Generator Installation Method Statement Including Fuel Tank Installation at High Level

This method statement covers the generator and fuel tank installation for any kind of project.

Prior to commencement of the works, all activities shall be coordinated with Project Safety Officer and PTW holder, who will assess the associated risks, and monitor the implementation of the work as per the Project Safety Plan and liaise with the construction team to ensure a safe working environment.

Project/Construction Manager shall be responsible for the overall implementation of this method statement, and to ensure that section engineer and general foremen are well informed of the applicable requirements. He is responsible for providing all required resources in terms of manpower, equipment and materials. Responsible for the coordination between all involved parties to ensure Safety, Quality and schedule requirements are met.

Electrical section engineer and general foreman in-charge shall be responsible to:

Control and ensure the construction work is carried out to the required contract specification and approved shop drawings.

Implement the PTW as required by applicable HSE Procedures.

Notify QC engineer and issuing the WIR (request for inspection) in timely manner (normally 24 hours in advance) when work is ready for inspection as detailed in the relevant ITP.

Accompanying the quality engineer for ongoing inspection and obtain approvals to proceed.

Quality Manager shall be responsible for :

Reviewing all relevant documentation and test reports and prepare all handing over dossiers.

Clearing all non-conformances relevant to the generator installation activity.

Ensuring that all activities subject to inspection are recorded and cleared.

Controlling and organizing the inspection works.

Ensuring that inspections are carried out in a timely manner.

Quality control engineer ( QCE) shall be responsible for:

Inspecting and ensuring the fuel tank and diesel generator installation work is carried out in compliance with the contract specifications and approved layout drawings.

Preparing and issuing the work inspection requests to carry out the inspection as per the approved ITP.

Accompanying the client/consultant representatives for inspection to release the hold points and getting final approvals for electrical installations.

Necessary Tools and Equipment

Following tools shall be arranged before starting the job.

• General Electrical Toolbox
• Hydraulic jacks, complete with Power pack, Manifolds and hoses
• Jacking and packing equipment, consisting of steel and timber cribs
• Toe jacks, 10 T SWL
• Castor rollers
• Tank rollers, 60 T SWL, with C-channels
• Skid beams
• Tirfor, 3.2 T SWL, with pulling wire.
• SL 100 hydraulic gantry, 100 T SWL
• Top beams and platform
• Forklift
• Step Ladder
• Torque Drivers and Wrenches
• Personal protective equipment PPE such  as  safety  shoes,  safety  helmet, safety glasses, fluorescent vest, safety gloves and dust mask as required.

Material Handling and storage

On receipts of the equipment/material at site, necessary precautions shall be taken for unloading, shifting and storage, as follows:

The equipment / units will be stored in a clean, dry place and adequate covering by tarpaulin sheets will be provided to protect the equipment from deposition of construction dust till it is finally shifted to its foundation.

All Material received will be checked to ensure that they are complying with the approved material submittals in terms of their make, model, type, capacity, etc.,

Any discrepancy or damages etc., it will be notified and reported immediately for further action. It should be noted on the carrier’s freight bill. Damage claims should be filed with the carrier immediately.

Material found not suitable for site use will be removed immediately from site and the same will be replaced by correct equipment.

Site Engineers have to ensure that all material used at site are of free from any damages or deformities of any kind.

Units found not suitable for site use will be removed immediately and the same will be replaced by correct items.

Prior To Start the Work

Permit to work PTW must be secured before starting the installation works.

Install the necessary barricades and signages.

Ensure work place / area is available and clearance is obtained from other trades / disciplines.

Make sure the mandatory safety requirements have been implemented to start the installation of generator and fuel tank.

Ensure adequate lightings are provided as required depending upon the site conditions and incase the works went beyond the normal working hours (night works).

Make sure that all materials / equipment’s delivered to site are inspected properly by QA/QC Engineer and approved from the client.

Fuel Tank Lifting and Installation at High Level (Mezzanine Floor)

Prior to the commencement of lifting and installation, a pre-operational meeting will be held with all concerned parties.

Skidding and jacking equipment will be lifted to the Mezzanine floor using forklift.

Skidding beams / channels will be positioned on mezzanine floor, level with the parapet wall, this will be achieved by placement of steel and timber cribs under the skid channels to the correct level.

Gantry will be built up at the lifting location on the ground floor

Fuel tank will be transported outside the building and using the forklift taken inside the building.

The tank will be positioned on the lifting platform.

Lifting platform will be raised to mezzanine floor parapet floor height.

Skid channels and tank rollers will be positioned under the tank.

The fuel tank will be rolled off the platform.

Tank will be jacked up, rollers and channels shall be removed, and tank to be jacked down onto the floor.

The tank will be shifted to foundation.

Once the fuel tank is over foundation, the tank will be jacked up, rollers to be removed, and tank shall be lowered onto the foundation.

Setting up of Gantry

The gantry components will be offloaded from the truck, and brought into the building using forklift.

Four gantry legs will be positioned in location.

The gantry top beams will be positioned onto the gantry legs using the forklift.

Platform will be positioned onto the top beams using the forklift.

As the gantry legs are on rollers, the individual distances can be corrected during the installation.

Upon completion of set-up, the wheels will be blocked using wooden wedges to prevent uncontrolled movement/shifting.

Placement of Fuel Tank onto Gantry

The forklift will carry the fuel tank from outside to the platform.

Wooden or steel blocks will be positioned onto the platform onto which the fuel tank will be positioned.

The blocks will be of such a height that the skid channels and rollers can be inserted underneath.

Lifting of Gantry Platform to Mezzanine Floor /High Level

The gantry legs will be extended using the built-in power packs.

One rigger will be stationed at Mezzanine floor level, and will inform the supervisor once the platform has reached the required height.

The power packs will be switched off, and the riggers will be relocated to the Mezzanine floor

Removal of Fuel Tank from Platform

• C-channels will be extended from the Mezzanine floor onto the platform, under the fuel tank.
• The tank rollers will be positioned inside the C-channels, and pushed to location under the fuel tank.
• Using hydraulic jacks, the tank will be lifted from the blocks.
• The blocks will be removed from underneath the tank, and the tank lowered down until resting on the rollers.
• Using manpower, the fuel tank will be pulled from the platform to the Mezzanine floor.
• Jacks will be positioned under the fuel tank, and raise the fuel tank from the rollers.
• The C-channels and tank rollers will be removed from under the tank and from the lifting platform.

 Shifting of Fuel Tank to Foundation

• Fuel tank will be lowered, using the hydraulic jacks, until on floor level. This will be done using standard jacking procedures.
• The tank will be lowered onto castor rollers, and the jacks removed.
• Fuel tank will be shifted from the lowering location to the final location using manpower.
• Once over final location, the tank will be jacked up, and the rollers removed from underneath.
• The tank will be lowered until resting on the ground, and the jacks will be removed.

Removal of lifting platform

The platform will be lowered to lowest location by retracting the hydraulic cylinders.

Once all legs are retracted, the forklift will lift down the individual components, and prepare for demobilization.

Diesel Generator DG Set Installation Method

Prior to the commencement of DG set lifting and installation, a pre-operational meeting will be held with all concerned parties.

Steel cribs will be placed between the foundations, to level the area.

Skid beams will be positioned from outside the plant room to inside.

On the sloped area, cribs and shims will fill the area under the beams to ensure level beams.

Skid beams will be positioned across the foundations to the incoming beams.

General Steps:

DG set will be lifted from the trailer, and placed onto rollers on the skid beams.

The DG set will be pulled into the building, using tirfors.

At the turning location, the DG set will be jacked up, the rollers turned 90 degrees into the new orientation, and the DG set lowered back down onto the rollers.

Using tirfors, the DG set will be pulled across the skid beams until over foundation.

Once over foundation, the tank will be jacked up, rollers removed, and tank lowered onto foundation.

Receiving and initial skid of DG set

The rollers will be positioned on the skid beams.

DG set will be lifted form the trailer, and lifted to above the rollers.

With the DG set hovering just clear of the rollers, the roller position will be adjusted until in position.

The DG set will be placed onto the rollers.

Tirfors will be connected to the DG set. The other side of the tirfors will be secured using shackles to the end of the skid beams.

Lifting tackle will be removed from the DG set.

The tirfors will pull the DG set along the beams until it has reached the turning location.

Turning of rollers

Hydraulic jacks will be positioned under the DG set.

The jacks will lift the DG set from the rollers.

Rollers will be turned 90 degrees, along with the beams, in line with the beams leading to the foundation.

The DG set will be lowered back onto the rollers, and the jacks removed.

Skidding to foundation and Placement

The tirfors will be connected to the DG set, and commence pulling the DG set sideways.

DG set will be pulled until it reaches over its foundation.

Hydraulic jacks will be positioned under the DG set, and will lift the DG set from the rollers.

The rollers and skid beams will be pulled out from underneath the DG set using a combination of manpower and forklift.

Anti-vibration pads / springs will be positioned on the foundation under the DG set.

The jacks will lower the DG set until it is resting on its springs / pads.

Jacks will be removed from underneath.

Upon completion of placement of the DG sets, the equipment will be removed using the forklift.

Area shall be cleaned after completion of work.

Check the installation after completion of work and raise the (WIR) for fuel tank and generator installation.