SAFE WORK METHOD STATEMENT (SWMS) FOR EMERGENCY LIGHTS CENTRAL BATTERY SYSTEM TESTING AND COMMISSIONING

 

Table of Contents

1. The Scope of Work Method Statement

2. The Purpose of Work Method Statement

3. Abbreviations

4. Reference & Related Standards

5. Roles and Responsibilities

5.1. Commissioning Manager

5.2. Commissioning Team/CT.

5.3. QA/QC Engineers

5.4. Specialist Sub-Contractors

5.5. Health & Safety Team

6. Necessary Instruments & Tools

7. Pre-Commissioning of Emergency Lights System

7.1. Visual Inspections

7.2. Pre-Commissioning Checks and Cold Testing

8. Testing and Commissioning of Central Battery System

8.1. Emergency Lights Power up Test and Commissioning

8.2. Functional Test:

8.3. Timing of Test (Through Software)

8.4. Battery Duration Test

8.5. Mechanical Check

8.6. Insulation Measurement

8.7. Switching on the unit

9. Commissioning Check sheet elements

10. Inspection Test Plan / Commissioning Plan

11. Hazard Identification & Risk Assessment – Control Measures

12. Inspection Checklist for Emergency Lights Central Battery System Testing and Commissioning

13. Attachments

1. The Scope of Work Method Statement

This method of statement is to guide in carrying out the testing and commissioning of the central battery system which has been installed at the project, following the approved Project Quality Plan, contract specifications and Commissioning plan.

2. The Purpose of Work Method Statement

2.1. The purpose of this method of statement is to control the testing and commissioning activities for the central battery system in line with the Project Quality Plan and Project Commissioning Specification requirements to achieve optimum results.

2.2. The emergency lights system shall include Static Inverter Central Battery (SICB) systems feeding emergency Lighting luminaries to gain a backup period of approximately 3-hours. This system shall also be backed up by the standby generators for additional redundancies in case of long power failures.

3. Abbreviations

3.1. CBS: Central Battery System

3.2. BMS: Building Management System

3.3. BCS: Building Control System

3.4. CB: Circuit Breaker

3.5. CT: Current Transformer

3.6. CM: Commissioning Manager

3.7. CA: Commissioning Authority

3.8. DC: Direct Current

3.9. EMS: Energy Management System

3.10. MSB: Main Switchboard

3.11. ITP: Inspection and Test Plan

3.12. HSE: Heath Safety and Environment

3.13. DB: Final Distribution Board

3.14. LV: Low Voltage

3.15. MAR: Material Approval Request

3.16. MIR: Material Inspection Request

3.17. LCM: Lighting Control Module

3.18. MCB: Miniature Circuit Breaker

3.19. LCS: Lighting Control System

3.20. ELS: Emergency Lighting System

3.21. MCCB: Moulded Case Circuit Breaker

3.22. PPE: Personal Protective Equipment

3.23. GUI: Graphic User Interface

3.24. PD: Presence Detector

3.25. W: Watts

3.26. ELCB: Earth Leakage Circuit Breaker Emergency Lights Central Battery System Testing and Commissioning Method Statement

4. Reference & Related Standards

4.1. Project Quality Plan / Commissioning Plan

4.2. Project Technical Specifications

4.3. Project Approved Material Submittals

4.4. Safe Energy and Isolation Method of Statement

4.5. Manufacturer Recommendations for Installation & Commissioning

4.6. Project HSE Plan

4.7. Project Shop Drawing References

5. Roles and Responsibilities

5.1. Commissioning Manager 

5.1.1. CM shall be responsible for the entire Pre-commissioning and Commissioning of the emergency lighting system. All necessary manpower, apparatus and instruments which are required for Pre-commissioning and commissioning activities shall be supplied by the commissioning team.

5.1.2. Commissioning manager leads, plans, schedules, and coordinates the Commissioning team to implement the procedure for Central Battery System.

5.1.3. Notification of any witnessing of Pre-commissioning & Commissioning activities shall be forwarded to the client/consultant two working days before the commencement of the activity.

5.2. Commissioning Team/CT.

5.2.1. All Pre-Commissioning and Commissioning activities of the Central Battery System are the responsibility of the Testing & Commissioning Team.

5.2.2. CT shall check the Commissioning works before submission for inspection and approval.

5.2.3. In case of failure in any test, the Commissioning team will rectify it, and CT re-offer the test for re-inspection and approval.

5.2.4. All Original Test reports witnessed and approved will be retained by the CT. A copy of the final testing & Commissioning Report for the Central Battery System will be forwarded to the CA.

5.2.5. Notification of any witnessing of Pre-commissioning & Commissioning activities shall be forwarded two working days before the commencement of the commissioning activity.

5.3. QA/QC Engineers

5.3.1. The quality engineer shall inspect the installation activities to ensure system completeness/readiness is achieved before the commencement of any Commissioning activity.

5.3.2. QA/QC Engineers shall be monitoring the Commissioning activities to ensure quality standards are maintained throughout the testing and commissioning of the Central Battery System.

5.3.3. QA/QC Engineers shall witness all the Pre-Commissioning and commissioning activities.

5.3.4. Notification of any witnessing of Pre-commissioning & Commissioning activities shall be forwarded to the QA/QC Engineer two working days before the commencement of the activity.

5.4. Specialist Sub-Contractors

5.4.1. The subcontractor who shall supply the Central Battery System for the project shall be responsible for conducting the entire testing and commissioning process under the supervision of the Commissioning Team.

5.5. Health & Safety Team

5.5.1. All the safety requirements as per HSE rules shall be strictly followed by every individual to have a safe working environment and avoid hazards.

5.5.2. Prepare safety permits in advance and obtain approval as per the site safety requirements.

5.5.3. Isolation of the area, and warning signs display, if necessary, to be carried out for any testing and energizing. Ensure all concerned personnel use PPE and all other safety items as required.

5.5.4. Notification of any witnessing of Pre-commissioning & Commissioning activities shall be forwarded to the Safety Team two working days before the commencement of the activity.

6. Necessary Instruments & Tools

6.1. Portable hand Tools

6.2. Multimeter

6.3. Clamp Meter

6.4. All the instruments for the commissioning shall have valid Calibration Test Certificates at the place of work.

7. Pre-Commissioning of Emergency Lights System

7.1. Visual Inspections

7.1.1. Carry out a visual inspection of the outside and inside of installed central battery panels, Substation Panels, and emergency/exit light fittings.

7.1.2. Visually check Control Panels as well as Central PC with the printer to ensure that all equipment is installed in line with approved construction drawings, approved material submittal, Project Specification and in line with the manufacturer’s recommendations and Civil Defense Regulations.

7.1.3. Record results on the pre-commissioning report.

7.2. Pre-Commissioning Checks and Cold Testing

7.2.1. This activity is the responsibility of and should be completed by subcontractor QA/QC under the direct supervision of the main contractor. This is to make sure all equipment, device machinery and/or systems are fully ready for Pre-Commissioning Activities (PCA).

7.2.2. The following checks will be made before powering up the system by the supplier engineers who are the specialist manufacturers.

7.2.3. The emergency lighting system power cabling must be mandatory Meggered, and Continuity checked and rectified of all Open/Short/Earth Faults before the commencement of connection and powering up of the circuits.

7.2.4. Disconnect Lamps, Address modules, Central Battery and Substation Panels and PC from the power circuit and connect 500VDC Megger taster between Phases to Neutral, Neutral to Ground as well as Phase to Ground.

7.2.5. The values of resistance measured must be more than 1000 Mega Ohms. This must be done by the MEP contractor and the necessary megger and continuity reports must be filled in by the Testing and Commissioning document controller.

7.2.6. Address each emergency light and exit fitting as in layout drawings.

7.2.7. Record results on electrical test sheets and Commissioning reports.

8. Testing and Commissioning of Central Battery System

8.1. Emergency Lights Power up Test and Commissioning

8.1.1. Check Mains (PE, N, L) cables

8.1.2. Check battery (+, -) along with polarity.

8.1.3. Check mains voltage.

8.1.4. Check the battery voltage.

8.1.5. Energize the incoming main supply to the panel.

8.1.6. Insert the battery side fuses.

8.1.7. Check for charger operation/battery circuit operation.

8.1.8. Start function test of the panel.

8.2. Functional Test

8.2.1. Record outgoing circuit failures. (Lamp & Circuit)

8.2.2. Record battery circuit failure / charging current failure.

8.2.3. Ensure all components connected to the control report are back in full status and are fault free.

8.2.4. Set up AUTO Function Test from monitoring computer PC.

8.3. Timing of Test (Through Software)

8.3.1. The test will be done every 7 or 14 days

8.3.2. Duration test will be done every 6 or 12 months

8.3.3. Adaptive test or Manual test can be done at any time

8.4. Battery Duration Test

8.4.1. Connect the power supply to the panel to charge the batteries.

8.4.2. Confirm batteries are fully charged.

8.4.3. Connect the existing load.

8.4.4. Record the Battery data before starting the discharge test.

8.4.5. Discharge the Battery for 1 hour at the suitable current as per the cell end voltage.

8.4.6. Record the Battery data during the discharge.

8.5. Mechanical Check

8.5.1. Check whether the screw connections are screwed down on the terminal blocks.

8.5.2. Remove the NH fuses before connecting the batteries

8.5.3. Check the tightness of the cable entry

8.5.4. Check the batteries in respect of any exterior damage.

8.5.5. Check the Plant Configuration

8.6. Insulation Measurement

8.6.1. Disconnect and bridge the mains connecting lead

8.6.2. Disconnect and bridge the cable to the emergency lights.

8.6.3. Carry out insulation measurements to PE.

8.6.4. Remove bridges after the insulation measurement.

8.6.5. Reconnect the mains connecting the lead and the lead to the emergency lights.

8.7. Switching on the unit

8.7.1. Remove mains fuses.

8.7.2. Replace the main fuse.

8.7.3. Check the polarity on the fuse load switch.

9. Commissioning Check sheet elements

9.1. Panel Detail

9.2. System Voltage Input

9.3. Battery Output

9.4. Battery Capacity

9.5. Number of Blocks

9.6. Battery Discharge Duration

9.7. On Load – Output Voltage (Mains Present)

9.8. On Load – Output Voltage (Mains absent)

10. Inspection Test Plan / Commissioning Plan

10.1. The Commissioning Engineer should verify that the CT who is responsible for Testing & Commissioning responsibilities for Commissioning is familiar with this Method Statement and is issued with copies of the inspection checklists and test plans.

10.2. CT Engineer should satisfy the procedures provided by Commissioning Engineer inspections to ensure the Commissioning of the emergency lights system testing meets the specified Engineering requirements and approved drawings.

10.3. As part of the assessment, the CT Inspection Procedures must ensure quantitative or qualitative acceptance criteria for determining the prescribed activities have been accomplished satisfactorily.

10.4. The CT should verify any as-built record of testing and confirm that the information meets the project requirements.

10.5. Request for Work Inspection Request (WIR) shall be submitted by Commissioning Engineer to the contractor’s QA/QC department for verification and inspections.

10.6. The commissioning Engineer will forward WIR to the consultant for inspection and approval following ITP.

10.7. Readable stamped approved Method of Statement to be available during the T&C works.

10.8. All the instruments engaged for testing shall have valid calibration and the certificate should be furnished at the site.

11. Hazard Identification & Risk Assessment – Control Measures

11.1. Only the competent Testing and Commissioning team Employees are allowed to carry out the testing and commissioning of the Lighting Control System.

11.2. Preliminary Checks will be made to ensure a safe working environment: Visual inspections to confirm that there are no other apparent hazards within the testing areas and the area is free from dust and construction debris.

11.3. Only the competent Operatives from the specialist subcontractor will be allowed for connecting the testing devices to the Central Battery Units and it will be supervised by the in charge of the testing and commissioning team.

11.4. All Supporting documents for the testing that includes calibration certificates, third-party inspection certificates for the monitoring devices, etc. must be provided to the safety department before starting the work.

11.5. Arrange to light on the work area and provide task light and ventilation in the work area.

11.6. Keep all the leads and cables off the ground and use cable hangers as applicable.

11.7. The areas where ladders will be used the ladders, should be inspected by a competent inspector and should be colour-coded, use both locks on the styles, keep the ladder on a firm surface and while working don’t climb onto the top three steps.

11.8. Do not use a ladder where there is a risk of falling.

11.9. No one is allowed to climb up or down the ladder with tools or materials.

11.10. For energizing the Central Battery System Panel, the testing commissioning team must follow the approved Lockout/ Tag out Procedures without fail.

11.11. Conduct special training and explain to all the employees regarding the hazards and emergency procedures.

11.12. Before starting the testing evacuate all other workers from that area that are not related to the testing.

11.13. Isolate all the electrical devices which are not necessary.

11.14. Ensure adequate power supply through isolating devices RCD, ELCB/GFCI.

11.15. All the power tools and leads that will be used must be inspected by competent electricians.

11.16. Provide adequate information to others working nearby and display warning tapes and signage (Danger Testing Going on; keep away, No Unauthorized entry, etc. within that area of testing.

11.17. Maintain housekeeping throughout the work activity.

11.18. The responsible testing engineer must always be present in the testing area to ensure the work is being carried out safely.

11.19. Use cotton hand gloves while working as mandatory.

11.20. Do not work on a live system; isolate the supply from the main and physically remove the connections before starting any maintenance.

11.21. Adequate supervision is mandatory throughout work activity.

11.22. In case of an electrical emergency, follow the project emergency procedures.

11.23. Display suitable numbers of Emergency Contact Numbers in the work area.

11.24. The safety team will monitor the entire activity and they shall be informed before the start of every activity by the responsible testing commissioning engineer.

11.25. All accidents, incidents and near misses must be reported to the safety team immediately.

12. Attachments

12.1. Risk Assessment Sheet

12.2. Pre-Commissioning & Start Up Check List

12.3. Testing & Commissioning Test Sheets

DOWNLOAD THE FILE

METHOD STATEMENT FOR EMERGENCY LIGHTS CENTRAL BATTERY SYSTEM TESTING AND COMMISSIONING