Electrical Engineering Installation and Commissioning Technology Manual

Author: Chief Editor: Bai Yumin
Publisher:
Publish Date: 1998-09-01
Features: This book is primarily based on practical experience, detailing the preliminary preparations, installation techniques, debugging methods, and construction management techniques for various electrical engineering, electrical equipment, and low-voltage engineering installations. The book is divided into two main parts. The first part covers the preliminary preparations for electrical installation engineering, with main contents including electrical engineering drawings and review, writing of construction organization design, preparation of engineering budget and material lists, fabrication and prefabrication of electrical control cabinets and installation components, and coordination with civil engineering for pipe and component pre-embedding. The second part covers the installation techniques and debugging methods for electrical engineering, with main contents including lighting and single-phase circuits, power circuits and low-voltage distribution rooms, backup generators and UPS, electrical equipment for lifting machinery, overhead lines and indoor/outdoor substation and distribution equipment for 35kV and below, cable engineering, electrical equipment for special locations, elevators, lightning protection and grounding systems, installation and debugging techniques for low-voltage systems, and handover acceptance of electrical engineering. This book can serve as a reference for personnel engaged in the installation, design, and management of electrical engineering, as well as a training textbook for young electricians, and a teaching or reference material for electrical engineering students and faculty in technical colleges. Excerpt: 2. Master the starting control methods, speed regulation and braking principles, conventional control circuits and system installation and debugging methods for common motors (including DC motors, multi-speed motors, AC slip-ring motors, high-voltage large AC motors, synchronous motors, and small-to-medium capacity AC generator sets), master the wiring, repair, and testing methods for various motor windings, and be able to troubleshoot system faults, handle accidents, and resolve issues during installation, debugging, and operation. Master the installation and debugging methods for the complex relay-contactor control systems, thyristor-electronic circuit control systems, and programmable/digital control systems in single or multiple motor linkage systems, as well as the installation and debugging techniques for complex electrical drive automatic control systems. Lead large-scale electrical engineering linkage commissioning and coordinate the debugging of automation instruments for production process operation, develop commissioning operation plans, guide commissioning, troubleshoot and diagnose faults during commissioning, and ensure smooth commissioning. 3. Master the control circuits and installation of lighting circuits and various types of lighting fixtures. 4. Master the installation techniques and debugging methods for transmission and distribution systems up to 110kV and below. The transmission system refers to overhead lines and power cable lines (including large-span, special environments, and special cables), master the measurement and installation techniques for overhead lines and the transportation methods for pole and cable, master the laying methods for various cables and the fabrication of cable heads. The substation system refers to transformers (capacity unrestricted) and accessories, as well as various high-voltage switch components, backup power sources, generator sets, and AC static uninterrupted power supply devices (UPS systems), master their installation and debugging techniques and testing methods, master the transportation, hoisting methods for transformers and large heavy-duty components, and core inspection. The distribution system refers to high- and low-voltage distribution cabinets, circuit breakers, fuses, and circuit distribution, energy measurement, and relay protection devices, master their installation and debugging techniques, relay protection setting and verification, master the prefabrication and installation of large busbars, capacitor banks, and cabinets. Master the system debugging techniques for transmission and distribution systems, lead system energization, de-energization, and trial operation, troubleshoot faults, handle accidents, resolve technical issues, and develop energization and trial operation plans. 5. Master the installation and testing techniques for lightning protection and grounding systems. 6. Master the installation techniques and debugging methods for common elevators, troubleshoot faults, and handle accidents. 7. Master the installation and debugging techniques for low-voltage systems, which generally include communication and broadcasting, cable television, anti-theft alarm, fire alarm and automatic fire protection, microcomputer monitoring and management systems, etc. 8. Master the installation and testing techniques and system debugging methods for common instruments, including temperature, pressure, flow, level, composition analysis, and mechanical quantity measurement instruments; master the installation and debugging techniques for automatic control systems, fault troubleshooting, and the commissioning of instruments and automatic control systems; master the use and maintenance of electrical instruments, including oscilloscopes and AC bridges. 9. Be familiar with various types of electrical engineering drawings, understand complex automatic control and automatic regulation schematic diagrams, be familiar with the laying methods and requirements for electrical pipelines, be familiar with the installation methods, elevation, and positions of common electrical appliances, be familiar with the calculation methods for electrical engineering and low-voltage systems, master the selection methods for common electrical equipment components and empirical formulas, and have the ability to identify discrepancies in drawings. 10. Master the methods and techniques for preparing construction budget, compile budget documents, be familiar with quotas, usage methods, fee standards, and relevant policies and regulations of government departments on engineering projects; master the preparation methods for material lists, be familiar with material consumption quotas and usage methods. 11. Master the methods and techniques for preparing construction organization design for electrical engineering projects; be familiar with construction management methods, determine construction plans and on-site layout, compile plans for material, equipment, and material supply, and material management; be familiar with installation processes and procedures, master the calculation of project quantities and progress, be familiar with critical project sections and complex processes, be familiar with the allocation of technicians and labor in projects, and master labor quotas. Effectively and efficiently allocate personnel to organize team work plans and lead construction. 12. Master electrical safety operation procedures, be familiar with the use and inspection cycle standards for electrical safety tools and protective equipment, master electrical shock first aid and care, and electrical fire prevention methods, conduct safety briefings and arrange protective technical measures for specific projects to ensure safe construction. 13. Master the processing and fabrication techniques for metal work and line fittings in electrical engineering, as well as the standards for complex control cabinets and switchboard fabrication, and master component testing and overall system debugging; master sheet metal processing, be familiar with the assembly and process procedures for electrical secondary circuits, to standardize and serialize products. 14. Be familiar with the structure and basic knowledge of civil engineering, understand basic knowledge of other disciplines such as pipelines and equipment; be able to coordinate and cooperate during installation, and coordinate with civil engineering for pre-embedding and laying of pipelines, boxes, and panels to ensure no leaks or errors; be familiar with the basic operation methods for welding, gas welding, plumbing, and heavy lifting. 15. Master the installation and debugging for electrical engineering in special locations, be familiar with the codes, standards, and zoning boundaries for fire-risk and explosion-risk locations, master the safety codes for special locations and procedures for handling hot work, and arrange on-site fire protection technical measures. 16. Master the market dynamics and technical-economic information for electrical engineering materials and equipment, as well as the performance and applications of new processes, technologies, materials, and equipment; teach operational skills, explain technical knowledge and skills in this field, cultivate technical experts, and be good at discovering and utilizing talent. 17. Collect various technical data, parameters, and records of completed electrical engineering projects, lead the quality assessment of electrical engineering projects, and provide data and information. The above technical qualities and skills are not achieved overnight; they are accumulated through continuous learning and in-depth practice over time. As an excellent electrical installation technician, one must not only learn from books but also more importantly, learn from practical knowledge and the strengths of others, on one hand to compensate for one's own shortcomings, on the other hand to verify the correctness of the technical skills and knowledge already mastered. Only in this way can one become an excellent electrical installation technician. In summary, electrical engineering installation technology is a highly specialized, complex, and comprehensive field involving deep and broad knowledge and technology, differing from electrical maintenance and operation in factories and enterprises, power operation and maintenance in power generation and supply departments, electrical engineering design, and basic electrical theory and teaching. It is a distinct discipline, which we can call Electrical Engineering.
V. Means to Ensure Electrical Engineering Installation Quality and Safety The main indicators of engineering construction projects are investment, schedule, quality, and safety. Quality is the center of construction projects, "a hundred years of plan, quality first," while safety is the means to ensure the smooth progress of construction projects and the primary condition for guaranteeing quality. Engineering quality and production safety hold a crucial and prominent position in engineering construction, and both are inherently inseparable, a fact that cannot be ignored by any installation and construction enterprises or personnel involved in engineering construction projects. How can quality and safety be ensured? How can the connection between quality and safety be maintained? This is a challenge and a must for installation enterprises and personnel to address well. Practice has proven that establishing corporate quality and safety assurance systems can effectively solve the above problems. (I) Installation Engineering Quality Assurance System A quality assurance system is a scientific management network established by a unit or system to implement comprehensive management and systematic analysis of quality work, ensuring product or work quality and the normal operation of processes. It is not a lagging mechanical management system but a dynamic, proactive, comprehensive, and systematic quality assurance system. Figure 1-2 provides a reference for the quality assurance system of an installation unit. 1. Main Content and Function of the Quality Assurance System (1) Tasks Based on the characteristics and procedures of production processes, start from each factor affecting quality, implement intermediate detection and control or proactive control of production processes and products, strengthen quality inspection and supervision, and ensure product or installation quality to achieve the planned quality level. (2) System Composition A quality assurance system is generally composed of five subsystems: the quality supervision and management system led by the chief engineer, the quality assurance system led by the chief engineer and quality assurance engineer, the production operation system and material supply system led by the chief production director (manager), and the labor management system led by the chief labor allocation director (manager). These five subsystems are closely interconnected and ensure the normal operation of the system. (3) Central Link The production operation system is the central link for ensuring quality and the manufacturing system for engineering quality. Installation engineering is gradually completed by production workers using technical skills, tools, and equipment according to national engineering standards and specifications. During the installation process, the quality assurance system and supervision system conduct detection and control, forming a cyclic feedback system until the quality plan level is achieved. (4) Conditions for Ensuring the Central Link First, it is necessary to establish a quality information management system composed of production front-line workers, that is, production front-line workers must develop a self-quality awareness and participate in quality and information feedback, promptly reflecting factors detrimental to quality in production details (such as personnel and skills, materials, process operation procedures, tools, and equipment), achieving proactive control, and eliminating quality accident tendencies and hidden dangers before they become actual facts. This is a dynamic process. Second, the material supply system must ensure the quality and delivery dates of materials, preventing counterfeit and substandard products from entering the site. At the same time, under the conditions of ensuring quality and delivery dates, material prices should be minimized. (5) Total Quality Management Every employee's work behavior is related to engineering quality. (6) Installation Technical Skills Training Improve the technical skills and professional quality of all workers and staff to ensure the normal operation of the quality assurance system. (7) Quality Accident Analysis and Handling After a quality accident occurs, it must be reported to all relevant departments within 24 hours, analyze the accident causes from 26 aspects affecting engineering quality, and use the means of the central link to rectify the situation and achieve the quality plan level. Serious actions should be taken against those involved. 2. Installation Quality of Electrical Engineering is an Important Part of the Entire Project and the Basic Guarantee for the Realization of Project Functions. (II) Installation Engineering Safety Assurance System A safety assurance system is a scientific management network established by a unit or system to implement comprehensive management and systematic analysis of safety work, ensuring production safety, the safety of personnel, and the safety of various facilities. It is not a lagging mechanical management system but a dynamic, proactive, comprehensive, and systematic safety assurance system. Figure 1-3 provides a reference for the safety assurance system of an installation unit. 1. Main Content and Function of the Safety Assurance System (1) Tasks Based on the characteristics and procedures of production processes, start from each factor affecting safety, conduct safety prevention and proactive prediction, strengthen safety inspection and supervision, and ensure production safety, the safety of personnel, and the safety of facilities.