Abu Dhabi Plaza – Astana, Kazakhstan Document No.

Work Package 4 – Main Works ADP-263623-007

Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 2 of 29 Rev 001

REVISION DESCRIPTION SHEET

Rev. Para. Revision Description

000 Issued for Review / Comments
001 Issued for Review / Comments

Hold
Para. Description of Hold
No.

The Inspection Forms are controlled within this MS and are

included during the Review and Approval cycle.

The latest revision of an Inspection Form shall be used during

work execution.

Revisions after Rev.0 are denoted by a triangle in the left

hand margin against the revised text, with the revision
number displayed next to revision line. As shown by the
example below:-

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Work Package 4 – Main Works ADP-263623-007

Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 3 of 29 Rev 001

Item
Comments On Rev.000 Contractor’s Response
No.

Comply.
1. Interlocking of the MDB Panel Bus
Coupler shall be verified in MDB T&C.

 MAR for LV Panel is used for the

GSP.
2.
 Comply.
 Comply.

3. Comply.

Cummins is responsible for the

4.
Synchronizing Panels T&C.

5. Comply.

 Comply
 The installed load shall be used
6. during Load Sharing and shall be
performed at a later phase.

7. Comply.

 Comply.

8.  Cited parameters shall be recorded

in the performance test report
during Diesel Generator T&C.

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Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 4 of 29 Rev 001

Comply.

Schedule can be referred to the

9. referenced Outline Drawings & Wiring
Schematics for Generator Power
Synchronization & Distribution Panel.

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Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 5 of 29 Rev 001

Table of Contents

1.0 Purpose

2.0 Scope of Work

3.0 References

4.0 Definitions & Abbreviations

5.0 Resources, Roles & Responsibilities

5.1 Competency
5.2 Roles and Responsibilities of Commissioning Engineer
5.3 Roles and Responsibilities of QC Engineer
5.4 Roles and Responsibilities of Foreman
5.5 Roles and Responsibilities of Equipment Specialist

6.0 Tools Requirements

7.0 Method and Sequence of work

7.1 General
7.2 Safety Precautions
7.3 Pre-Commissioning
7.4 Commissioning
7.4.1 LV Synchronizing Panel Tests
7.4.2 Synchronization and Load Share Test
7.4.3 Interfacing

8.0 Quality Control

9.0 Health, Safety & Environmental

9.1 Induction
9.2 PPE
9.3 Hazard Identification, Risk Assessment & Control
9.4 Toolbox Talks
9.5 Permit to Work
9.6 Environmental Impact
9.6.1 Safety Training
9.6.2 Trades & Qualifications
9.7 Training of Personnel

10.0 Attachments:

10.1 Inspection & Test Plan (ITP) – Generator Synchronizing Panels: ITP-1122-407 T&C
10.2 Form No: FM-MS-ADP-263623-007-001
10.3 Form No: FM-MS-ADP-263623-007-002
10.4 Form No: FM-MS-ADP-263623-007-003
10.5 JSTI
10.6 Risk Assessment

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Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 6 of 29 Rev 001

1.0 PURPOSE
The main purpose of this method statement specifies the sequence and methodology for the execution of the
Generator Synchronizing Panels Testing and Commissioning in this project.

2.0 SCOPE OF WORK

This method statement covers the onsite physical inspection and verification of the Generator Synchronizing
Panels including the operations of all associated equipment such as Generator LV Switchgear incoming &
outgoing breakers, Generator LV Switchgear Bus Coupler, ATS, Generators w/ Load Sharing Management, and
Fire Pump Panels w/ built-in ATS.

3.0 REFERENCES
 Project Health & Safety Plan ADP-013529-002.
 Specifications: 260126 – Operation, Maintenance, & Testing of Electrical Systems
 Specifications: 263623 – Automatic Transfer Switches
 Specifications: 263213 – Diesel Generators
1  MAR: ADP-262413-010 – LV Panel Switchboard
 MAR: ADP-265200-001 – Diesel Generator Set
 Approved Testing & Commissioning Plan by CML, Ref.ADP-CML-CO-RPT-W-00016
 General Method statement for winter working, Ref. No.: ADP-015000-036
 Risk Assessment Plan Ref. No: ADP-013529-028.001.
 Project Quality Plan Ref. No.: ADP-014000-020
 QMP Ref.: ADP-014000-040 rev.003 Field Inspection & Testing.
 Fall Protection Procedure, Ref No: ADP-013529-026
 Lock-Out and Tag-Out, Ref No. ADP-013529-026
 Generator LV Switchgear Panel Sequence of Operation: ADP-262413-042
 Block B - Outline Drawings & Wiring Schematics for Generator Power Synchronization & Distribution
Panel: ADP-262413-021
 Block O – Outline Drawings & Wiring Schematics for Generator Power Synchronization & Distribution
Panel: ADP-262413-022
 Block P - Outline Drawings & Wiring Schematics for Generator Power Synchronization & Distribution
Panel: ADP-262413-023
 Block R - Outline Drawings & Wiring Schematics for Generator Power Synchronization & Distribution
Panel: TBA
 Method Statement for Testing & Commissioning of Main Distribution Board: ADP-262413-027
1  Method Statement for Testing & Commissioning of Diesel Generators: ADP-263213-007

4.0 DEFINITIONS
MML: Mott Macdonald LTD.
CSC: Construction Supervision Consultant. (AECOM-KZ)
ACCL JV: ACCL Joint Venture.
P & T: P & T Architects (JV Architect/Lead Design).
RED: Red Group Services FZ-LLC Dubai, UAE (MEP design consultant).
CXA: CML International (Commissioning Authority)

5.0 RESOURCES, ROLES & RESPONSIBILITIES

The Commissioning Manager has the overall responsibility for the implementation of this Method of
Statement, also will individually assess the manpower required for T&C of the Generator Synchronizing
Panels to meet the schedule. Typically these will include:
 Commissioning Engineer
 Foreman
 QC Engineer
 Equipment Specialist

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Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 7 of 29 Rev 001

5.1 Competency
The competency of all construction personnel shall be controlled in accordance with the
Competent Persons Designation Procedure Ref: ADP-013529-066.

5.2 Roles & Responsibilities of Commissioning Engineer

 Commissioning Engineer will be in charge of all operations during Testing & Commissioning
following Project HSE requirements and Project Quality Plans.
 Maintains work permits with coordination of the HSE Supervisor.
 Coordinates with QC Engineer for inspections and raise RFIC with complete attachments such
as approved (ITP, shop drawing, check list etc.).
 Ensures that only trained and competent personnel are involved for Final Testing of the
Generator Synchronizing Panel.
 Ensures that tools & equipment are certified, maintained and used correctly.
 Ensure that all testing tools are calibrated and calibration is up to date.
 Ensures that all required documents and related drawings to execute the works are up to date.
 Shall prepare liaise his crew and the planning department for progress reporting and schedule
monitoring.

5.3 Roles & Responsibilities of QC Engineer

 Ensure that all inspection and test reports pertaining to everyday work activities are submitted to
the QC inspection.
 Prevent the use of equipment that could cause improper test relative to project Specifications.
 Stop test activity that is not being done in accordance with the specified requirements and
approvals.
 Ensure that test have been done in accordance with approved method statement and Project
specification to offer for CSC’s & CxA’s inspection.

5.4 Roles & Responsibilities of Foreman

 The foreman will carry out his duties by maintaining continuous coordination with the
Commissioning Engineer on daily basis, and ensure proper distribution of the workforce in the
required and planned locations.
 To ensure that his assistant foreman/charge hand are aware of the job requirements and they
have enough information to carry out their duties properly.
 To ensure in consultation with the site engineer that the manpower involved in the works are
moving as agreed and planned for the work.
 To ensure that the daily work is progressing as planned and advice the Commissioning Engineer
of any requirement for additional resources.
 To ensure full coordination with the safety officer to maintain safe working and proper
housekeeping of the site, following the approved safety measures and further ensure that all his
working team are aware of the same to prevent accident and losses.
 To inform the Commissioning Engineer and of the areas ready for inspection.

5.5 Roles & Responsibilities of Equipment Specialist

 Cummins’ Representative shall conduct the testing & commissioning of the Synchronizing Panel.
 Cummins’ Representative shall sign off the pre-commissioning check list and commissioning
test sheets when the requirements stated in this Method Statement are satisfied.

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Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 8 of 29 Rev 001

6.0 TOOLS REQUIRMENTS

The following tools & equipment will be used during the Testing and Commissioning of the Synchronizing
Panel.
 Standard Electrician Tool Kit
 Digital Multimeter
 Torque Wrench
 Insulation Resistance Tester
 Hi-Pot Tester
 Low Resistance Ohmmeter
 CB Full Function Test Kit
 Secondary Injection Test Kit
 Phase Rotation Tester
1  Ear Muffs/Plugs
 Scaffolding/Ladder
 PPE (Hand Gloves, Safety Goggles)
 Safety harness while working in high level in ladders or scaffolding

Note: All tools and equipment’s will be inspected and colour coded before use at site. All testing
instruments shall have valid calibration certificates.

7.0 METHOD AND SEQUENCE OF WORK

7.1 General

 All necessary work permits shall be approved before commencement of the work.
 Prior to commencement of work, a tool box meeting shall be held for proper distribution of testing
personnel and relocation of other workers working during the testing.
 Prior to start the work, conduct pre-work start tool box talk and related method statement shall
be read and signed off by concerned engineers.
 All personnel involved carrying out the testing activity shall be briefed via HSE Tool box talk, on
site condition, work area, task in hand, risk, hazards, and mitigation of potential of risk.
 Secure valid calibration certificate for all testing equipment, which will be used for test.

7.2 Safety Precautions

 All safety precaution shall be followed as per established project safety plan.
 Only experienced and skilled technician shall be engaged for carrying out the start-up and
commissioning of the Synchronizing Panel.
 Appropriate warning signs and tapes shall be placed during start-up and commissioning as
required.
 All PPE shall be worn as appropriate according to the nature of job.
 Work area shall be maintained neat and clean.
 Lock-Out & Tag-Out procedure (Ref. ADP-013529-026) shall be followed during entire activity
related to Testing and Commissioning as applicable

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Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 9 of 29 Rev 001

7.3 Pre-Commissioning

Room conditions shall have a maintained room temperature of about 25°C and the room must
have sufficient lighting and ventilation.
 Ensure Synchronizing Panel installation is completed with RFIT signed off.
 Ensure Generator is tested with RFIC signed off or Generator installation is completed
with RFIT signed off if it is to be tested simultaneously with the Synchronizing Panel.
 Ensure LV Cable is tested with RFIC signed off.
 Ensure ATS is tested with RFIC signed off.
 Ensure Earthing System is completed with RFIC signed off.
 Ensure Discrimination Study is available for ACCB & MCCB Electronic Trip Testing and
1 Final Setting if applicable.
 Ensure latest approved shop drawings, system layout, schematic diagram, equipment
schedule, method statement & T&C checklists are available at site.
 Verify the nameplate data and tags match with the drawings or schedule.
 Verify ratings, quantity, and make for all components in the nameplate as per drawing or
design specifications.
 Check for the metering, indication lamps, and selector switch arrangements on the panel.
 Check tightness and termination of the cable entries.
 Check the equipment in respect of any exterior damages.
 Check the equipotential bonding of the equipment.
 Check the drawing in the pocket is available.
 Check the cables are bunched neatly and dressed properly.
 Check the PLC is being fed by the UPS (230V AC).
1  Check the Fail Status Signals from the MDB Panel, ATS Panel & Fire Pump Panel, w/
built-in ATS, are connected properly.

7.4 Commissioning

After the pre-commissioning, has been completed, the system will be ready for Testing and
Commissioning. The entire system will be checked for full functionality as per the project specific
sequence of operation. The system is applicable only to generators running in parallel (Block B, P,
O, & R) and will be sequentially tested and commissioned.

7.4.1 LV Synchronizing Panel Test

Synchronizing Panels shall be tested according to the approved T&C method statement
of Main Distribution Board (ADP-262413-027) and record the results in FM-MS-ADP-
263623-007-002. The tests to be carried out where applicable are as follows:
 Torque Test.
 Insulation Resistance Test (Before and After Dielectric Test).
 Dielectric Test.
 Contact Resistance Test on the busbar with the bus coupler closed.
 Circuit Breaker Test for Electronic Trip Units.
 Current Transformer Tests (Secondary Injection).
 Energy Meter Test (Secondary Injection).

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Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 10 of 29 Rev 001

7.4.2 Synchronization and Load Sharing & Shedding Verification

Sequence of operation and various operating conditions are defined and elaborated in
the Generator LV Switchgear Panel Sequence of Operation - ADP-262413-042. The
Actual Testing Condition and Result shall be fully described in the report. Genset
Synchronization shall be performed through the PCC at no load condition for not more
than 10 minutes according to Cummins. The LV Switchgear “Power Fail Status” in the
1 terminal block needs to be looped so that the PLC could start the Genset and feed the
dead bus, the PCC will then commence synchronization. Load Demand, Sharing, and
Shedding shall be performed at a later phase when the designated load is installed. The
connected load shall be manually switched to simulate the demand requirement. Verify
the conditions and record the measurements in FM-MS-ADP-263623-007-003.
Output Voltage Active Power
Output Current Reactive Power
Frequency Power Factor

7.4.2.1 Block B

GSP-B is feeding to ELV2-B, ELV3-B and FEP-B1/2 with built-in ATS. Under normal
operation (all utility supply healthy condition), ELV2-B & ELV3-B and FEP-B1/2 are
energized by utility power supply. GSP-B will come into picture with the following
operating conditions:
 Any ELV2-B or ELV3-B or FEP-B1/2 ATS utility supply fail condition.
1  Return of normal supply after ELV2-B, ELV3-B or FEP-B1/2 ATS utility supply
failure.
 Generator failed to come on bus due to any reason.
 Generator failed during operation due to any reason with load demand active.
 Short circuit on GSP-B busbar condition.
Legend:
ELV2-B ADP-B-B01-0017-LV-EMDB-0001 Emergency MDB 1
ELV3-B ADP-B-B01-0017-LV-EMDB-0002 Emergency MDB 2
GSP-B ADP-B-B01-0016-LV-GSP-0001 Generator Sync. Panel
FEP-B1 TBA Fire Pump Panel (Duty)
FEP-B2 TBA Fire Pump Panel (Standby)

7.4.2.2 Block P

GSP-P is feeding to ATS-P1 and ATS-P2. Under normal operation (all ATS utility supply
healthy condition), ATS-P1 and ATS-P2 panels are energized by utility power supply.
GSPP will come into picture with the following operating conditions:
 Any ATS Panel utility supply fail condition.
1  Return of normal supply after ATS supply failure.
 Generator failed to come on bus due to any reason.
 Generator failed during operation due to any reason with load demand active.
 Short circuit on GSPP busbar condition.
Legend:
ATS-P1 ADP-P-B01-0039-LV-ATS-0001 Automatic Transfer Switch 1
ATS-P2 ADP-P-B01-0039-LV-ATS-0002 Automatic Transfer Switch 2
GSP-P ADP-P-B01-0039-LV-GSP-0001 Generator Sync. Panel

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Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 11 of 29 Rev 001

7.4.2.3 Block R

GSP-R is feeding to ATS-R1, ATS-R2, ATS-R3, and FEP-R1/2 with built-in ATS. Under
normal operation (all ATS utility supply healthy condition), ATS-R1, ATS-R2, ATS-R3,
and FEP-R1/2 ATS are energized by utility power supply. GSP-R will come into picture
with the following operating conditions:
1  Any ATS Panel utility supply fail condition.
 Return of normal supply after ATS utility supply failure.
 Generator failed to come on bus due to any reason.
 Generator failed during operation due to any reason with load demand active.
 Short circuit on GSPP busbar condition.
Legend:
ATS-R1 TBA Automatic Transfer Switch 1
ATS-R2 TBA Automatic Transfer Switch 2
ATS-R3 TBA Automatic Transfer Switch 3
GSP-R TBA Generator Sync. Panel
FEP-R1 TBA Fire Pump Panel (Duty)
FEP-R2 TBA Fire Pump Panel (Standby)

7.4.2.4 Block O

GSP-O is feeding to MDB ELV2-O, ELV3-O, ELV4-O, ATS-O, and FEP-O1/2 with built-
in ATS. Under normal operation (all ATS utility supply healthy condition), ELV2-O, ELV3-
O, ELV4-O, ATS-O, FEP-O1/2 ATS are energized by utility power supply. GSP-O will
come into picture with the following operating conditions:
 Any ELV2-O, ELV3-O, ELV4-O, ATS-O or FEP-O1/2 ATS utility supply fail
1 condition.
 Return of normal supply after ELV2, ELV3, ELV4, ATS-O, & FEP-O1/2 ATS
utility supply failure.
 Generator failed to come on bus due to any reason.
 Generator failed during operation due to any reason with load demand active.
Short circuit on GSP-O busbar condition.
Legend:
ELV2-O ADP-O-B01-0013-LV-EMDB-0001 Emergency MDB 1
ELV3-O ADP-O-B01-0013-LV-EMDB-0002 Emergency MDB 2
ELV4-O ADP-O-B01-0013-LV-EMDB-0003 Emergency MDB 3
ATS-O ADP-O-B01-0013-LV-ATS-0001 Automatic Transfer Switch 1
GSP-O TBA Generator Sync. Panel
FEP-O1 TBA Fire Pump Panel (Duty)
FEP-O2 TBA Fire Pump Panel (Standby)

7.4.3 Interfacing

Integration shall be validated during the testing & commissioning of BMS and FAS.

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Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 12 of 29 Rev 001

8.0 QUALITY CONTROL

 MEP RFIC should be issued by T&C Engineer for verification before submission to CSC & CxA.
 Refer to ITP No. ITP-1122-407 T&C and strictly follow inspections steps.
 Refer to QMP-ADP-014000-625 for RFIC submission process.
 Work should be approved by consultant (submitting RFIC).

9.0 HEALTH, SAFETY & ENVIRONMENTAL

9.1 Induction

Prior to commencing work all personnel shall have attended the HSE induction course conducted by the
JV HSE department. No work shall be undertaken by personnel who have not attended the Project HSE
induction. In all aspects, work is to be carried out in a safe manner and in accordance JV approved Health
and Safety Plan and in accordance with HSE requirements

9.2 Personal Protective Equipment (PPE)

All personnel involved in the Testing and Commissioning will comply with the Project requirements for
PPE:
 Work Boots with toe protectors
 Safety Helmet
 Eye Protection with side shields
 Dust masks (as required)

Additional PPE identified by the task risk assessment shall also be provided. Personnel shall sign and be
responsible for their own items of PPE issued to them and the Engineer shall ensure that his team is
complying with the minimum required PPE and that damaged or defective PPE is replaced or repaired
immediately.

9.3 Hazard Identification, Risk Assessment & Control

Hazard identification, risk assessment and control are detailed in the appropriate risk assessment and
Job Safety Task Instruction (JSTI) attached herewith. Hazards may vary as the works progress and shall
be re-evaluated. All personnel undertaking testing and commissioning activities shall be aware of
particular location hazards. The Project Risk Assessment Procedure ADP-013529-028 is to be referred
to during the planning stages. Should changes occur during the course of commissioning which alters
the associated risks then the risk register shall be updated to reflect any additional risk and mitigation
measure.

The attached JSTI is provided to cover the initial work tasks relating to Testing and Commissioning of the
Generator Synchronizing Panels- JSTI (attached). This JSTI is prepared based on theoretical information
interpreted from the project documents. A further assessment will be required at the actual work site to
verify the control measures and address any additional hazards. Reference is to be made to the relative
Health, Safety, Environmental & Security procedures to control the risks associated with activities where
they occur.

9.4 Toolbox Talks

Prior to the commencement of site activities the Engineer, with support from the HSE Officer, shall
conduct a pre-start toolbox talk with all the crew present. The MEP Supervisor shall explain the testing
and commissioning activities, focusing on the hazards and risks involved in the activity and the mitigation
measures that shall be taken as detailed in the Risk Assessment. Regular Toolbox talks shall be
conducted in order to prevent complacency within the crew. The Engineer shall conduct a Pre-start
toolbox talk for the new person/s prior to starting work.

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Method Statement for Testing & Commissioning the Generator Synchronizing Panels Page 13 of 29 Rev 001

9.5 Permit to Work

A Permit shall be obtained when and where applicable in accordance with the requirements of Permit to
Work Procedure (ADP-013529-034) prior to performing the Installation, Testing and commissioning of
the Generator Synchronizing Panel. The supervisor will ensure that all relevant risk assessments, method
statements and permit to work control measures are in place and that all relevant procedures contained
within these documents are fully understood by the operative personnel.

9.6 Training of Personnel

9.6.1 Safety Training

All personnel involved in Testing and Commissioning of the Generator Synchronizing Panels
works shall be trained in accordance with the requirements of the Project HSE Program. No
personnel shall be assigned tasks that they have not received appropriate training in or have
been assessed for competency. Further training shall be given as required and when additional
training is identified during the risk assessment process.

9.6.2 Trades & Qualifications

All personnel involved in Testing and Commissioning of the Generator Synchronizing Panels
activities shall be assessed for qualifications, competency and if they have the required trade
skills and experience, or trained in accordance with the requirements of the project standards..

10.0 ATTACHMENTS

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Document Title:
Inspection & Test Plan (ITP) – Generator Synchronizing Panels Page 1 of 1 Rev.001
(JV REF. ITP-1122-407 T&C)

Testing Inspection and

Reference
Requirement / Acceptance
No. Activity Description Type of Inspection Reference Document Transmittal
Acceptance
T&C AECOM CML Form
Criteria
 Specification 263623
 Specification 260126
 Approved MS
 Approved Generator
RFIT or RFIC
 Approved Sync Panel All relevant
Pre-Commissioning RFIC & FM-MS-
 Review of Documents Installation RFIT document must be
1. Checklist of Generator S R R ADP-263623-007-
 Pre-Commissioning  Approved LV Cable approved by
Synchronizing Panel 001
RFIC. Consultant.
 Approved ATS RFIC
 Approved Earthing
System RFIC
 Approved
Drawings/Schedule
 Torque Test
 Insulation Resistance Test  Specification 263623
All relevant
Performance Test  Di-electric Test  Specification 260126 RFIC & FM-MS-
document must be
2. Sheet of LV  Contact Resistance Test  Approved Test H W W ADP-263623-007-
approved by
Synchronizing Panels  CB Full Function Test Procedure
Consultant.
002
 Energy Meter Test  Calibration Certificate
 CT Test
 Specification 263623
All relevant
Synchronization and  Specification 260126 RFIC & FM-MS-
 Synchronization Checks document must be
3. Load Sharing Test  Approved Test H W W ADP-263623-007-
 Load Share Checks approved by
Report Procedure 003
Consultant.
 Calibration Certificate

Legend: S – Surveillance Inspection W – Witness Inspection Point H – Mandatory Hold Point for Inspection R – Record Review
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Pre-Commissioning Checklist of Generator Synchronizing

Panels
FM-MS-ADP-263623-007-001 Revision:001 Date: 10-Nov-17 Page 1 of 2

RFIC No.: Date: System: Low Voltage

Block: Level: Sub System: LV Distribution Boards, Panels and Enclosures

Station Reference:

Sync. Panel Reference:

ACCEPTANCE STATUS
REQUESTED DOCUMENTATION SUBMITTED
Yes/No REMARKS
1. T&C MS

2. Signed Off Synchronizing Panel Installation RFIT

3. Signed Off Generator Installation RFIT or Testing RFIC

4. Signed Off LV Cables RFIC

5. Signed Off ATS RFIC

6. Signed Off Earthing System RFIC

7. Discrimination/Coordination Study is available.

8. Equipment Schedule, Schematic Diagram, Single Line Diagram, & Layout Drawings
ACCEPTANCE STATUS
ACTIVITIES / ITEMS TO BE INSPECTED
Yes/No REMARKS
1. Nameplate data and tags match with the drawings or schedule.
2. Ratings, quantity, and make for all components in the nameplate are as per
drawing or design specifications.
3. Metering, indication lamps, and selector switch arrangements on the panel are Ok.

4. Cables are tight and correctly terminated.

5. Equipment is checked in respect of any exterior damages.

6. Equipotential bonding of the equipment is checked.

7. Drawing in the pocket is available.

8. Cables are bunched neatly and dressed properly.

9. PLC is being fed by the UPS (230V AC).

10. Fail Status Signals from the MDB Panel, ATS Panel & Fire Pump Panel, w/ built-in
ATS, are connected properly.

FM-MS-ADP-263623-007-001
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Pre-Commissioning Checklist of Generator Synchronizing

Panels
FM-MS-ADP-263623-007-001 Revision:001 Date: 10-Nov-17 Page 2 of 2

T&C Complete and Conformant

POSITION NAME SIGNATURE DATE

Cummins’ Representative

JV Commissioning Engineer

JV QA/QC Engineer

(CSC) AECOM KZ

(CxA) CML

FM-MS-ADP-263623-007-001
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Performance Test Sheet of LV Synchronizing Panels

FM-MS-ADP-263623-007-002 Revision:001 Date: 10-Nov-2017 Page 1 of 3

RFIC No.: Date: System: Low Voltage

Block: Level: Sub System: LV Distribution Boards, Panels and Enclosures

Station Reference:

Sync. Panel Reference:

Torque Test
Joint Busbar Bolt Torque Applied (N/m) Remarks

Insulation Resistance Test (before Dielectric Test) Ambient Temp. Voltage Applied
Test Connection Withstand Time (1min) Insulation Resistance Value Remarks
L1 to L2+L3+N+E

L2 to L1+L3+N+E
L3 to L1+L2+N+E
N to L1+L2+L3+ E
Dielectric Test Voltage Applied
Test Connection Withstand Time (1min) Leakage Current Value Remarks
L1 (L2+L3+N to E)

L2 (L1+L3+N to E)
L3 (L2+L1+N to E)
N (L1+L2+L3 to E)
Insulation Resistance Test (after Dielectric Test) Ambient Temp. Voltage Applied
Test Connection Withstand Time (1min) Insulation Resistance Value Remarks
L1 to L2+L3+N+E

L2 to L1+L3+N+E
L3 to L1+L2+N+E
N to L1+L2+L3+ E

Contact Resistance Test on Busbars Ambient Temp.: Injected Current:

Test Connection Resistance Value Acceptable (Yes/No)

L1 – E

L2 – E

L3 – E

N-E

FM-MS-ADP-263623-007-002
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Performance Test Sheet of LV Synchronizing Panels

FM-MS-ADP-263623-007-002 Revision:001 Date: 10-Nov-2017 Page 2 of 3

Circuit Breaker Test Panel Name:

Breaker Reference Tripping Curve Breaker Setting Current Injected Tripping Time Remarks

Energy Metering Tests Panel Name & No.

Displayed Meter Reading (V) Reference Std. Meter Reading (V) Acceptable
Applied Voltage (V)
L1 L2 L3 L1 L2 L3 YES/NO

50%

100%
Displayed Meter Reading (A) Reference Std. Meter Reading (A) Acceptable
Injected Current (A)
L1 L2 L3 L1 L2 L3 YES/NO

50%

100%

Current Transformer Ratio Test Panel Name & No.

Percentage of Injected Injected Current Measured Current
CT Details Error / Remarks
Current (A) (A)
CT1 – L1 50%

_______ A / ______ A 100%

CT2 – L2 50%
_______ A / ______ A 100%
CT3 – L3 50%
_______ A / ______ A 100%

FM-MS-ADP-263623-007-002
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Performance Test Sheet of LV Synchronizing Panels

FM-MS-ADP-263623-007-002 Revision:001 Date: 10-Nov-2017 Page 3 of 3

INSTRUMENT USED
Equipment Name Model No. Serial No. Calibration due date
1.

2.

3.

4.

T&C Compliant and Conformant

POSITION NAME SIGNATURE DATE
Cummins’ Representative

JV Commissioning Engineer

(CSC) AECOM KZ

(CxA) CML

FM-MS-ADP-263623-007-002
 ARABTEC CONSOLIDATED CONTRACTORS COMPANY LTD.
ABU DHABI PLAZA – ASTANA, KAZAKHSTAN

Synchronization and Load Sharing Test Report

FM-MS-ADP-263623-007-003 Revision:001 Date: 10-Nov-17 Page 1 of 1

RFIC No.: Date: Block: P Level: System: Low Voltage Sub System: Engine Generator System

Input Voltage Bus Voltage Current (A) Active Reactive

Power Freq.
Generator Power Power Remarks
L1-L2 L2-L3 L3-L1 L1-L2 L2-L3 L3-L1 L1 L2 L3 Factor (Hz)
(KW) (kVAr)
ADP-P-B01-0041-LV-GR-0001
ADP-P-B01-0041-LV-GR-0001

Generator Synchronizing Panel Reference: ADP-P-B01-0041-LV-GSP-0001

Operating Condition Actual Testing Condition Result Remarks
1. Any ATS Panel utility supply fail condition.
2. Return of normal supply after ATS utility
supply failure.
3. Generator failed to come on bus due to any
reason.
4. Generator failed during operation due to any
reason with load demand active.
5. Short circuit on Generator Sync., Panel
busbar condition.

Instrument Name Model No. Serial No. Calibration Due Date

1.
2.

Position Name Signature Date

Cummins’ Representative
JV Commissioning Engineer
(CSC) AECOM KZ
(CxA) CML

FM-MS-ADP-263623-007-003
 Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза

Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
Step 1: Task Planning (task identification and details)/ Шаг 1: Планирование задания (выявление задачи и деталей)

Supervisor name: Work area: Date:

ФИО Супервайзера: Рабочая зона: Дата:
Activity: Testing & Commissioning the Generator Work specific location:
Деятельность: Synchronizing Panels Определенное место работы:
Number of crew members: JSTI Number:
Число работников: Номер Оценка Риска:
Start time/ Finish time/
Work Duration: Permit To Work number:
Начало работы Завершение работы
Продолжительность работы: Номер Наряда-Допуска:
_______________ ______________
Step 2: Job Planning (competent persons, tools and equipment necessary to do the job) Шаг 2: Планирование работы (компетентные работники, инструменты и
необходимые оборудования)

Competent Persons Required Tools Required Equipment Required

(Example: Lifting, Equipment Operator, Scaffolder, Vendors) (Example: radios, special testing meters, electric tools, special tools, (Example: excavator, man lift, compressor, crane,
Компетентные Работники SCBA.) forklift, truck)
(Пример: Операторы подъемника, лесамонтажники, производители) Необходимые инструменты (Пример: рация, метровка, Требуемая техника: (Пример: эксковатор,
электрические инструменты) подъемник, компрессор, кран, погрузчик,
грузовик)
 Commissioning Engineer  Standard Electrician Tool Kit
 Foreman  Digital Multimeter, Torque Wrench
 QC Engineer  Insulation Resistance Tester
 HSE Supervisor  Hi-Pot Tester, Load Bank (Resistive Load)
 Equipment Specialist  Low Resistance Ohmmeter
 CB Full Function Test Kit
 Secondary Injection Test Kit

Step 3: Risk Management (list any nearby activities that may impact the work) Шаг 3: Управление Рисками (перечень деятельности которые могут повлиять на работу)
 Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза

Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
Step 4: Job Safety/Hazard Analysis/ Шаг 4: Анализ/Оценки Рисков
Activity
(What must be done? i.e. tools, Hazards Risks
equipment, and material used) (How could an injury occur?) What Can Happen Recommendations
Item
(Can hazards be eliminated or modified?)
Планирование работы. Опасность Риски Меры контроля
Номер (Что надо для работы. Например: (Как может произойти (Что может произойти) (Как опасность может быть устранена)
инструменты, оборудование и травма)
материалы)

 Pay attention during tool box talks.

 Work flow will be discussed.
 Understand your role.
 Not paying attention  Wear all required PPE’s.
 Injury to personnel due to
during meeting  Safety shoes (steel toe)
being unprepared for the
 Not being informed task.  Hard hat
when work starts
 Hypothermia  Visibility Vest
1 Pre-start Meeting  Icy surfaces  Dust mask as
 Cold weather  Safety glasses
 Required PTW must be obtained prior to
commencement of work.
 Monitor the temperature, and wind chill index.
 Implement the work rest period.
 Wear Winter PPE.(as per weather condition)
 Provide hot beverage for employees

 All personnel must wear sufficient PPE.

 Proper supervision from the concerned
 Contact with sharp  Injury to personnel
supervisors.
objects because they are not
 Tools must be inspected by the competent
 Pinch points wearing sufficient PPE’s
person prior to use.
2  Icy surfaces  Property damage due to
Hauling of materials  Monitor the temperature, and wind chill index.
 Cold weather failure of machines.
 Implement the work rest period.
 Hypothermia
 Wear Winter PPE. (as per weather condition)
 Provide hot beverages for employees
 Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза

Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
 Ensure that personnel engaged of working at
 Serious injury to personnel height are trained and competent to the given
or even fatality due to fall task.
 Fall of material from height.  Supervisor must provide full body harness for
 Fall from height  Injury to personnel due to personnel engaged of working at height.
Working at heights  Collapse of scaffold falling debris.  Workplace place must be barricaded underneath
3
 Cold weather  Injury to personnel or even prior to start the work.
fatality due to collapse of  A proper work platform should be provided
scaffolds.  Monitor the temperature, and wind chill index.
 Hypothermia  Work rest period implemented.
 Wear Winter PPE. (as per weather condition)
 Provide hot beverage for employees.

 All personnel must wear sufficient PPE’s.

 Proper supervision from the concerned
supervisors.
 Evaluate the condition of floor along path from
 Injury to personnel origin to destination.
 Improper manual because they are not  Monitor the temperature, and wind chill index.
handling posture wearing sufficient PPE’s  Work rest period implemented.
 Slips, Trips & Fall  Property damage due to  Wear Winter PPE. (as per weather condition)
4 Material handling  Pinch points failure of machines.  Provide hot beverage for employees
 Cold weather  Back injury  When lifting bend at the knees and hold load
 Hypothermia close to your body. Use legs as the source of
power to lift object.
 The allowable load each person can carry is
only 20 kg. /person.
 Ask for help if object too heavy.
 Ensure personnel involve in task have manual
handling training.
 Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза

Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности

 Keep unauthorized personnel away from the

workplace
 Contact with sharp  Barricade the workplace and provide signage for
edges people awareness
 Slips, Trips & Fall  Back injuries  Secure all exposed wires
Pre-Commissioning:  Trailing cables  Foot injury
 Ensure Fire Extinguishers are available inside
5  Exposed live wires  Personnel injury or death
the room
 Cold weather due to electrocutions
 LOTO not applied  Hypothermia  Proper supervision from the concerned
supervisors.
 Tools must be inspected by the competent
person prior to use.
 Implement LOTO procedure

 Keep unauthorized personnel away from the

Commissioning area.
 Barricade the workplace and provide signage for
people awareness
 Improper manual
handling posture  Valid calibration certificate for all testing
 Back injuries Equipment’s.
 Slips, Trips & Fall
Commissioning  Foot injury 
 Noise Secure all exposed wires
 Hearing impairment
- LV Panel Installation Tests  Trailing cables 
6  Personnel injury or death Proper supervision from the concerned
 Exposed live wires supervisors.
-Synchronization and Load Share Test due to electrocutions
 LOTO not applied 
 Hypothermia Hearing protection required
-Interfacing  Cold weather  Ensure sufficient ventilation at the workplace
 Tools must be inspected by the competent
person prior to use.
 Implement LOTO procedure
 Fire Extinguishers are available inside the
room.
 Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза

Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
 Wear all required PPE’s.
 Slips, trips and fall due to  work boots/ rubber boots with toe
 Slips
scattered materials or protector
 Trips  hard hat
rubbish.
 Fall  visibility vest / jacket
 Foot injuries
7 Housekeeping  Dust  safety glass
 Hand injuries
 Dust Mask ( as required )
 Personnel injury due
 Gloves
slippery surface
 Supervisor must ensure that used materials
must be stored in designated, to prevent
scattered at work area
 Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза

Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности

Step 5: Unplanned Events (if any of the following occurs, stop work and talk to your supervisor)/ Шаг 5: Незапланированные мероприятия: если следующие случаи имеют
место, то остановите работу и известите супервайзера
Nearby work hazards Chemical spills or release
Excessive noise Fires and explosions Unusual odours Heat stress
Опасности на рабочем Утечки химических
Черезмерный шум Пожар и взрывы Странный запах Тепловой удар
месте веществ
Extreme weather/high
winds
Significant near miss Change in the following work conditions:
Evacuation alarm Экстримальные
Существенное, возможное Изменение в процессе работы:
Эвакуация/тревога погодные условия и
происшествия
сильный ветер

Step 6: Unplanned Events (if any of the following occurs, stop work and talk to your supervisor) Шаг 6: Незапланированные мероприятия: если следующие случаи имеют
место, то остановите работу и известите супервайзера
Emergency telephone number: Alarm Code (for commission period)
Телефон экстренной связи: +77015301064 Код сигнализации (при пусконаладке)
Nearest Muster Point/Safety Shelter location: Nearest First Aid Station location:
Ближайший пункт Место Сбора: Ближайший пункт Первой Помощи:
Evacuation Route (Supervisor to explain to workers): Safety shower / eye washer location:
Пути эвакуации(Супервайзер должен объяснить работникам): Пункт промывки глаз:

Step 7: Working Crew Details Шаг 7 Список работников (рабочей бригады)

I acknowledge receiving & understanding these instructions, I will fully comply with the assigned job requirements.
Я, подтверждаю что полученную информацию понимаю в полной мере , и я буду полностью соответствовать должностным требованиям.
Sr. Badge No. Signature Sr. Badge No. Signature
Name Ф.И.О Name Ф.И.О
№ № Бейджа Подпись № № Бейджа Подпись
1 26
2 27
3 28
4 29
5 30
6 31
7 32
8 33
9 34
 Astana/Kazakhstan, Abu Dhabi Plaza Project Астана/Казакстан, Проект Абу Даби Плаза

Job Safety Task Instructions Form (JSTI) Форма Оценки Риска по Технике Безопасности
10 35
11 36
12 37
13 38
14 39
15 40
16 41
17 42
18 43
19 44
20 45
21 46
22 47
23 48
24 49
25 50

Supervisor Name:
Ф.И.О Супервайзера: ________________________________________ Signature/ Подпись: __________________ Date/Дата: ____________________________ /______/________

Foreman/charge hand Name:

Ф.И.О Мастера/Бригадира: ___________________________________ Signature/ Подпись: __________________Date/Дата: ____________________________ /______/________

HSE Officer Name:

Ф.И.О Инспектора по ТБ: ____________________________________ Signature/ Подпись: ___________________Date/Дата: ____________________________ /______/________

This JSTI is prepared based on theoretical information interpreted from the project documents. A further assessment will be required
at the actual work site to verify the control measures and address any additional hazards. Reference is to be made to the relative
Health, Safety, Environmental & Security procedures to control the risks associated with activities where they occur.