Lightning Protection Grounding Installation Work Method R.1

Doc No.
: 0603A/PLTU-HBP/XI/2019
LIGHTNING PROTECTION AND
Print dated : November 2019
GROUNDING INSTALLATION Page :
WORK METHOD
OWNER : PT. PLN PERSERO
MAIN CONTRACTOR : SINOHYDRO CORP.
PROJECT TITLE : ADMIN BUILDING PLTU 3&4 LANGKAT - INDONESIA

CONTRACT NO :
LOCATION : ADMIN BUILDING PLTU 3&4 LANGKAT - INDONESIA
REFERENCE : DRAWING-ADMIN BUILDING-ME 01~08
STANDARD & CODES : AS PER SPECIFICATION
COMMENT SHEET
ISSUED NO REV REVISION DATED REMARKS/COMMENT
01 14-11-2019
SIGN
Prepared by, Checked by, Approved by,

DESCRIPTION STATUS
PT. HORAS
SINOHYDRO PLN-E PLN PERSERO
BANGUN
PERSADA Approved
Approved as note
Issued for
Not Approved
Approval
Name : Name : Name : Name : Information
Dated: Nov 14, 2019 Dated: Dated: Dated:

Doc No. : 0603A/PLTU-HBP/XI/2019
WORK METHOD
Catalog
1. Compilation basis -1-
2. Engineering survey and working range -1-
3. Job preparation and requirements -2-
4. Construction progress -2-
5. Key Quality Control Points for Work Procedure -3-
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 - 10 -

WORK METHOD
1) Compilation basis
Indonesia pangkalan Susu power plant 3 & 4 (2 * 200 MW) coal-fired unit. Administration Building
installation engineering plant lightning protection grounding design and construction plans, electrical
equipment grounding installation drawings.
2) Engineering survey and working range

a) Engineering survey
10.1. Indonesia pangkalan Susu power plant 3 & 4 (2 * 200 MW) coal-fired unit installation
engineering plant grounding lightning protection network using electrode, pvc cable, (SNI
-SPLN 42- NYA 70mm2 450/750 V- LMK type) from terminal with brass joint , standing mast,
Galv. Ø 2." (from roof peak) . Ground Control Box, (Earth pit), 40 x 40 x 40, c/w Steel plate
covered, 3mm. Copper Bar 5 x 25 x 250mm' c/w Brass Bolt - Nut - Ring plate Ǿ12mm x 3 cm
( for Termination) -BC 1 x 50 mm2 - Electrode - ( Minimum Depth = 6m), incuding Galvanized
casing pipe Ø 3/4" (6m) . Plant and equipment grounding the installed around the plant,
around the main grounding bus bar And all must be connected to the equipment from the main
grounding bus bar connected. area by independent lightning needle for lightning protection
and grounding.
b) Working range
This construction activity includes the main grounding, equipment grounding and lightning
protection within the following areas, for Administration Building Construction.
PANGKALAN SUSU COAL FIRED STEAM POWER PLANT PROJECT UNIT 3 & 4 (2*200MW)
page： - 1 -
WORK METHOD
3) Job preparation and requirements

a) Technical requirement
1.1. Organization personnel distribution: familiar with the drawings, site and construction technology
requirements of professional and technical personnel, one professional qualification certificate
of welder, fitter, two or three auxiliary workers.
1.2. 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.
1.3. Complete the construction personnel's technical disclosure and safety work.
b) Work environment
1.1. The construction drawings by discipline review work instruction has been prepared, the
formalities have been done.
1.2. Then trench excavation is completed, the depth to meet the design requirements, the site has
the construction conditions.
1.3. Grounding bus bar and the electrode materials have been transported to the site, and test
specifications to meet the requirements.
1.4. The site shall be configured stacked grounding materials in space, and there is enough space for
grounding copper processing.
c) Main tools and machines
1.1. Main tools and machines include two electric welding machines, two electric cutting
machines,one bending machine, four cable cutters, five electricians’ tools, all kinds of welding
moulds and supporting facility.
4) Construction progress
Because the entire plant lightning protection need to cooperate with other professional
construction managements, it especially be restrained by the schedule of civil engineering
company. So the scheduling of lightning protection should be on the basis of the schedule of civil
engineering company , and try to keep the continuation of project, and ensure the quality and
technology of project on the premise of safety.
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WORK METHOD
5) Key Quality Control Points for Work Procedure

a) Point W: Grounding pole installation, main grounding net welding and installation, conjunction
point welding, lightning rod installation, and equipment grounding;
b) Point H: NO.
c) Point R：Resistance measurement.
6) Construction method and construction requirements

a) Construction flow chart
Preparation
Trench construction
Main Grounding Screen

Installation
Grounding Electrode Installation
Manufacturing and installation of lightning Connection of grounding facility Grounding of electric facility
device
Test for grounding screen
page： - 3 -
WORK METHOD
b) Brazing joint construction procedure

1.1. Prepare construction tools and materials and check whether all welding moulds are in line with
those joints.
1.2. Bear copper stranded wire laying and vertical grounding electrode installation.
1.3. Wipe from copper stranded wire with wire brush and keep the joint clean, and also wipe off the
moisture on the surface of the conductor and grounding electrode by heating the copper
stranded wire and grounding electrode with baking device.
1.4. The welding mould shall be lightly lifted, and first clean up the welding mould with hairbrush and
then wipe off the moisture in the welding mould by heating the welding mould with baking
device.
1.5. Install the cleaned and dry copper stranded wire grounding electrode into the welding mould and
compress the welding mould tightly, and then check whether the conductor joint is connected
tightly or not.
1.6 Put the aluminum sheet into the welding mould to choke up the die orifice and also pour down
the relevant welding powder into the welding mould, and then uniformly spill the lead-in powder
on the surface of the welding powder within the welding mould and on the mouth of the welding
mould.
1.7 Ignite the lead-in powder by firelock, weld the conductors together within the joint by welding
powder, and one minute later, open the welding mould and check whether the joint welding is
qualified or not
1.8 Wipe out the welding slag on the joint with wire brush and wipe off the welding slag within the
welding mould by heating the welding mould by baking device and clean it with hairbrush
1.9 Coating anticorrosive paint in welding After completion of welding.
c) Installation Technical Requirements

It is necessary to carry out the grounding resistance test after the construction of the project is
completed,, the test of the grounding resistance value must meet the design requirements.
i) Using electrode, pvc cable, (SNI -SPLN 42- NYA 70mm2 450/750 V- LMK type) from terminal
with brass joint , standing mast, Galv. Ø 2." (from roof peak) . Ground Control Box, (Earth pit),
40 x 40 x 40, c/w Steel plate covered, 3mm. Copper Bar 5 x 25 x 250mm' c/w Brass Bolt -
Nut - Ring plate Ǿ12mm x 3 cm ( for Termination) -BC 1 x 50 mm2 - Electrode - ( Minimum
Depth = 6m), incuding Galvanized casing pipe Ø 3/4" (6m) Copper bit shall be used for-
page： - 4 -
WORK METHOD
-connecting those grounding lines and also for connecting the main line and earth pole, and
the connecting method applies for thermit welding (TW)
ii) Factory main connected to the level of net grounding is usually buried deep -0.8m and
ground lines from the building should not be less than 1.5m, the grounding grid should be
closed and aid edge angle should be made into a circular arc shape, arc radius is not less
than 5m. Main grounding grid design of vertical grounding electrodes and with horizontal
connected grid firm fireclay fusion connected, vertical grounding electrode spacing of not
less than 15m vertical grounding deep need to 6m.
iii) Ground wire must wear inside the pipe when they across the floor or wall.
iv) As to the grounding device under the ground, after the laying, it is a must to immediately
compact the soil. There must be sufficient length left about all grounding materials. The
laying of EL -0.8m main grounding screen shall be completed before soil backfilling, and the
grounding part of equipment shall be completed after the installation of equipment and
before terrace plastering,backfill should be pure soil without ballasts and sundry.
v) In the construction area to meet the grounding grid position, copper stranded wire should be
set aside 1 meters or so enough copper wire to expose the ground margin, ready to connect
with the late construction of the grounding grid.
vi) Should be set respectively grounding sign at the entrance of the grounding line into the
building and maintenance of temporary grounding terminals
vii) Grid should be installed at the walkway besides the edge of grounding grid where people
always pass by.
viii) The grounding conductors should be prevented from mechanical damnification and chemical
corrosion. Protection should be made to the grounding system at the place where it goes
across road, railway or chemical conduits and where mechanical damage might happen.
ix) The electrical installation team should cooperate with the structure team to the construction
of grounding grid.Confirmation and record for embedment should be made.
10.2. The equipment grounding of buried pipes are not allowed to use by cable.
The connection of equipment and conductor could use bolt and spring washer for shockproof. Joint of
bolt should be anti-rust.
1) The zero connection protection of single-phase 220V electrical equipment, should set up separate
protective zero line, not using the device's own work zero line doubles as a ground zero protection.
2) Electric facilities within the same system are prohibited for partial grounding and partial neutral
connection
3) The grounding for AC power equipment of Turbine Hall shall apply for 40*3 copper bar as the
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WORK METHOD
grounding line, for generator macro-axis grounding carbon brush and 400V and below equipments,
the grounding conductor shall apply for copper stranded wire (16 mm2), and for medium pressure
equipment grounding conductor applies for copper stranded wire (35 mm2). Each grounding part of
electric facility shall connect with grounding main line through independent grounding wire, and it is
prohibited for cascading several grounding parts on one grounding line
4) Boiler equipment and boiler proper casing connect with steel column which needs to conduct
grounding lead-down wire at EL +0.3m, applying for bolt connection to connect with the closest main
grounding screen; The grounding system should form a loop, part is not isolated in the system
when a point off.
Grounding electrode and measurement well
1 The location of grounding electrode shall be base don the design drawing and the main
grounding line shall be connected with grounding electrode or main grounding screen by thermit
weld.
2 Grounding measurement well is used to check the grounding resistance of each area; the
connecting sheet of the groundling wire shall be installed within the well that can be seen on the
ground, and the grounding connecting sheet within the grounding measurement well shall be bolt
fastening.
3 Lightning protection and grounding and relevant requirements
4 As to all frames with lightning rod and lightning wire, microwave tower shall be equipped with
centralized grounding device.
5 Lightning rod shall be equipped with centralized grounding and its grounding wire shall be
connected with earth screen in the shortest distance.
6 Independent lightning rod (line) should be set up independent centralized grounding device,
grounding resistance should not be more than 10Ω.
7 Independent lightning rod (wire) should not be located in the local people often pass. Lightning
rod (line) and its connection device and roads or entrance with a distance not less than 3m.
Otherwise, it shall be take all measures, the laying of move stone or asphalt surface.
page： - 6 -
WORK METHOD
7) Quality and Technical Standard for Acceptance

a) Quality and technical standard
1) Materials for grounding net shall meet the design requirements and the specification of those
materials must be in line with the requirements of relevant drawings.
2) All grounding led-up wire shall be continuously and reliably connected with the main grounding net
and the welding must meet the requirements of thermit weld.
3) The size and the location of the grounding line and grounding installation must comply with the
design requirements, and grounding into depth must conform to the requirements.
4) The material dimensions of the equipment ground wire must meet the design requirements and the
actual operation requirements.
5) All electric facilities, metal steel structure, oil tank, oil pipe and armoured cable shall be grounded
reliably, the main grounding net shall be connected together, at least two points shall be connected,
and the welding joint should be strong.
b) Technological Requirements’ Standard
1) The welded mould must be cleaned with hairbrush instead of wire brush, and make it dry with fire
before use it.
2) The welded mould must be in good condition without any copper water leakage.
3) The welding for grounding copper conductor shall be polished with wire brush, wipe out aerugo and
oil contamination and make it dry, and mould shall be tied tightly with the conductor.
4) Conductor jointing of different specification shall use different welding mould and powder, and the
detailed specification of powder shall be in line with that of the welding mould;
5) Powder shall be kept dry and no moisture. All shall be poured down into the welding mould when use
it so as to guarantee the quality of welding
6) All copper welding head should be the conductor within the joint penetration, guarantee the
connectors with wires have enough conductive section, copper welding head surface should be
smooth, no bubble phenomenon.
7) Grounding on line in the above the ground must wear protection of PVC pipe.
8) It is a must to protect the product and take relevant protective measures, and it is prohibited for any
vehicles or pedestrian to spreading or trample it or be stolen.
9) The grounding copper lugs of equipments shall be in line and be pleasing to eye.
10) The equipment grounding copper platoon radian should consistent，it looks beautiful.
11) Mark out above the main grounding screen after backfilling, and there must be an identification for
the joint position of the ground screen and equipments.
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WORK METHOD
c) Check for acceptance based on the following requirements:

1.1. Complete the construction according to the design drawing and the grounding construction
quality meet the requirements of this provision;
1.2. Reliable connection of the exposed grounding wire, right specification, and complete and
obvious mark of grounding wire;
1.3. The installation location and height of lightning rod (belt) must meet the design requirements;
1.4. The quantity and location of connection plate for connecting temporary grounding wire must
meet the design requirements;
1.5. The grounding resistance value and other test parameters of the design requirements are in line
with the design requirements.
8) Safety Measures
The do’s and don’ts
1. Construction workers must seriously study < electric power construction safety production work
procedures >, must grasp the construction procedures with electrical and instrumentation;
2. When enter into site, it is a must to carefully check the construction environment, thus to avoid any
accident such as strike or falling and so on;
3. It is a must to master each construction gist when conducting every work activity;
4. When using any specific tool or machine, it is a must to master the use method of those tools or
machines;
5. Before conducting the thermit welding (TW), it is a must to carefully check whether the mould and
welding powder is moisture or not; clean and dry the mould and check the specification of the mould
and gun powder before use it;
6. Before welding, it is necessary to clean all flammable articles around to avoid any fire disaster; after
the welding, keep and store the mould and cool off the welded junction to avoid any heat injury.
Meanwhile, clean up the welded junction so as to ensure the welding quality;
7. After finish the construction, take protective measures to prevent any stolen or damage to those
materials and equipments.For example: let the security guard; backfill immediately after construction
completion
8. Keep civilized construction and clean up the construction site after finish the relevant construction;
9. Conduct supervision and inspection during the construction: absolutely stop those violation activities
and as to those construction with potential danger, first relieve the potential danger and take
precautious measures to avoid any further accident;
10. Must be unified dress and wearing a safety helmet before into the construction site,the height of the
work must be correctly hoisted safety belt, is strictly prohibited to wear slippers, sandals, high heels,
page： - 8 -
WORK METHOD
shoes with nails;

11. Don't allow to drink before work;
12. Don't allow smoking in the construction area;
13. Tool-box meeting is needed for everyday; the monitor must make good work arrangement everyday
and give safety technical disclosure for each work; as to those dangerous operations, it is a must to
establish safety construction scheme and transact work sheet and make summary about the
relevant work activity everyday.
a) Materials storage
- l claimed Thermit welding (TW) materials must be stored in the appointed
container, and specific management staff shall be appointed for materials record;
the quantity of welded junction must be in line with the consumption of welded
powder, and those unused welded powder shall be returned back to the appointed
container;
- All welding moulds shall be stored in the appointed container with anti-moisture
and anti-breakage measures. Welding mould shall be lightly both lifted and lay
down and the welding and cleaning shall meet the requirements of welding
procedure;
- Bear copper stranded wire shall be in collection storage and make records about
the claim; take protective measures for those installed ground screens without
backfilling and give notice to security department about security guide.
9) Environmental Protection Requirements

1.1. 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;
1.2. 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;
1.3. Recycle and classify all waste oil and materials during the construction;
1.4. Keep to the principle of “project complete, materials used up, and site clean”.
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WORK METHOD
10) Technical records

a) Drawing review records
b) The Construction technology and safety clarificaiton records
c) Installation records
d) The acceptance record
page： - 10 -

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Doc No.

OWNER : PT. PLN PERSERO

MAIN CONTRACTOR : SINOHYDRO CORP.

PROJECT TITLE : ADMIN BUILDING PLTU 3&4 LANGKAT - INDONESIA

LOCATION : ADMIN BUILDING PLTU 3&4 LANGKAT - INDONESIA

REFERENCE : DRAWING-ADMIN BUILDING-ME 01~08

STANDARD & CODES : AS PER SPECIFICATION

ISSUED NO REV REVISION DATED REMARKS/COMMENT

Prepared by, Checked by, Approved by,

Name : Name : Name : Name : Information

Dated: Nov 14, 2019 Dated: Dated: Dated:

2. Engineering survey and working range -1-

3. Job preparation and requirements -2-

4. Construction progress -2-

5. Key Quality Control Points for Work Procedure -3-

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 - 10 -

2) Engineering survey and working range

3) Job preparation and requirements

5) Key Quality Control Points for Work Procedure

6) Construction method and construction requirements

Main Grounding Screen

Grounding Electrode Installation

Test for grounding screen

b) Brazing joint construction procedure

1.9 Coating anticorrosive paint in welding After completion of welding.

c) Installation Technical Requirements

7) Quality and Technical Standard for Acceptance

c) Check for acceptance based on the following requirements:

shoes with nails;

9) Environmental Protection Requirements

10) Technical records

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