CLIENT: ZIMPLATS

CONTRACT: SMC SOLAR PROJECT

ACTIVITY: SUBSTATION EQUIPMENT ERECTION

REVISION: 00
PLANNED
CONSTRUCTION 2024
DATE:

V. Chiremba
Compiled by:
Jecca Site Engineer Date

M. Ncube
Verified by:
Shenxin QAQC Engineer Date

Lilian Nyajena
Verified by:
SHEQ Officer Date

Hany Ragab
Approved by:
Elsewedy SHEQ Officer Date

Mohamed Nawar
Approved by:
Elsewedy Site Manager Date

Andrew Mutamiri
Approved by Zimplats
Zimplats Project Manager Date

Amendment Record

This document will be updated when necessary by distribution of a complete replacement. Revisions will be
highlighted in italic and underlined.

REVISION DATE AMENDMENT DETAILS

 ADMIN 000-1
REVISION 00
EFFECTIVE 29/04/24

SUPERVISOR’S BRIEFING I HAVE READ CONTENTS OF THIS DATE

METHOD
STATEMENT AND UNDERSTAND IT :

RESPONSIBILITY

Project Manager/ Site Agent

Generally responsible for ensuring implementation of this procedure.

Site Engineer and or/ Supervisor

Responsible for overseeing, planning and tracking the site activities.

SHERQ Officer and/ or SHERQ Rep

Responsible for providing guidance to the team in ensuring SHEQ compliance.

ABBREVIATIONS

SHERQ Safety Health Environment R i s k and Quality

PPE Personal Protective Equipment
MS Method Statement
QA/QC Quality Assurance / Quality Control
ITP Inspection Test Plan

OBJECTIVES JECCA ENGINEERING (PVT) LTD No. 17 Fowey Drive, Vainona, Harare
[email protected]
Objective of this method statement are:

 To execute the task in the practically least possible time.

 ADMIN 000-1
REVISION 00
EFFECTIVE 29/04/24

INTRODUCTION
JECCA ENGINEERING (PVT) LTD No. 17 Fowey Drive, Vainona, Harare
[email protected]
 ADMIN 000-1
REVISION 00
EFFECTIVE 29/04/24

For the purposes specified in the report or in the instructions that commissioned it, this report has only been generated for
the exclusive benefit, use, and information of the client, Zimplats. However, the explained methods and referenced
manuals and drawings will illustrate the procedure of installation. Elsewedy (and by implication, Jecca) carries all
responsibility and obligation for this procedure. The methods explained in this method statement are based on the data
available. Our research, which includes an evaluation of the SHEQ requirements and site logistics outlines how this task
will be carried out.

SCOPE
 Transportation of substation equipment from the main store to the substation site
 Erection of substation equipment at the designated foundations

JECCA ENGINEERING (PVT) LTD No. 17 Fowey Drive, Vainona, Harare

[email protected]
 ADMIN 000-1
REVISION 00
EFFECTIVE 29/04/24

1. INSTALLATION OF SUBSTATION EQUIPMENT

1 Scope of works/tasks
This Method Statement provides the details of equipment, manpower and the procedure for the erection of CTs, CVTs,
132kV disconnector switch, 132kV circuit breaker, steel support structures erection. The detailed description of the steel
structures are found in the construction drawings from Elsewedy.
2 Risk Assessment
A Risk Assessment Form (RAF) must be filled out before any work occurs. An evaluation of the risk classification as extreme
or high (necessitates contacting the appropriate supervisor and developing a Job Safety Analysis).

3 Labor requirements 4 Plant/Tools requirements

Engineers Plant
Supervisor Forklift
Telehandler operator Telehandler
Fork lift operator Mobile crane
Mobile crane operator
Rigger Tools
Electrician Spanners
Electrician assistants Rachet
SHEQ Rep/ SHEQ Officer D Shackles (17T)
Manual handlers Guide rope
Spotters Slings
Tape measure
3M ladders

5 Identity of any Hazardous substances

 Metal fragments
 Loose ground
 Substandard tools

6 Methodology

6.1 Pre-Installation
 Check on the area of installment for accessibility.
 Check for compactness of the ground where the mobile crane will stand.
 Check on all the tools to be used for defective and substandard tools.
 Coordinate transportation of equipment, support structures and assembly accessories required for complete
installation of a named equipment to site.
 Quality check on all the equipment, support structures and assembly accessories for any physical damage
before erection.
 Position the mobile crane on a position where equipment ca be easily lifted into position.
 Position stabiliser arms and rams to stabilise crane.
 Acquire from construction drawings, the position and alignment of equipment
 Acquire from erection manuals, the weight of equipment, slinging positions and erecting sequence.

JECCA ENGINEERING (PVT) LTD No. 17 Fowey Drive, Vainona, Harare

[email protected]
 ADMIN 000-1
REVISION 00
EFFECTIVE 29/04/24

o Erection of equipment
 Rigger to place the shackles in the slinging positions of the equipment and secure the slings on the
shackles and the crane hook.
 Hoist equipment and move to erecting position.
 Raise equipment to erecting position.
 Artisan and assistants to fasten equipment securing bolts into position according to the erection
manual using spanners.
 Remove slings and inspect for damage.
 Complete erecting and assembly as prescribed by equipment supplier.

o Installation of substation equipment

 Installation of 132kV circuit breaker

Installation of steel support structures
 Erect the breaker frames onto the circuit breaker foundations using the method in 6.2.
 Using a digital level, adjust the north-south and east-west verticality by adjusting the tightening nuts
on bolts between the base plate and the foundation of the breaker frames.
 Tighten the nuts to a torque of 300 to 350 Nm for M24 nuts.
 Using the method in 6.2, erect the pole beam onto the circuit breaker frames.
 Tighten the M20 bolts between the pole beam and the braker frames to a torque of 420Nm.
 Fasten the crimped lug on the 120mm2 copper riser from the earth grid on the breaker frame 14mm
diameter holes provided for earthing.

Assembly of the operating mechanism on the pole beam

 Using the method in 6.2, erect the operating mechanism using the 4 slinging positions to the pole
beam.
 Fit the M12 bolts and attach the nuts with flat and spring washers and fasten to 190Nm.
 Fit brackets on the two lifting bolts on the front of the operating mechanism.
 Fit the nuts with washers and tighten to 190Nm.

Assembly of circuit breaker poles

 Erect the breaker poles according to the method in 6.2
 Refer to the ABB 132KV SF6 circuit breaker installation manual (p.60) for the assembly of the torsion
bar and the correct sequence of assembly i.e B1, A1, C1

Assembly of the gas monitoring system

 Refer to the ABB 132KV SF6 circuit breaker installation manual (p.69)

Installation of electrical connections

 Refer to the ABB 132KV SF6 circuit breaker installation manual (p.76)
 Connect the automatic operating mechanism to the 110V dc power supply cable
 Fit the rails or lines
 Charge the closing spring electrically

Pressurize breaker poles

 Refer to the ABB 132KV SF6 circuit breaker installation manual (p.79)

 Installation of post insulators

Steel support structures installation

JECCA ENGINEERING (PVT) LTD No. 17 Fowey Drive, Vainona, Harare
[email protected]
 ADMIN 000-1
REVISION 00
EFFECTIVE 29/04/24

 Coordinate assembly and erection of 132kV PI (busbar) steel structure supports with a total weight of
203kg.
 Fasten on the M14 bolts the nuts and washers
 Use a digital level to adjust the north-south and east-west verticality by adjusting the tightening nuts
on bolts between the base plate and the foundation of the post insulator.
 Coordinate assembly and erection of 132kV PI feeder steel structure supports with a total weight of
807kg.
 Fasten on the M16 bolts the nuts with flat and spring washers.
 Fasten the crimped lug on the 120mm2 copper riser from the earth grid on the breaker frame 14mm
diameter holes provided for earthing using M14 bolt and nut.

Post insulator erection

 Verify that the support structures are plumb.
 Erect the insulator with crane using method in 6.2
 Secure and fasten the 8, M18 bolts holding together the plate on top of the support structure and the
base plate of the insulator.
 Check post insulator is plumb.
 Ensure that nuts torqued to the correct torque.
 Nuts to be marked once torqued.

 Installation of 132V disconnector switch

Steel support structures installation

 Coordinate erection of 6 vertical steel structure supports with a total weight of 842kg.
 Fasten on the M14 bolts the nuts and washers
 Use a digital level to adjust the north-south and east-west verticality by adjusting the tightening nuts
on bolts between the base plate and the foundation of the post insulator.
 Fasten the crimped lug on the 120mm2 copper riser from the earth grid on the breaker frame 14mm
diameter holes provided for earthing using M14 bolt and nut.
 Coordinate erection and assembly of the horizontal steel supports with a total weight of 694kg.
 Fasten on the M12 bolts the nuts with flat and spring washers.

Switching mechanism installation



Operating mechanism installation



 Installation of surge arrestor

Steel support structures installation


Surge arrestor erection



 Installation of CVTs
Steel support structures installation
JECCA ENGINEERING (PVT) LTD No. 17 Fowey Drive, Vainona, Harare
[email protected]
 ADMIN 000-1
REVISION 00
EFFECTIVE 29/04/24

CVT Erection

 Installation of CTs
Steel support structures installation

CT Erection

Commissioning
 All instruments necessary for inspection and testing shall be supplied and shall be properly calibrated
operated by skilled personnel.
 Allowance shall be made for disconnection of certain joints/points to satisfy requirements for testing.
 Measure earth resistance when the soil is dry and without any means of alteration or reduction of earth
resistance.
 Where resistance to earth exceed a specified threshold, notify the main contractor and provide
recommendations to decrease earth resistance.
 Restore the surface features at areas disturbed by the works of this section

7 Permit Requirements
 The permit to work shall be issued by an authorized permit issuer on daily basis before task commences.

8 Review access
Review will be performed using traffic management Plan (Revision on the Site Traffic Management Plan will be shared
as a separate document for the movement of all equipment associated in carrying out the task.)

9 SHEQ requirements
 Daily safety talk
 Training on Procedure and IBRA (The IBRA will be shared)

 Pre-task risk assessment

 Permit to work

 Spotting flags

 All necessary PPE:

 safety shoes,

 work suits with elastic bands

 long sleeve reflectors,

 engineering gloves,

 safety goggles,
JECCA ENGINEERING (PVT) LTD No. 17 Fowey Drive, Vainona, Harare
[email protected]
 ADMIN 000-1
REVISION 00
EFFECTIVE 29/04/24

 earplugs
 masks
10 REFERENCE DOCUMENTS

 IEEE Std 80-2000.

11 RISKS
 Human-machinery interaction
 Muscle strains during heavy lifting of the materials.
 Use of damaged or worn out PPE resulting in injuries
 Unsecured loads during transportation of earthing euipment from the storage area to the site may fall from height
resulting in an employee being crushed resulting in fatalities
 Overloading the pallet jack may decrease its stability when the load is lifted heightening the likelihood that the load
will fall and the forklift may tip over endangering the operator and potentially damaging the load or machinery.
 Unexpected movement of attachment with suspended load is more likely to impact the stability of a telehandler
resulting in overturning thereby causing injuries
 Dust
 Fatigue
 Heat stress
 Snake/insect bite
 Unstable ground

JECCA ENGINEERING (PVT) LTD No. 17 Fowey Drive, Vainona, Harare

[email protected]
 ADMIN 000-1
REVISION 00
EFFECTIVE 29/04/24

Safety and Health requirements

 All the workers at the area shall always wear PPE (job specific).
 All the workers must be briefed about the earthing/grounding installation procedure, IBRA, installation specifications
and safety requirements.
 Deploy enough trained spotters for the machines that are involved in carrying out the task.
 Sign boards to be kept at all visible places and to be protected and barricade tapes and nets should be put to show
demarcations.
 Close supervision and recording by site engineer/ supervisor is required.
 All the machinery must be checked by the operators every morning before the start of work and to fill the check lists
with signature.
 SHEQ rep personnel (assisted by SHEQ Officer) will be appointed to oversee the works in line with the Zimplats BMS
Plan, Policies and Procedures.
 All SHEQ Issues shall be observed according to the Zimplats BMS Plan, Policies and Procedures.
 As the works are being carried out adjacent to the client’s operations all risks associated to the interaction, such as fall
of ground due to mining activities, interaction with mobile machinery, high voltage electricity, noise, dust, e.t.c will
need to be captured and mitigation plans put in place.
 All workers will be inducted on matters of Safety, Health and Environment and Quality before commencement of duty.
 The responsible supervisor shall ensure housekeeping at the work area after work.
 Pre-task risk assessment shall be done before any work commences.
 The permit issuer shall issue the general work permit before any work commences.

JECCA ENGINEERING (PVT) LTD No. 17 Fowey Drive, Vainona, Harare

[email protected]