Doc No.

: 0606A/PLTU-HBP/XI/2019
LIGHTING INSTALLATION Print dated : November 2019
WORK METHOD
Page :

OWNER : PT. PLN PERSERO

MAIN CONTRACTOR : SINOHYDRO CORP.

CONTRACT NO :
PROJECT TITLE : CHIMNEY PLTU SULUT-3 2x50MW PROJECT
LOCATION : ADMIN BUILDING PLTU 3&4 LANGKAT - INDONESIA
REFERENCE : DRAWING-ADMIN BUILDING-ME 01~08
STANDARD & CODES : AS PER SPECIFICATION
`
COMMENT SHEET

ISSUED REV REVISION REMARKS/COMMENT

NO DATED
01 14-11-2019

SIGN

Prepared by, Checked by, Approved by,

PT. HORAS
DESCRIPTION STATUS
BANGUN SINOHYDRO PLN-E PLN PERSERO
PERSADA
Approved

Approved as note
Issued for
Not Approved
Approval

Name : Name : Name : Name : Information

Dated: Dated: Dated: Dated:

 Doc No. : 0506A/PLTU-HBP/XI/2019
LIGHTING INSTALLATION Print dated : November 2019
WORK METHOD
Page :

CONTENT

1. Compilations basis………………………………………………………………………………………..…………………….….1

2. Engineering survey and working range…………………………………………………………….……………….…….1

3. Job preparation and requirements………………………………………………………………………….……………….1

4. Construction progress …………………………………………………………………………………………………………….2

5. Key Quality Control Points for Work Procedure ………………………………………………………………………2

6. Construction method and construction requirements……………………………………………………………..3

7. Quality and Technical Standard for Acceptance………………………………………………………….…………..7

8. Safety Measures………………………………………………………………………………………………………………………8

9. Environmental Protection Requirements…………………………………………………………………………………9

10. Technical records…………………………………………………………………………………………………………………….9

 LIGHTING Doc No. : 0501A/PLTU-HBP/XI/2019
INSTALLATION WORK Print dated : November 2019
METHOD
Page :

1. Compilations basis

1.1. The lighting drawings of Admin Building, electric precipitator body and the roads in the plant
provided by the design Pangkalan Susu Coal-fired Power Plant Unit 3&4 (2×200MW), the data
provided by the manufactures and IEC 60598-2-3，IEC 60598-2-22，IEC 60061-3 Amend.26

2. Engineering survey and working range

2.1. Engineering survey

The lighting erection of Indonesia Pangkalan Susu Coal-fired Power Plant Unit 3&4 (2×200MW) erection
engineering equipments and constructions includes: electric precipitation body, the roads , the lighting of
Administration Building. Take exposed laying method for the lighting of Administration Building and
electric precipitation, lamp posts shall be fixed at the handrails in each layer, they shall be separated as
normal lighting and emergency lighting. The lighting of electric precipitation shall be erected as the design
and instructions provided by the manufactures.

2.2. Working Range

The lighting erection of Indonesia Pangkalan Susu Coal-fired Power Plant Unit 3&4 (2×200MW) erection
engineering equipments and constructions includes: Admin Building, electric precipitation body, the roads ,
the lighting of equipment bodies.

3. Job preparation and requirements

1) Because of the limitation of designed lighting depth, there are some unreasonable places. Before
construction, optimize and rearrange the unreasonable parts of the equipment arrangement and
cable laying, making the overall arrangement of lighting is sequential, simple and reasonable.

2) Construction personnel professional types of work must have the technical level of qualification
certificate before the appointment, the auxiliary workers in the work required to carry out targeted
technical safety training.

3) Complete the construction personnel's technical disclosure and safety work.

4) The construction drawings by discipline review work instruction has been prepared, the formalities
have been done.

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METHOD
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5) The materials shall be complete and be accepted qualifiedly. The components needing fabricating
shall be complete.

3.2. Main tools and machines

The main tools and machines includes: 3 sets of angle grinders, 2 sets of electric welding machines, 2
pieces of leveling instruments, 1 piece of 500V tramegger, 1 piece of multimeter, 3 sets of tapes, 2
sets of pipe benders, 2 sets of common tools.

4. Construction progress

The lighting erection of boilers and electric precipitation shall be finished before the erection of steel
structure body, after the erection of platform stairs and the aisles. Before equipments commissioning,
complete the lighting commissioning. Roads lighting in the plant shall be completed on civil roads, the
erection shall be started after completing the foundation.

5. Key Quality Control Points for Work Procedure

5.1. Point W: NO.

Point H: NO.

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INSTALLATION WORK Print dated : November 2019
METHOD
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6. Construction method and construction requirements

6.1. Construction flow chart

construction preparations, check materials

the location of lighting distribution

the locations of the switches and sockets of lamps(erection)

allocation and erection of wire tubes

wires matching, threading and wiring

circuits verification

power-on tests, acceptance

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INSTALLATION WORK Print dated : November 2019
METHOD
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Working contents and requirements

1) Construction preparation, technical disclosure: technicians shall inform the construction personnel
of the construction scope, construction content, line route, and the matters needs attention during
the construction period and other relevant content according to the drawings provided by the
design institute and relevant regulations.

2) Be familiar with the site, ensure the lighting pipes route. Ensure the lighting routes do not conflict
with other specialties.

3) Inspect whether lighting materials are complete, lighting boxes, lamps and the accessories shall be
complete without deformation or damage. The routes shall conform to the requirements of routes
and technical contracts.

4) Erection of wiring tubes：

The wiring tubes are laid in wet or dusty places, whole orifices and the connections shall be sealed well.

There shall be no cracks or depressions at the bends of wiring tubes, whose bending degree shall be no
more than 10% of the external diameter of tubes.

5) Junction boxes or pull boxes shall be set in the middle when it comes to the following situations, the
locations of junction boxes or pull box shall be convenient for threading:

6) The length of wiring tubes is longer than 30m without any bends

 The length of wiring tubes is longer than 20m with one or more bends.
 The length of wiring tubes is longer than 15m with two or more bends.
 The length of wiring tubes is longer than 8m with three or more bends.

7) The fixation methods of wiring tubes: the wiring tubes of equipments and lamps along steel
structure(columns, platforms, stairs, steel structure) shall be taken with exposed laying methods.
The supports shall be welded on steel structure and handrails.

8) The arrangement of wiring tubes laying shall aligned. The fixation points of exposed welding shall be
homogeneous.

9) The connection of wiring tubes shall conform to the following requirements:

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 When taking threads for connection, the length of the threads at the tube side shall be no less than
1/2 of the tube joints, the threads shall be better to be left 2 or 3 after connection.

 When taking pipe sleeves for connection, the length of pipe sleeves shall be 1.5-3 times of the
external diameter of pipes, the counter parts of two tubes shall be the center of pipe sleeves.

10. Erection of lamps and switches：

 The erection height of lamps shall conform to the designing requirements:

 Lamps shall be fixed on handrails or steel columns solidly and reliably. The fixation points of each
lamp shall be no less than 2. The wires of lamps shall not be close to the shells of lamps , and there
shall be margin in the lamp boxes.

 Lamps cannot be erected on flammable components, when the parts with high temperature on
lamps get close to flammable objects, the locations of lamps shall be adjusted suitably or take
heat insulation or heat dissipation measures.
 The erection of anti-explosion lamps in the explosive and fire hazard environment shall conform to
the following requirements:
 The categories, models and power of lamps shall conform to designing and technical requirements,
which cannot be change randomly.
 The inlet holes of electricity equipments and junction boxes shall be sealed and fixed with seal rings
or sealing materials.

Erection of lighting boxes：

 The erection height of lighting distribution boxes shall be 1.3m from the ground, the centerlines of
switches shall be 1.3m from the ground.
 The grounding of lighting distribution boxes shall be in good condition. The names of electric
circuits shall be marked on lighting distribution boxes after erection.

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INSTALLATION WORK Print dated : November 2019
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Wires matching, threading, wiring

The color marks of lighting wires：

Phrase R ：Black wires,

Phrase S : Brown wires,

Phrase T : Grey wires,

Neutral lines : Blue wires,

Grounding conductors : Yellow and green double color lines,

Control lines(incoming switch) : Yellow wires.

All the lighting circuits shall be distributed uniformly on Phrase R,S,T as much as possible, making
the load of three phrases shall be balanced.

The laying and threading of lighting wires shall conform to the following requirements:

 The same kind of lighting circuit is allowed to be laid in the same tubes, the lighting circuit with
different voltage or different kinds of lighting circuits are not allowed to be laid in the same tubes.
 There shall be no contacts or kinking in tubes, contacts shall be set in junction boxes.
 Wires shall be set with bushings to protect wires when threading into wire tubes, the vertical tube
orifices that do not get into junction boxes shall be sealed after threaded with wires.
 The grounding of electrical lighting devices shall be fixed. The electric contact shall be good.
 The wire cores cannot be damaged when peeling the insulation layers of wires. After connecting
the core wires, the insulation tapes shall wrap them uniformly and closely, whose insulation
strength shall be no lower than the primary strength of the wires.

After the threading and wiring works, roundly inspect whether there are holes that may inflow water
on the tubes, such as cover plates of junction boxes, junction boxes and multiple standby interfaces. Take
effective sealing measures to ensure the whole lighting system is sealed well.

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Circuits verification

Circuits verification shall be done with circuits outage, firstly inspect whether the circuit signals on
distribution boxes are clear and correct, then take test lamps to inspect whether the circuit is in good
condition , finally inspect the insulation resistance of each circuit, the ones who are more than 0.5
megohm(take 500V tramegger for testing)shall be qualified. If there is something wrong with one certain
circuit during the verification process, find out the reason and deal with it , then shall verify the next circuit.

Record the circuit inspection well.

Power-on tests and acceptance

Power-on tests shall be taken after the circuits have been verified and been qualified. Before power
on, inspect whether the main incoming switches and branch switches conform to designing requirements,
then take power-on tests for each circuit, inspect whether the brightness and control performance of lamps
conform to the designing and technical requirements of the manufactures, inspect the on-off performances
of switches.

7. Quality and Technical Standard for Acceptance

7.1. The bend radius of tubing shall be no less than 6 times of the external diameter of tubes. If there is
one bend, it shall be no less than 4 times of the diameter of tubes.

7.2. Ensure the concrete locations of supports and hangers according to the erection standard. The
distance between fixation locations shall be uniform, the distance between pipe clamps and the
terminal of wire tubes or the edges of boxes shall be 150-500mm. The maximum distance is 2m of
the clamp in the middle of steel pipes.

7.3. The fracture of all tubes shall be flush, pipe orifices shall be polished to be smooth without burr. The
screw threads of pipe sleeves shall be clear and clean, the sealing of wiring tubes and threading
boxes shall be reliable.

7.4. The erection of all the pipelines, lamps and supports shall be straight, flat.

The phrase of wires must be distinguished strictly according to regulations, avoid short circuit or confusion
phenomenon.

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INSTALLATION WORK Print dated : November 2019
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8. Safety Measures

Hazards identification

Accidents may
Operations Hazards Corresponding measures
happen

The shells of welding machines

Welding machines have
electric shock must be grounded reliably,
not been grounded yet,
welding operations personnel must wear
the personnel do not
insulation gloves and
wear insulation gloves.
insulation shoes.

Safety belts must be worn for

working at height, avoid
Operation at height Don`t wear antiskid
Personnel or objects crossing operation as much as
and crossing shoes or safety belts for
falling from height. possible, if cannot be avoided,
operations. working at height.
the specialized shall be sent
for supervision.

The grounding of electric shock inspect before sending

electricity equipments is
electricity.
not qualified.

Construction
power supply
The electricity
erection The electricity equipments
equipments with 127V or electric shock
with 127V or more must be
more shall be erected
with grounding or neutral
with grounding or neutral
protection.
protection.

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8.1. Construction personnel must wear protective appliances when doing welding works.

8.2. When using cutting machines, the personnel cannot stand in front of the direction that sparkles
splashing.

8.3. Avoid electric shock when using welding machines, prevent arc hurting eyes.

8.4. When working in fireproof or anti-explosion areas, obey the regulations.

8.5. When working on ladders, the opening angle of ladders shall be no more than 60 degree, prevent
ladders getting slipping or turning over.

When working at height, wear safety belts, and suspend them on the reliable locations above.

9. Environmental Protection Requirements

Strengthen the environmental protection management and raise the environmental protection
awareness, establish environmental protection measures within the construction design and construction
scheme, make good arrangement before construction and implement it seriously during the construction;

9.1. Publicize the environmental protection awareness of “prevent pollution and make continuous
improvement” to all staffs, thus to let them be in self-awareness of environmental protection and be
abide by relevant provisions and procedures;

9.2. Recycle and classify all waste oil and materials during the construction;

9.3. Keep to the principle of “project complete, materials used up, and site clean”.

10. Technical records

10.1. Drawing review records

10.2. The Construction technology and safety clarificaiton records

10.3. Installation records

10.4. The acceptance record

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