L & T Construction - PT & D Ic: Safe Operating Procedure

L & T Construction – PT & D IC Location:
Date:
HQ - Chennai
EHV SS & IE - Segment Rev: 00

SAFE OPERATING PROCEDURE Doc No: EHV /SOP /0
Panel Erection Page no: 1 of 20
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Prepared by Supersedes:
Reviewed by Date Issued:
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REVISION CONTROL SHEET
Rev. No Date Details of Revision Purpose of Revision Approved By

Date:
HQ - Chennai

Table of Contents
REVISION CONTROL SHEET .................................................................................................... 2
1.0 PURPOSE ..................................................................................................................... 4
2.0 SCOPE ......................................................................................................................... 4
3.0 REFERENCES ................................................................................................................ 4
4.0 ABBREVIATIONS .......................................................................................................... 4
5.0 DEFINITIONS ............................................................................................................... 5
6.0 RESPONSIBILITY .......................................................................................................... 6
7.0 PPE TO BE USED .......................................................................................................... 6
8.0 PLANT, MACHINERY, TOOLS & TACKLES USED .............................................................. 7
9.0 FLOW CHART - SEQUENCE OF OPERATION ................................................................... 9
10.0 PROCEDURE .............................................................................................................. 10
11.0 RELATED DOCUMENTS & CHECKLIST .......................................................................... 20

Date:
HQ - Chennai

1.0 Purpose
To describe the procedure for safe execution of Panel Erection activity at Electrical Substation
projects.
2.0 Scope
This SOP is applicable to all L&T Employees, Sub contractors and their employees. It shall be
applicable to activities pertaining to Panel Erection at site for various projects of EHV SS & E & I,
in all its domestic operation.
3.0 References
 EHS manual
 IMS Manual
 The Electricity Act 2003 and The Electricity Rule 2005
 Manufacturer’s instruction, manuals and drawings to erection of equipment.
 Site specific EHS Plan.
4.0 Abbreviations
SOP – Safe operating procedure
EHS - Environment, Health and Safety
PPE - Personal Protective Equipment
PTW - Permit to Work
PM - Project Manager
SI /SE - Section Incharge / Site Engineer
EHSO - Environment Health and Safety officer

Date:
HQ - Chennai

5.0 Definitions
Responsible Person A person who has sufficient knowledge and training with one year
experience in execution, shall be able to recognize obvious defects and
is responsible to the Section Incharge / Site Engineer the 'in Service'
inspection and maintenance of equipment.
Competent Person Someone who has sufficient training and experience or knowledge and
other qualities that allow them to assist you properly. The level of
competence required will depend on the complexity of the situation and
the particular assignment.( minimum two years of experience in the
respective area of work)
Lifting Gear / Lifting Any item used to connect a load to a lifting machine or appliance, but
Tackle which is not in itself capable of providing any movement to lift or lower the
load. Lifting Gear is in some circumstance known as Lifting tackle
Lifting Appliance Any machine which is able to raise, lower or suspend a load but
excluding machines incorporating a guided load (i.e., lifts) and continuous
mechanical handling devices (i.e., conveyors).
Automatic Safe Load A device fitted to a Crane, or incorporated in its design, that automatically
/ Indicator gives visual indication to the operator when the load being lifted or
carried by the crane approaches the Safe Working load, and that also
gives a continuous audible warning to the operator and other persons in
the vicinity, when the load being lifted or carried exceeds the Sate
Working Load.
Load Radius A device fitted on a Crane that shows the radius of the hook and the
Indicator corresponding Safe Working Load.
Operating Radius The horizontal distance between the point at which the centre of rotation
of the Crane meets the ground, and the vertical centerline through the
hook.
Capacity Chart (or A notice fitted on a Crane specifying the lifting capacities of the Crane at
Plate) different load-radii and for different operational conditions.
EOT Crane Electric overhead travelling crane, this is used for erection, handling and
moving specified weight of the equipment’s called capacity of the crane
within a specified area.

Date:
HQ - Chennai

6.0 Responsibility
It shall be the responsibility of the line function (Construction Manager / Section In charges/ Site
Engineer /EHS Engineer) to implement this Procedure.
7.0 PPE to be used
Safety Helmet, ISI Certified

Made of HDPE, Nape Type
Suspension with Chin Strap & Sweat Band
Full body harness webbing made of Nylon with front D-

ring / Textile Loop for fall arrestor attachment (Class: L),
with double lanyard & double scaffold hook, Shoulder &
Thigh adjustable, ISI or CE Certified
Safety Shoe
Leather Safety Footwear with Direct Injection Moulded,
Poly urethane (PU) Sole – Single Density, with steel /
fibre toe
REFLECTIVE JACKET
Red – Workmen ; Green - Staff
Background Fabric - 100% Polyester Low Mesh (80

GSM)
Cotton Hand gloves

Date:
HQ - Chennai

8.0 Plant, Machinery, Tools & Tackles used

Name of the Equipment /
Pictorial View Check Points
Tools & Tackle
Hydra Crane 12 T / 14 T  Physical condition

 Third party certification
 (Escort TRX 1550 14T /  Hydraulic jack function
ACE FX 12)  Operator fitness
Mobile Crane – 18 T  Physical condition

 Hydraulic jack function
 Operator fitness
Truck - 10 T  Physical condition

 Operator fitness
Web Sling – 6T  No Damage in the Web belt

& stiches
 Colour code tag

D Shackle – 5 T  Check for wear and
Straightness
 Check that pin is always
seated
 Check that shackle is
opening up

Date:
HQ - Chennai

PP Rope – 25 mm dia  Broken ropes

 If any kink present
 Colour Change
Chain pulley block – 2 T / 5  Chain links

T capacity  Hook Latches
 Physical condition
Pallet Truck – 1 T capacity  Physical condition


Date:
HQ - Chennai

9.0 Flow chart - Sequence of operation
Panel Erection
Man Material Machinery
Check for fitness of the
Identify the Panel Machinery / tools
Select the work Group
Check the Packing Verify the lifting accessories
Screen & Induct

Decide Mode of
Validate the lifting plan
Transport
Load the equipment on Vehicle

Issue PPE Clear the approach
and shift
Plan for transport Unload near the erection point

Task Briefing (Pep Talk)
Arrange Resourse Check the orientaion and erect
Supervise Check tightness of bolt and

Monitor
nuts
Relaese the lifting

Equipment & tackles

Date:
HQ - Chennai

10.0 Procedure
a) Pre operational Checks
 Select the Workers and screen for competency and physical fitness to perform the
activity.
 Ensure EHS induction training provided before engaging on work.
 PEP talk specific to the erection activity shall be conducted explaining hazards
associated with the job and the safety measures to be adopted including ERP,
First aid.
 All workers at site to wear Safety shoe, helmet, hand gloves.
 For work at height, full body harness with double lanyard, fall arrester and height
pass are required.
 A standard signals to use in passing / communicating / controlling erection
activities.
 Fully equipped First Aid box should be made available at each erection location.
 Emergency contact details to be displayed in the workplace.
 The requirement identified in the Emergency response plan shall be in place
 Engage skilled workmen for loading and unloading of panels.
 Approach and access to work area to be ensured.
 Before erection, check all tools and tackles.
 Ensure Permit to Work System where ever applicable is in place before starting the
job
 Site / work-front clearances to be obtained.

Date:
HQ - Chennai

 Un-authorized person shall not be allowed to the area of erection

 Erection work will be carried out under supervision of responsible persons.
 Unloading arrangements are to be planned before receipt of panels at erection
site.
 Soil condition shall be checked for the load bearing capacity and its level.
 Check the equipment fitness of Crane as per ( IM – 15 B Equipment Fitness
Report For Vehicle & Earth Moving Equipment)
 Attach the web sling on the hook and pass them under the wooden pallet provided
on the bottom of the Panel.
 Packing shall be used for edge protection and slinging.
 Lift the transportation unit of the Panel.
 Load the panels from storage yard on truck by using crane. Panels shall be placed
on the truck in vertical position. ( Fig : 1)
FIG : 1 PANEL LOADED @ VERTICLE POSITION

Date:
HQ - Chennai

 Panels shall be tied with web slings to prevent the movement of the panels tied
with guy rope from both sides.
 Ensure correct panel is being received from the store as per drawing and it is
being taken to its correct destination at the site.
 Check the approach from unloading spot to erection spot for any obstruction.
 Ensure the area is levelled to avoid toppling of panels.
 Ensure identification markings on the panels for their easy traceability in
workplace.
 Ensure that the panels are not given any undue jerks.
 No person shall stand below crane or even in the boom radius during lifting,
lowering and swinging.
 No person / workmen should travel / sitting on heavy equipment while
transportation of materials.
 While travelling by trailer no person should sit on trailer except driver.
 Ensure that a workmen who is going to work on height is competent, having safe
climbing arrangement (like scaffold, ladder, staircase, etc.), equipped with
required PPEs, having fall arrestor to arrest falling from height.
 Scaffold shall be inspected by the competent trained person and scaff tag to be
provided.
 Colour coding system is to be in place to ensure only inspected tools are in use.
 If welding machine is engaged for welding, equipment earthing also to be ensured.
 Direct earting shall be provided from the machine to parent material to be welded.
 Cables shall free of any damage.
 Before operation, check all tools and tackles to be ensured.

Date:
HQ - Chennai

 Lifting tools & tackles are to be stacked in such a manner that they can be taken
out easily.
 Audio visual alarm should be in operation while operating the EOT Crane (if the
facility is available).
 Emergency switch shall be operating Condition.
 Illumination level of 200 lux shall be maintained at erection site.
 Opening if any in and around the panel unloading or erection area to be guarded /
covered with rigid material ( 6mm chequred plate / 25mm thick wooden planks)
 Before erection complete Panel room levelling shall be taken in 4 or 5 places and
take average of the levels to maintain the same level for all panels.
 If any Bus duct are to be connected with panels check the outside transformer
levels, distance from switchgear to facilitate the Bisducts.
 Clearance between panel’s rear side, front side, left & right side should be
maintained 1500mm or otherwise specifically mentioned as per O&M manual
issued by the manufacturer.
 Provide Rail track with ISMC Chennel to roll out the trolley for shifting of panels.
 Crowbars, ISMC channels, Wooden blankets are to be used for tracking the
panels on the floor.
 Check Panel board gland plate’s position to facilitate the cable terminations, it
should not come the base channels or floor concrete beams.
 Panel erection should be started after completion of the switchgear panel Room
civil work like plastering, window, door installation, internal painting.
 Approach for the vehicle movement to the panel room at least plain road should be
there to avoid tilting.

Date:
HQ - Chennai

 Leveling of the panels should be made in such a way that bottom of the panel
base frame should match with flooring.
 Panel coupling to be done with correct hardware’s to avoid gap between panels.
 Main bus bars jointing with spring washers applying petroleum jelly.
 Control wiring between the compartments to be done as per the drawing.
 Tightness of joints to be done & checked with torque wrench pressure as per
recommendation of the manufacture.
 Loose items supplied like relays , meters, draw out type module to be installed on
the cutouts. Fixing of panel with Base frame after final alignment or welding with
base channel as per the specification.
b) Operational Checks
Receipt and storage of panels.
 Unload the panels in storage yard at

specified / identified location using 12 T
mobile crane
 Panels, and accessories received shall be
checked with the shipping release and
packing list.
 Check that the packing of the panels is not
damaged anywhere.
 Position the crane hook on top of
Fig: 2
transportation unit.

Date:
HQ - Chennai

Fig : 3 Tag line

 Manufacturers’ instruction for
lifting & shifting shall be strictly
followed.( Fig : 2)
 Suspend the ropes from the
hook and pass them under the
wooden pallet under the
bottom of the panel to be
transported.
 Use tag line Rope minimum of
3meter long to control the oscillation.( Fig: 3)
 Store the panels in closed storage

till the site is ready for the erection
of it.
 Keep proper tag markings on the
panels for their easy traceability in
stores.( Fig:4)

Date:
HQ - Chennai

Handling & Shifting Of Panels
 Shifting of the panel shall be

done as per manufacturer’s
instruction with truck and
crane.( Fig :5)
 Panels shall be placed on the

truck in vertical position as
shown in Fig:1
 Panels shall be tied at two
Fig : 5
places to prevent the jerk or
toppling of the panels.
 Ensure correct panel is received at
store as per drawing
 It is being taken to its right destination
at the site.
 Unload the transportation unit of Panel
near to the erection spot.
 Verify the route from unloading spot to
erection spot for free access.
Fig: 6

Date:
HQ - Chennai

Panel shifting inside the building
 Pallet truck shall be used for panel

movement inside the building. (Fig:6)
 Where the use of pallet truck is not possible,
2 nos of ISMC 100 channels shall be
provided to place the Trolley with 4 wheels
and Panel shall be kept on trolley for
internal movement inside the panel room.(
Fig :7)
 Top anchoring arrangement made of 12 mm Fig : 7
steel wire rope shall be provided at top support in order to restrict toppling of
panel.
 In case of narrow base, the panel is shall lift the case at either end, to insert pallet
truck but never lift too much.
 Workers handling panels should be CAUTIOUS IN ORDER to avoid injuries to toe
& fingers getting caught under roller
 Workers should always be behind the panels while pushing. To avoid tilting
sideways tag line ropes can be provided.
 Embedded parts (EP’s) provided for panel erection shall be checked for level.
 After the panels have reached the erection spot wooden packing shall be
removed from the panel.
 Use step ladder for unpacking as shown in the Fig:8

Date:
HQ - Chennai

 Dispose the wood packing

material to its allocated area.
Removal of protruded nails from
the wooden planks is to be
done.
 Ensure that the communication
between the signal man are the
concerned fitter gang is correct.
 Skilled rigger shall be engaged
to control hoisting & de-hoisting
of crane.
Fig:8
 3 Meter of long Tag line should be used from both the ends to minimize oscillation
of equipment.
 Chain pulley block should never be used for horizontal / oblique pulling.
 Only “tirfor” is to be used for such pulling.
 When lifting the panel, area must be protected and no un- authorized person
should be permitted to enter the area.
 Do not load beyond the rated capacity of the crane.
 While lifting of panel, sharp edge protection such as gunny bags, cotton pads
should be provided.

Date:
HQ - Chennai

Panel Erection
 Embedded parts (EP’s) provided for panel erection shall be checked for leveling
 After the panels have reached the erection spot wooden packing shall be removed
from the panel.
 Place panels with hydra / EOT Crane with their own base frame over EP’s as per
sequence indicated in drawing.
 Check the leveling and alignment of panels.
 Panels shall be coupled together with given fasteners wherever applicable.
 Check for alignment and leveling.
 If the gap exists
between base
frame and EP,
then the
procedure for
welding shall be
decided on a
case-to-case
basis.
 Lower the crane
hook and de sling
from the panel
 Release the crane and continue for next panel erection.
 Follow the same sequence for subsequent panel erection.

Date:
HQ - Chennai

c) Post operational Checks
 All the tools & tackles used for such activity are to be taken back by the group of
workmen after completion of day work.
 Opening if any in and around the panel erection area shall be closed.
 Work permits shall be returned after completion of the activity.( if obtained)
 Remove the unwanted material from workplace.
 Dispose the wood to its allocated area. ( Packing material if any)
 Supervisor should ensure all workers have left the building before leaving the
workplace himself.
 Handed over the lock & Key to the identified security incharge / section incharge.
11.0 Related Documents & Checklist
 Erection schedule / Approved Drawing

 Safety Induction card to all workmen
 EHS Risk Assessment - IM - 08 B Rev 03
 Training Records - IM -11-B Rev 03
 Pep Talk Report - IM -12 A Rev.03
 Equipment Fitness Report
Vehicle & Earth Moving Equipment - IM -15 B Rev.03
 Crane Inspection Checklist - IM -09-A7 Rev 03
 Erection Safety Checklist - IM -9 A3 Rev 03
 General EHS Inspection Checklist - IM -09-A1 Rev 03
 Working at Height Checklist – IM -09-A2 Rev 03
 Project Emergency response plan


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L & T Construction - PT & D Ic: Safe Operating Procedure

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L & T Construction – PT & D IC Location:

EHV SS & IE - Segment Rev: 00

Name & Signature Date Document Control

EHV SS & IE - Segment Rev: 00

REVISION CONTROL SHEET

Rev. No Date Details of Revision Purpose of Revision Approved By

Name & Signature Date Document Control

EHV SS & IE - Segment Rev: 00

REVISION CONTROL SHEET .................................................................................................... 2

1.0 PURPOSE ..................................................................................................................... 4

2.0 SCOPE ......................................................................................................................... 4

3.0 REFERENCES ................................................................................................................ 4

4.0 ABBREVIATIONS .......................................................................................................... 4

5.0 DEFINITIONS ............................................................................................................... 5

6.0 RESPONSIBILITY .......................................................................................................... 6

7.0 PPE TO BE USED .......................................................................................................... 6

8.0 PLANT, MACHINERY, TOOLS & TACKLES USED .............................................................. 7

9.0 FLOW CHART - SEQUENCE OF OPERATION ................................................................... 9

10.0 PROCEDURE .............................................................................................................. 10

11.0 RELATED DOCUMENTS & CHECKLIST .......................................................................... 20

Name & Signature Date Document Control

EHV SS & IE - Segment Rev: 00

SOP – Safe operating procedure

EHS - Environment, Health and Safety

PPE - Personal Protective Equipment

PTW - Permit to Work

SI /SE - Section Incharge / Site Engineer

EHSO - Environment Health and Safety officer

Name & Signature Date Document Control

EHV SS & IE - Segment Rev: 00

Name & Signature Date Document Control

EHV SS & IE - Segment Rev: 00

7.0 PPE to be used

Safety Helmet, ISI Certified

Full body harness webbing made of Nylon with front D-

Background Fabric - 100% Polyester Low Mesh (80

Cotton Hand gloves

Name & Signature Date Document Control

EHV SS & IE - Segment Rev: 00

8.0 Plant, Machinery, Tools & Tackles used

Hydra Crane 12 T / 14 T  Physical condition

Mobile Crane – 18 T  Physical condition

Truck - 10 T  Physical condition

Web Sling – 6T  No Damage in the Web belt

Name & Signature Date Document Control

EHV SS & IE - Segment Rev: 00

PP Rope – 25 mm dia  Broken ropes

Chain pulley block – 2 T / 5  Chain links

Pallet Truck – 1 T capacity  Physical condition

Name & Signature Date Document Control

EHV SS & IE - Segment Rev: 00

9.0 Flow chart - Sequence of operation

Check the Packing Verify the lifting accessories

Screen & Induct

Load the equipment on Vehicle

Plan for transport Unload near the erection point

Supervise Check tightness of bolt and

Relaese the lifting

Name & Signature Date Document Control

EHV SS & IE - Segment Rev: 00

a) Pre operational Checks

Name & Signature Date Document Control

EHV SS & IE - Segment Rev: 00