METHOD STATEMENT –PREVENTIVE MAINTENANCE

Client :

Owner :

Contractor :

Project Title : 4.5 MWp On-Grid PT. ElangPerdana Tyre Industry

Document No : EPTI-OM-MS-01

Purpose : Issued For Approval

Notes : Critical Document

Rev. Description Date Prepared Checked Approved

1. Issued for Approval 28-01-2022 HH RS

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REVISION HISTORICAL SHEET

Rev. No. Date Description

00 28-01-2022 Issued for approval
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Contents
1. Work Safety Instruction ......................................................................................................................................4

2. Scope of Work ........................................................................................................................................................5

3. PV Module Cleaning .............................................................................................................................................5

3.1 Tools and Equipment ..................................................................................................................................5

3.2 Cleaning Procedure .....................................................................................................................................6

4. PV System Periodic Check & Inspection .........................................................................................................8

4.1 Tools and Equipments ................................................................................................................................8

4.2 Working at Height Instruction ..................................................................................................................9

4.3 PV Module Check & Inspection ............................................................................................................. 10

4.4 PV Module Mounting Structure Check & Inspection ...................................................................... 11

4.5 DC Cable and Wiring Check & Inspection ........................................................................................... 11

4.6 Meteorological Station Maintenance .................................................................................................. 12

4.7 Inverter Maintenance .............................................................................................................................. 12

4.8 Grounding system Check & Inspection ............................................................................................... 14

4.9 AC Cable and wiring Check & Inspection ............................................................................................ 14

4.10 Monitoring System Check & Inspection ............................................................................................. 15

4.11 HT & LT Panels Maintenance ................................................................................................................ 15

5. Risk Assessment and Emergency Preparedness ..................................................................................... 16

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1. Work Safety Instruction

WARNING!!
Please read the safety instructions before installing,
using or maintaining the solar power plant system.

❖ All personnel are required to wear Personal Protective Equipment (PPE) when carrying
out operations and maintenance work
❖ The system contains sophisticated electronic equipment and must be installed and
maintained by qualified and experienced electricians. Every question about the system
must be referred to the supplier of goods.
❖ Every maintenance and installation of the system must refer to national or
international electricity regulations.
❖ All precautions relating to the installation and operation of electrical voltage equipment
must be observed when installing the system. These include considerations for cable
insulation, access to bare conductors, grounding, and protection from moisture.
❖ Do not operate the equipment or system if the lid and inverter are still open.
❖ After the system has been turned off the possibility of an electric current is still present
in the inverter, therefore make sure that all equipment has been disconnected from the
electrical connection.
❖ Do not operate inverters and electrical panels under ambient conditions that are not
recommended.
❖ Do not expose the inverter and all electrical panels to rain, snow, water spray or dust.
To reduce the risk of danger, do not install inverters and electrical panels close to water
leaks, and leave the panel rooms with sufficient air ventilation.
❖ To avoid the risk of fire and electric shock, ensure that the cables are in good condition
and accordance with the recommended size, do not operate the system if there are
damaged or out of standard cable sizes.
❖ This system contains elements that can cause sparks, to avoid fire or explosion do not
place flammable objects close to the panel.
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2. Scope of Work
Scope of Work and Schedule for this Preventive Maintenance work are stated in the Annex 1
and Annex 2 attached to PO and Master Agreement.

The checklist form has to be filled for reporting purpose, accompanied by documentation to
support the report. The checklist form is stated in Annex D on the Master Agreement.

3. PV Module Cleaning

Cleaning solar panels help ensure solar installations generate optimal electricity. Most solar
PV module have been designed for easy installation and minimal maintenance, however,
dust, pollen, leaves and other contaminants often find their way onto the panel and soil the
surface. To overcome this, solar PV module are manufactured so that normal and regular
levels of rainfall will clean them naturally if installed at a sufficient angle.

3.1 Tools and Equipment

a b c
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a. Standard flexible water hose

b. Microfiber cloth
c. Telescopic cleaning pole
d. Personal Protective Equipment:
- Safety helmet
- Safety shoes
- Safety gloves
- Body harness

3.2 Cleaning Procedure

a. Ensure all personnel are in good condition
b. All personnel must use standard fall and personal protection measures throughout the
cleaning process.
c. Ensure there is a safety life line or guard rail to hook the body harness
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Safety life line (left) and guard rail (right) illustration

d. Make sure all the guard rail installed at the edge of the roof to prevent accident
e. Before cleaning, thoroughly inspect modules for cracks, damage, and loose connections
to avoid lethal shock hazard when modules are wet.
f. Module cleaning should be done outside working temperature, i.e., early morning or late
evening and must only be cleaned with water at ambient temperature.
g. Apply as much water to the panel or array as necessary using standard flexible garden
hose with domestic water pressure and allow the water to run down the entire surface.

PV module cleaning illustration

h. If the panels require more cleaning effort to remove stubborn marks, use a soft sponge,
microfiber cloth or a soft and nonabrasive brush and lightly wipe over the affected area.
i. Leave the modules to dry naturally in the air.
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4. PV System Periodic Check & Inspection

4.1 Tools and Equipments

a b

c d

e
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a. Infrared Thermal Camera

b. PV Tester
c. Multimeter
d. Earth Tester
e. Cable Insulation Tester
f. Personal Protective Equipment:
- Safety helmet
- Safety shoes
- Safety gloves
- Body harness
g. Phone/Camera

4.2 Working at Height Instruction

a. Ensure all personnel are in good condition
b. All personnel must use standard fall and personal protection measures throughout the
cleaning process.
c. Ensure there is a safety life line or guard rail to hook the body harness
d. Make sure all the guard rail installed at the edge of the roof to prevent accident
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4.3 PV Module Check & Inspection

❖ PV Module Visual/Physical Inspection
a. Make sure all personnel follow Working at Height instruction
b. Visual inspection of PV module is carried out periodically
c. Walk through the walkway to visually inspect PV modules for any cracks, damages,
heavy dirt or dust that obstruct the surface of the PV module
d. Take a picture and specify the location if there are any cracks, damages, and heavy
dirt that developing on the modules
e. Visually check the junction box of the modules by sampling for any damages. The
samples have to be representative to the overall PV system.
f. If there is any damage, take a picture and note the specific module/string
g. Fill out the checklist form

❖ Termographic Inspection
a. Make sure all personnel follow Working at Height instruction
b. Turn on the thermal camera to see if there are any hotspots
To turn on the camera, push and hold MENU button for 2 seconds. A start-up
screen shows on the display and an indicator bar shows the status, see Figure
below. The indication bar increases on power up and decreases on power down.
After the start-up screen, the Product is ready to use. To turn off the camera, push
and hold MENU button for 2 seconds. The Auto Off feature turns off the Product
after 10 minutes of inactivity.

Start-Up Screen and Status Indicator

c. Point the camera on to the surface of the PV array

d. Take a note and picture if there are any hotspots developing in PV modules
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e. Fill out the relevant checklist form

4.4 PV Module Mounting Structure Check & Inspection

a. Make sure all personnel follow Working at Height instruction
b. Walk through the walkway and visually inspect PV module mounting structures for
any rusting or sharp edges
c. If there are any rusting or sharp edges, take a picture and note the specific location
d. Fill out the checklist form

4.5 DC Cable and Wiring Check & Inspection

❖ DC Cable and Wiring Visual Check & Inspection
a. Make sure all personnel follow Working at Height instruction
b. Walk through the walkway and visually inspect DC cable trays for any damage
c. Check through sampling if the connectors are tightened. The samples must be
representative for overall PV system
d. If there are any damages that require replacement, take a picture and note the
specific location

❖ Voc, Isc, and Riso Measurement

a. All personnel have to use standard PPE
b. Prepare the PV tester measurement according to the manufacturer manual
c. Turn off the MCCB on the ACDB panel relevant to the inverter where the
measured string is connected
d. Turn off the DC switch on the inverter
e. Disconnect the string MC4 connector from the inverter
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PV Tester and PV Module probe connection

f. Connect the MC4 probe of the PV tester to MC4 connector of the string
g. Press RPE and Auto button to turn on the PV Tester
h. Press VISO and select 1000V
i. Press Auto button and wait for the result
j. Press Save button to save the measurement result

4.6 Meteorological Station Maintenance

a. All personnel have to use standard PPE
b. Make sure all personnel follow Working at Height instruction
c. Clean the pyranometer/silicon sensor using microfiber cloth
d. Visually check the tilt angle of the sensor
e. Check bubble position on the pyranometer
f. Visually check for any damage and abnormalities from the sensor
g. If there are any abnormalities finding, take a picture and note it down
h. Fill out the relevant checklist form

4.7 Inverter Maintenance

a. Inverter Power Off Procedure
Step 1 Wear proper personal protective equipment (PPE).
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Step 2 If the solar inverter is not shut down due to a fault, send a shutdown
command on the SUN2000 app, SmartLogger, or management system. If the
solar inverter has shut down due to a fault, go to the next step.
Step 3 Turn off the AC switch between the solar inverter and the power grid.
Step 4 Measure the DC current of each PV input string using a clamp meter that is set
to the DC position.
- If the current is less than or equal to 0.5 A, go to the next step.
- If the current is higher than 0.5 A, wait until the solar irradiance decreases and the
PV string current decreases below 0.5 A at night, and then go to the next step.

Step 5 Open the maintenance compartment door, install a support bar, and use a
multimeter to measure the voltage between the AC terminal block and the
ground. Ensure that the AC side of the solar inverter is disconnected.
Step 6 Turn off all DC input switches of the solar inverter.

Inverter power off for maintenance

Step 7 Wait for 15 minutes and troubleshoot or repair the inverter

b. Ensure warning labels and sticker are still attached

c. Ensure the heat sink at the rear of the inverter is not covered (e.g. by insects or dirt)
d. Clean outer part of the inverter and fan using dry microfiber cloth
e. Check the surge arrestor physical condition
f. Clean the contacts of the PV load-break switch. Clean by cycling the switch to on and
off positions ten times. The PV load- break switch is located at the bottom of the
inverter. (this step have to be done every 6 months, according to Annex 2 – O&M
Maintenance Schedule)
g. Fill out the checklist form
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4.8 Grounding system Check & Inspection

❖ Quarterly Maintenance
a. All personnel have to wear standard PPE during the work period
b. Visually check all the earth pits for any physical damage
c. If there are any findings on damage, take a picture and add some notes on the
damage that has to be repaired
d. Check the continuity between earthing strip/structure and earthing using
multimeter
e. Check the tightness of all the fasteners in earthing pit, if it is not tight enough,
tighten.
f. Fill out the relevant checklist form

❖ Annual Maintenance
a. All personnel have to wear standard PPE during the work period
b. Carry out all steps from quarterly maintenance
c. Check the earth pit resistance of entire plant
d. Fill out the relevant form

4.9 AC Cable and wiring Check & Inspection

❖ Quarterly Maintenance
a. All personnel have to wear standard PPE during the work period
b. Visually inspect all AC cables to ensure there is no damage due to environmental
conditions
c. If there are any findings on cable damage, take a picture and add some notes on
the damage that has to be repaired
d. Check AC cable terminations (Lugs) for physical damage and/or heating issues
using IR thermal camera, the procedure is the same as PV module termographic
inspection.
e. Fill out the relevant checklist form
❖ Annual Maintenance
a. All personnel have to wear standard PPE during the work period
b. Carry out all steps from quarterly maintenance
c. Perform Insulation resistance test of the AC Cables for the entire plant to check
the healthiness of the cable
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d. Take a picture for documentation and fill out the checklist form

4.10 Monitoring System Check & Inspection

a. All personnel have to wear standard PPE before doing the work
b. Ensure data logger and UPS are intact
c. Check all the physical connections inside the cabinet for tightness
d. Check the monitoring cabinet for any physical damage
e. If there are any damage that have to be repaired, take a picture for documentation
f. Download backup monitoring data from Fusion Solar at every end of the month
g. Fill out the relevant checklist form after the work is done

4.11 HT & LT Panels Maintenance

❖ Monthly Maintenance
a. All personnel have to wear standard PPE before doing the work
b. Visually check the condition of LT panel for any damage
c. Check for any insects/debris inside the panel
d. Check all the indicators LED for their operation
e. Check all the MCBs for their operation
f. Check the support structure of ACDB for any rusting
g. Visually inspect all the connections inside the ACDB for any damage
h. Check the ACDB for any holes
i. Clean the LT panel with dry cloth
j. Take before and after photo of the panel
k. Fill out the checklist form

❖ Quarterly Maintenance
a. All personnel have to wear standard PPE before doing the work
b. Carry out all steps from monthly maintenance procedure
c. Visually check the relay status and auxiliary supply status
d. Visually check all MCCB and Isolator terminal for any abnormality
e. Check LT Panel earthing connection
f. Clean LT panel with a dry microfiber cloth
g. Fill out the checklist form
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❖ Half-Yearly Maintenance
a. All personnel have to wear standard PPE before doing the work
b. Carry out all steps from quarterly maintenance procedure
c. Check MCCB operating mechanism and trip mechanism condition
d. Fill out the checklist form

❖ Annual Maintenance
a. All personnel have to wear standard PPE before doing the work
b. Carry out all steps from half-yearly maintenance procedure
c. Carry out torque check of all busbar joints
d. Carry out torque check of all the bolts in the panels
e. Check the ACB terminals push and trip and operating conditions
f. Check the flexible joint between bus bar and main terminal
g. Check connection conductors, main circuit terminals, and current carrying
parts for heat discoloration
h. Remove arc chamber and check it for foreign object or dust accumulation,
deformation, cracks, chips and other damage. If foreign matter or dust is
accumulated, use vacuum cleaner to remove foreign matter of dust and wipe
off with dry, clean cloth
i. Carry out energy meter calibration
j. VCB inspections and testing, relays and operations for relay mechanism etc.
k. Check SHT mounting screws for looseness. If loose, retighten
l. Fill out the checklist form

5. Risk Assessment and Emergency Preparedness

Risk Assessment for this work is explained in JSA, attached alongside this document. In
emergency condition please refer to contact and location below :

❖ Citeureup Police Department (Polsek Citeureup)

Emergency Contact : (021-875-222-9)
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❖ Fire and Rescue Department Bogor

Emergency Contact : 021-875—354-7
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❖ FMC Hospital
Emergency Contact : 0251-8665-000