installation of generator protection system
Inspection and testing
Commissioning of generator
2.2.13.2. Installation of water and steam line system
Connecting the feed water source to the feed water inlet;
Connecting the generated clean steam outlet to the clean stem outlet;
Connecting the energy source (steam, boiler water, or high temperature
water) to the unit;
Connecting the condensate and steam/ water return line and piping it to
the recycling system; piping the pressure relief valve to an acceptable
vent and drain system;
Wiring the applicable source of power (if the unit is packaged with an
electrically activated pressure or control component);and
Connecting the appropriate instrument (control) air source.
2.2.13.3. Connecting electrically/pneumatically activated controls
Install electrically/pneumatically activated water level control valves
Install electrically/pneumatically activated pressure control valves
Connect the correct power sources the above devices
Installation of the control panels
Test& inspection of generators (pre-commissioning)
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2.2.14. Substation (switch yard) erection

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 Check for the preparation of structural foundation
Erection of supporting structures
Installation of over head systems (lightning protection& bass bars)
Installation of equipments (voltage transformer, current transformer,
disconnector, surge arrestor, transformer, control system, etc.
Installation of protection(earthling and lightning protection)control system
Test and pre-commissioning
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2.2.15. Installation of protection system
For safely operation of the factory, protection facility should be provided to
aware during fire hazard, protect equipments and system electrical lines,
factory buildings, & all infrastructures from lightning strike protect system
& workmen form electrical hazards and etc.
2.2.15.1. Fire alarm system installation
This guidance contains brief descriptions of the major components which go to
make up a fire alarm system.
Preparation of system drawing.
See national(EBCS) standard
Determine number of zones required
Identify maximum alarm load per alarm zone
Power supply requirement of the system
Understand the type of detectors in the system (heat detectors, linear
detectors, smoke detectors, light obscuring, light scattering, carbon
monoxide detector)
Conduct installation of sound system (horns or bells)
Conduct installation of detectors
Inspection and testing
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2.2.15.2. Earthling system installation
Earthling of electrical system is required for a number of reasons principally to
ensure the safety of people near the system and to prevent damage to the system
itself in the event of fault. The function of the protective conductor or earth is to
provide low resistance path for fault current so that the circuit protective device
operate rapidly. The resistance of the earth path must be low enough so that the
potential rise in the earth terminal and any metal work connected to it is not
hazardous.
Identifying the earthling system (direct connection to earth,
neutral,combined,and separate)
Selection of earthling materials(earthling conductor, bonding conductor,
earth electrode,rod,p.lates,electrode derivatives)
Determine point and location of earthling

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 Sorting of necessary materials and accessories
Perform earthling/grounding/system
Test & inspection
2.2.15.3. Lightening protection system installation
Design and working drawing
Referring code and standard of lightning protection system.
Preparation of down conductor
Preparation of air terminal
Preparation of clamping material
Preparation grounding electrode
Testing& inspection of down conductor and earth rode resistance
2.2.16. Testing and commissioning
This testing and commissioning (T&C) procedure aims to lay down the minimum
testing and commissioning requirements to be carried out on electrical installation
in sugar factories. Such requirements are applicable to both new installation upon
completion and existing ones after major alteration.
The objectives of the T&C works are
i. To verify proper functioning of the equipment installation ;and
ii. To verify that performance of the installed equipment /systems meet with the
specified design intent through a series of tests and adjustments.
iii. To capture and record performance data of the whole installation as the baseline
for future operation and maintenance.
Preparation of testing and commissioning plan
Preparation of test and commissioning procedure for systems
Assign testing & comm... personnel/ team
Conduct T&C for high &low voltage installations.
Conduct T&C for safety and protection system
Conduct T&C for equipments, control boards and distribution boards/
panels
Conduct T& C for generator
Analyze the result
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2.2.17. Project energizing and site hand over
After the proper testing and commissioning of the electrical installation, the
contractor shall notify the appropriate authority, and conduct the energizing or
operational test of the electrical system and hand over the project for the client
after complete documentation of the result.
Notify the concerned bodies
Prepare the energizing procedure
Step by step energizing (preliminary energizing)
System energizing

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 Analyze the result
Write comment, sign and submit for the responsible body
He beginning of a new construction project is an exciting time. the new
challenge is exhilarating and consuming. Possibilities seem limitless. But
the excitement can quickly change to frustration and become a source of
conflict when there are errors and discrepancies in the construction
documents. Errors and discrepancies occur in construction documents on
almost every project but they can largely be eliminated with some quality
control techniques.
Quality control in construction documents can be done by the owner,
contractor, engineer or architect. Better still, it should be done by all of
these parties as a team. Here are some ideas on how to get a handle on
errors in construction documents:
Quality control in construction plans
1. Look for and correct incomplete, unclear and ambiguous statements.
Proof read specifications, general and special conditions and contracts to
eliminate words missing from sentences and sentences or line missing
from paragraphs. Are sentences complete and do they have a meaning?
Edit statement that conflict with other statements and make sure that the
documents do not contradict each other.
2. Generally, a construction contract is between an owner and a
contractor. A construction contract cannot bind sub contractors,
manufacturers or suppliers hired by the contractor to perform work. Make
sure that the contract documents and specifications assign work
responsibility only to the contractor.
3. Define terms. Often an inspection is a requirement of the contract
documents but is not defined. When is the inspection required? By
whom is it performed? Another example: approved equal. If using the
term approved equal be sure to define how to get approval.
4. Verify that all technical reports are referenced. Include report dates and
revision and addenda numbers.
Quality control in project logistics
5. Review the architectural, structural and engineering plans to make sure
that they agree. Assumptions made about which set of plans is correct
may be costly later on. Can the plants be built as shown? Constructing a
window with a beam running through the middle will be embarrassing to
everyone involved.
6. Ensure that the local building jurisdiction is correctly identified. Often
construction documents are prepared from previously used templates.
Make sure that job specific details like drawing submittal requirements,
job location, delivery constraints and working hours are up dated.

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 7. Once on the job make note of any conditions that are not as shown on
the plans and communicate the actual jobsite conditions to all parties
8. Confirm that the drawings being used are current. If bidding on
preliminary drawings makes sure that the most current version is available
and is being used. If the drawings have been approved, are all required
signatures and dates shown?
Quality control in ongoing communications
9. Prepare a document checklist and use it to identify missing documents
and documents that need to be updated. This checklist can also be used to
track submittals and shop drawings during that stage of the project.
10. Communicate with the owner, architect and engineer about
construction document discrepancies so that they can be addressed and
resolved and resolved quickly.
Quality control in bidding and invoicing
11. If alternates in construction materials or methods are listed in the job
specifications make
Sure that the bid form includes a place for the bidder to enter prices for
proposed alternates.
12. Keep a set of drawing that shows construction progress on the job.
This will help with payment processing and will make preparing record
drawings at the end of the job easier.

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