METHODSTATEMENTS

1. PURPOSE :

The purpose of this procedure is to provide the details of installation of High mast System & other miscellaneous items like wire ropes, Trailing cables, winch, Motors, Head frame, Luminarie carriages etc.

2. SCOPE:

This procedure covers methods of installation of High mast and other miscellaneous items.

.3. SAFETY PRECAUTIONS 1. 1. Do not stand under the load and within the operating radius of cranes 2. 2. Check quality size and condition of all chain pulley blocks, slings, U-clamps, D-shackles, wire ropes etc. The same should not be damaged 3. 3. Safe working load shall be marked on all lifting equipments. 4. 4. Crane and all lifting gears should be tested by competent person. 5. 5. Proper Guiding and Signaling to Crane Operator. 6. 6. Tag line to be used during loading / unloading / shifting the material. 7. 7. Tag line to be used during erection of High mast Tower. 8. 8. All electrical connections must be away from water sources. 9. 9. Routine wise checking s/cleaning of all electrical panels should be made as per check list.

10. 10. Routine wise electrical safety audit should be made as per checklist. 11. 11. Proper checking of ear thing connection should be made and ELCB to be provided on outgoing cable. 12. 12. Fire extinguisher should be available at work site. 2. 4. CONTROLLING SPECIFICATIONS:

The procedure is in accordance with applicable codes, specifications, contract documents & approved drawings.

5. List of Tools and Tackles a) 5 ton capacity Chain pulley blockb) Steel Rod (Sabbal) c) Spanner set d) Combination Pliers e) Insulation remover f) Screwdriver set g) Line Testerh) Meggeri) Multimeter j) Hydra – Capacity 8 Ton k) Crane – Capacity 20 Ton, Boom Length – 45 ft l) Wire Rope – Sling 12 mm m) Belt – Not Used

6. PROCEDURE:

← • All items are to be located as per layout drawing. ← • Prior to installation, items shall be checked for correctness – type, model, area classification, etc. ← • All supporting / mounting structures shall be with proper surface preparation prior to installation. ← • Ensure for correct size, type of Trailing cables, correct size wire ropes, and correct ratings motors, winches – size, and other High mast accessories.-High mast data sheet inserted. ← • Use correct size Hardware’s for fixing and mounting the Winches, Motors, Wire rope and Cable clamps, Switch sockets etc. ← • Check for earthing as per standard. Also check earth continuity. Each mast will be provided with lightening protection system, Earth point shall be tested strictly in accordance with the requirements until the required figure of 10 ohms obtained. ← • Current & voltage of all the phases shall be measured at the lighting panel with all the circuits switched on with lamps. If required load shall be balanced on the three phases. ← • Ensure that proper mounting arrangements of Winch mounting bracket, and Board Mounting brackets, and Head frame, Junction Box with receptacles, Luminaries carriage etc. ← • Refer High mast installation and commissioning manual. ← • After satisfactory completion of above process system / equipment can be charged. ← • Proper documentation shall be maintained. ← • For assembling the mast, relevant pages of Erection and Operation Manual attached. ← • Mast Alignment – Spirit Level used on leveling nuts before erection & Checking of Lantern Carriage movement after Erection. ← • Removal of Tie Rope – Nylon Rope tied to the Crane Hook’s Clamp, After Erection Rope is pulled & Hook is lowered, Sling automatically move out of hook. ← • Trailing Cable Fixing – Aluminum Clamp fixed at Lantern Carriage on top & with wire

using Double Groove Cable Wire Clamp at the bottom. ← • Gear Box Motor Alignment – Clapper Plate ( hinged )mounted on Winch mounting bracket having slots to make proper alignment

1. 7. RESPONSIBILITIES: 2. 7.1 PROJECT MANAGER

The responsibility of ensuring the implementation of this Method Statement lies with Project Manager, Electricals Limited,

7.2. QC ENGINEER

QC Engineer shall be responsible but not limited to the following activities:

Identify and reporting to PM for any non conformance Control point clearance with contractor. To issue NCR’s when and where required and to check that the construction department

provided timely appropriate corrective and preventive action. Accompany the Site Engineer / Supervisors representative and QA/QC Engineer of

Contractor, to carry out the inspection at various stages i.e. after delivery during High mast and luminaires

Review all documentation and test / check list reports issued by Site Engineer and submit records to the QA/QC Engineer of contractor.

Keeping a daily log of the entire Inspection Request submitted by the Site Engineer. Carry out statistical analysis of the inspection and test result to improve quality control

operation on site, to verify testing / checking compliance and to advise the Site Engineer of the results.

7. 3. SITE ENGINEER

Site Engineer shall be responsible but not limited to the following activities:

To ensure that the relevant Project Specification, Approved Method Statement and Approved shop drawings are available in coordination with Construction Manager and QC Engineer.

To check the access and area for conduit prior to shifting and fixing of it and to report discrepancy if any to the QC engineer. To ensure safe unloading / shifting of High mast and luminiares during delivery and lying at site. To ensure that the High mast and luminaries work is done at site as per approved shop drawings, and Technical Specification. To inform all concerned parties for any inspection / test as required in coordination with the Site Manager and QC Engineer. To check and perform that all the laying is carried out exactly in line with the Project Specifications. Site engineer will submit the Check list for High mast shaft and luminaires to the QA/QC Engineer for review and approval

8.0 VERTICALITY TEST OF HIGHMAST

Equipment Used Topcon GTS 751 & GTS 721, Accuracy =1” Prism Pole with Prism Method as per attached sheet

Sr.No

High Mast No.

Instrum ent Height

Height of the Mast

Distance from instrucme nt

Measureme nt

Required Vertical Angle

Deff. In Angle.

Deflection in mm.

(Mtr.) (Mtr) (Mtr.)

1 9 49

2 45 90

3 18 3

4 45 55

5 27 86

6 24 97

Note: As per the Technical Report No.7 the maximum permissible limit of deflection for 30 mtr., High mast is 750mm in serviceability limit state or in general as follows :

1) Deflection is to be checked at the 2/3 of the design wind speed. 2) Deflection at the top most point is not be more than 1/40 of the mast height.

Methodology:

The Theory Right angled triangle was used for plotting the actual position of the High Mast and the difference of

the actual position and assumed position was measured in the Auto CAD. From this triangle the horizontal distance

and the vertical angle to the top of the High mast was measured with high precision electronic Total Station with

an accuracy of 1”. The Total Station was set up in a suitable place in such a way that the vertical angle to the top of

the mast could be measured easily. The horizontal distance from the pole to the Total Station was measured by

holding Prism Pole with prism close to the foot of the mast. This horizontal distance and the vertical angle was

measured and noted. This method is repeated three times and an average of these measurements were used to

plot the position of the mast. The difference between the actual position and assumed position is the difference in

the verticality of the High Mast.

9.0. ACCEPTANCE CRITERIA

Technical Specification Approved shop Drawing Approved FQP

Project quality PlanProject safety plan

10.0. RECEIPT OF MATERIAL:

For the method of UN loading and storage details for High mast and luminaires has furnished in Filed Quality Plan vide number xxxxx

11. AVAILABILTY OF FACTORY TEST REPORT:

All the factory inspection reports with respect to the High mast and luminaires supplied shall be made available at site by shipping the materials for reference.

1. 12. AVAILABILTY OF CALIBRATION CERTIFICATES OF TEST EQUIPMENT 2. 13. INSTALLATION CHECK LIST FOR HIGH MAST SYSTEM AND LUMINAIRES:

All the calibration certificate of test equipment carried out with which factory tests were conducted shall be furnished along with factory inspection reports.

Site :

OrderNo. :

Location :

DrawingNo. :

QualityChecksCarriedOut :

SR.NO. DESCRIPTION RESULT REMARKS1. Highmastwirerope2. CableTerminationTrailingCable

3. LightFixing&LightingWireEarthing‐CGBox‐Gland

‐

JuctionBox4. WinchandWinchMotorChecking5. Luminairecarriage6. Typeoffittings7. Mountingoffittingsasperdrawing8. Alignment

9. Aiminganglesetting10. Finishing

CheckedBy:________________________

Witnessedby:_____________

Date:

Data Sheet For 30 Mtr High Mast Lighting System

1.0 HIGHMAST SYSTEM

a) Height of mast Type Make

b) Material construction c) Cross section of Mast d) Length of individual sections

e) Thickness of Individual Section

Contact Stand High masts

f) Base dia. and top diameter (A/F)

Non Contact Stand High masts

Base dia. and top diameter (A/F)

g) Type of joints. h) Length of overlap I) Type of Metal protection treatment j)

Average thickness of galvanisation (As per BS EN ISO 1461) k) Size of opening and door at base

l) Thickness of base plate m) Size of anchor plate and thickness

n) Template

n) Lightning protection finial

o) Details of slack board inside the base

compartment. p) Provision for cable termination r) Design life of the High mast s) Approximate weight of

the mast

Contact Stand High mast Without Accessories Contact Stand High mast with Accessories Non Contact

Stand High mast with Accessories : 30 Mtr.: 20 Sided Polygonal.:

: BS-EN10 025 ,S-355

: 20 sided polygon.

: Top Middle Bottom : Top - 4 mm, : Middle - 5 mm : Bottom - 6 mm

: Top diameter Bottom diameter

: Top diameter Bottom diameter

: Stress fit at site : 9340 mm : 10980 mm : 10980 mm.

: 169 mm : 540 mm

: 150 mm : 585 mm

: Bottom: 750MM, Middle: 550 MM

: Hot Dipped Galvanised.

: 85 Microns

: 1200 x 250 mm

: 30 mm

: 730 PCD / 830 OD / TH. 8 MM (L&T scope)

: 730 PCD / 830 OD / TH.2 MM (L&T scope)

: G.I single spike of length 1200 mm

: PVC Board

200 mm x600 mmx8 mm : MCB Isolator : 25 Years

: 1590 Kgs Approx : 2166 Kgs Approx : 1650 Kgs Approx

3.0 Lantern Carraige

a) Material of construction

b) Diameter of carriage ring (mm)

c) Buffer between carriage & mast

d) Load carrying capacity e) Approx weight of Carraige assembly with fittings:

4.0 Head Frame

a) Type

b) Material of construction

c) Pulleys

5.0 Earthing Protection

a) Earthing Terminals

b) Lightening Finial

1. 6.0 Foundationa) details of Foudnation

2. 7.0 WINCH

a) Make of winch

b) Number of drums/winch

c) Gear Ratio

d) Capacity

e) Operating Speed

f) Type to Raise/Lower fully

g) Method of operation

h) Type of Lubrication arrangement

i) Type of lubricant

j) Tested load per Drum ( KG)

k) Positive Locking

l) Opearating speed

l) Individual drum operation

m) Method of operation

: 50 NB ERW Class B - M. S. Pipe : 711 mm(ID) Aproximate : PVC sleeve on carriage.

: 750Kgs. .(including Carriage) : 450 Kgs (Approx)

: Suitable for 2 way wire rope system : MS Hot Dip Galvanised : LM-6

: Provision for 2 Nos of 12 Mm Dia HDG bolt with Nuts washers privided in base compartment of High mast.

: 1.2 Mtr height lightening Finial provided for ligtening Protection

: The Scope of High mast Foundation are with L&T

: Double drum type. : 53:1

: 750 kgs. : 2 Meter per Minutes : 15 Minutes : Manual/ Electrical : Permanent oil

bath : SAE 90./SAE 140

: 750 kgs. : Gravity Activated Pawls : 200 RPM : Possible to operate : Manual / Electrical

o) Gear material : Cast Iron p) Tested load per drum : 750 Kgs q) SWL of winch at 200 RPM : 750 Kgs r) Lubricant oil SAE 140 / SAE 90 : shall be of any reputed oil company s) Viscosity : 460 cST t) Oil Replacement period : Once in 2 years f) Braking load capacity : Minimum. 2350kgs. X 2 g) Factor of safety : >5 for system at full load. 8.0 STAINLESS STEEL WIRE ROPE a) Make : Bharat Wire Rope Ltd b) Grade : AISI 316 c) Number of ropes : 2 rope system d) Material & Construction : SS , 7/19 e) Diameter (mm) : 6 mm e) Diameter (mm) : 6 mm f) Braking load capacity : Minimum. 2350kgs. X 2 g) Factor of safety : >5 for system at full load. h) Termination details of wire ropes : Talurit at one end, and SS Thimble with Copper Crimping at other end of the wire ropes. 9.0 HIGH MAST TRAILING CABLE a) Type : Trailing Cable b) Make : GEMSCAB Make c) Conductor size and insulation : LSZH, XLPE Copper cable d) Applicable Standard : IEC 332 (Part-1) & IEEE 383 e) Current carrying capacity : 28 Amp x 1 f) No. of cores : 8 Nos.and 3 Nos g) No. of circuits : Two h) Conductor Size : 4.0 Sq mm i) Switch sockets : 10 Pins and 3Pins Switch sockets for 8 Core and 3 Core, 4 sq.mm Trailing cables respectively. 10.0 Power Tool a) Model : Integral. b) Make : Hindustan Brand (HEM Make) c) Input supply : 3 PH 415 Volts. d) Power Rating (Wattage/HP ) : 1100 watts/1.5 H.P e) Frame Size : 90L f) Operating Speed ( Average ) : 2 Mtrs / Minutes g) Time taken for raising / Lowering : 15 Minutes h) No Of Poles : 6 Pole i) Speed of Motor : 930 RPM j) Number of speed : Single speed k) Control system : Push button l) IP rating of Motor : IP 55 j) Colour Shade : Deep blue Hammer Finish 11.0 TORQUE LIMITER a) Model : Heavy Duty b) Make : abc c) Lifting capacity : 750 kgs. d) Type of tripping device : Mechnical.

MATERIAL - RECEIPT/STORAGE/ PRE-ERECTION/ERECTION

HM&Luminiares FQP No.

ABBREVIATIONS A - Critical

B- Major

C- Minor

S.NO.

CHARACTERISTICS TYPE OF

INSTRUMENT

CLASS

QUANTUM OF

REFERENCE DOC.&

FORMAT OF

REMARKS

CHECK

CHECK ACCEPT.NORM

RECORD

(1) (2) (3) (4) (5) (6) (7) (8) (9)

1 RECEIPT OF MATERIAL

Unloading

1a i) High mast shaft is unloaded carefully with the help of

visual B

crane/hydra/slippers without any damage ii) For high mast accessories to be unloaded properly

visual A

100%

Checking

1b i) With respect to packing list visual B

100% Packing list

ii) With respect to Challan visual C

Challan

iii) Completeness with respect to G.A. drawings

visual B

100% GA Drawing

iv) For any damage during transit visual B

v) Damage to Galvanisation during transit.

visual B

Storage

1c i) Material to be stored in primary packing

visual B

ii) Materials like high mast shaft, stored on a open area.

visual B

iii) Different type of materials are segregated and kept separately

visual B

'v) Other materials are stored indoors visual B

v) Proper watch and wards are available.

visual B

100%

2 HIGH MAST SHAFT & ACCESSORIES

2a Pre-erection

i) Availability & correctness of foundation

visual A

100% Foundation design

ii) Aviailability of foundation nut. visual B

iii) Aviailability of Erection Manual. visual C

Erection manual

iv) Availability of all Accessories & connected hardware

visual A

v) Availability of Crane Or Derrick visual B

vi) Correctness of high mast sling. visual A

1 of 2 2 of 2 MATERIAL - RECEIPT/STORAGE/ PRE-ERECTION/ERECTION

HM&Luminiares FQP No.

ABBREVIATIONS A - Critical

B- Major

C- Minor

S.NO.

CHARACTERISTICS TYPE OF INSTRUMENT

CLASS

QUANTUM OF

REFERENCE DOC.&

FORMAT OF REMARKS

CHECK CHECK ACCEPT.NORM

RECORD

(1) (2) (3) (4) (5) (6) (7) (8) (9)

2b Erection

i) Assembly of high mast shaft

manual B 100%

ii) Alignment of foundation nuts.

manual water level

iii) Alignment and leveling of shaft

visual B

iv) Tightness of head frame & Winch

mech. spanner B 100%

v) Erection of high mast with the help of derrick/ crane

manual Crane A 100%

vi) Fitting of the lanterna carriage & installation of the Luminaires

manual B

vii) Commissioning of the high mast.

manual A

3 LIGHTING FIXTURES

3a Pre-erection

i) Availability of all components

visual B 100%

ii) Compatibility of different components

visual B

3b Erection

i) Fixing of mounting arrangement / bracket

manual B 100%

iii) Tightness of connections

mech. spanner B 100%

iv) Aiming. manual B

METHOD STATEMENTS FOR LUMINAIRES

1. PURPOSE :

The purpose of this procedure is to provide the details of installation of Luminaires

2. SCOPE:

This procedure covers methods of installation of Lighting and other miscellaneous items.

3. CONTROLLING SPECIFICATIONS:

The procedure is in accordance with applicable codes, specifications, contract documents & approved drawings.

4. PROCEDURE:

← • All items are to be located as per layout drawing. ← • Prior to installation, items shall be checked for correctness – type, model, area classification, etc. ← • All supporting / mounting structures shall be painted with proper surface preparation prior to installation. ← • Ensure for correct size, type of cabling; correct glanding – size, type, area classification; termination, ferruling. ← • Check for earthing as per standard IS 3043 - 1987. Also check earth continuity. ← • Check IR value of all items. For lighting without lamps – phase to phase, phase to neutral, phase / neutral to earth. ← • Lighting items shall be numbered & counted as per layout drawing. ← • Current & voltage of all the phases shall be measured at the lighting panel with all the circuits switched on with lamps. If required load shall be balanced on the three phases. ← • Lighting illumination level shall be measured in the area. ← • Ensure that switch provided for ON/OFF control point is only on LIVE side. ← • Ensure that all spare entries to equipment are plugged with correct plug. ← • After satisfactory completion of above process system / equipment can be charged. ← • Proper documentation shall be maintained.

5) Lux Level Measurement:

← • Lux level measurement shall be done at 10 x10 meter grid at working height. & 2 meter at Vertical height. ← • Luminiare Angle shall be set by using the protractor scale provided in luminaires, as per the lighting design.

STATEMENTS

LIGHTING ILLUMINATION TEST REPORT

Project : Report No.

Subcontract Package:

Lux meter make

Lux level meaurement shall be done at 10x10 meter grid at working height & 2 mtr at vertical height.

Sr. No.

Area / Location Illumination measured - Lux

Illumination required - Lux

Remarks

Details of instruments used - Inst.n Description, make, Sr.No., calibration validity.

Sign : Name :