This document describes the methodology for installation of MCC, ACB and control panels in any kind of the project, also to ensure that all concerned persons are familiar with the sequence of activities, utilization of resources.
By following this electrical method statement workers shall ensure the execution of the electrical works in compliance with applicable safety and quality procedures, and any other applicable documents, regulations, standards and specifications.
Below is list of necessary tools & equipment’s for panels installations.
- General Electrician Tools Box
- Drilling Machine with suitable drill bits
- Aluminium “A” type Ladder height as required
- Measuring Tape 5 Meter
- Markers (Chalk line power) and permanent Markers
- Ratchet
- Box Spanner set
- Sprit Level 30 CM, 100CM Long and right angled
- Multi Tester
- Hydraulic Cable Cutter
- Insulation resistance tester (0-500V)
- Torque Spanner
- Hydraulic Cable Crimping Tool up to 630 sq. mm size
Safety of Equipment’s and Assets
Necessary measures will be taken for the safety of the equipment, assets and any other works affected by the panels installation works.
Relevant entities which might require protection in the vicinity of the area of work or on the service access or discharge path, shall be protected suitably.
The installation / construction team will ensure that any such protection requirements are documented.
HSE Health, Safety & Environmental Requirements
A task based risk assessment and mitigation strategy shall be prepared as part of this electrical method statement.
Work will commence as per safety regulations laid down in the contract specifications and as per project safety plan.
Safety gears / PPE personal protective equipment shall be used as appropriate according to the nature of the job. For electrical works, provide nonconductive tools and PPE.
Working on live power cables/equipment is not allowed.
ELCB shall be used in temporary panel boards; always use industrial connectors/sockets for temporary power cable connections.
Always maintain cleanliness in the working areas.
Housekeeping shall be of good standard, all cut pieces and debris shall be removed by the end of workday.
Ensure that all lifting operations are carried out as per approved lifting procedures and safety regulations.
Ensure that adequate barricade and signage “DANGER KEEP-OUT, HEAVY LIFTING IN PROGRESS” is provided around the working area.
Installation and testing work will be executed through Permit to Work system.
Scaffoldings shall be checked by competent person and should carry green tags “safe to use”, prior to use for working purpose.
All plant tools tackles will have valid fitness certificates.
Lifting machines, appliances and gear to be examined by qualified rigger and shall be accompanied with valid certifications as applicable.
Workers working at height shall wear full body harness which shall be anchored to a rigid point.
No worker is allowed to stand on the top of the step ladder; worker should stand two rungs below from top of the step ladder. A co-worker must hold the step ladder while in use.
Work inside shafts are not allowed without work permit and supervision.
Working areas shall be provided proper lighting and ventilation at all times.
Method statement / risk assessments to be briefed to all concerned personnel and signed as read /understood by all relevant parties/personnel.
Quality and Inspection Requirements
Site engineer shall verify that the supervisor/foreman with construction responsibilities for installation is familiar with this method statement and is issued with copies of the inspection checklists and test plans.
The engineer should satisfy the procedures provided by QA/QC inspectors to ensure that electrical panels installation activities meet the specified engineering requirements and approved drawings.
QC inspection personnel, in coordination with Site Supervisor, should verify that the quality of the related cable tray, trunking and panels installation is within the prescribed acceptance criteria and applicable codes and standards.
Electrical supervisor shall verify the installation and update the as built drawings and details, and confirm that the information meets the project requirements.
Quality Control Engineer along with Project Engineer and Site Supervisor will monitor that all components are installed as per contract specifications, manufacturer instructions and approved submittals.
Request for Work Inspection Request (WIR) shall be submitted by Site Engineer to QA/QC department for verification and inspections.
Readable stamped approved drawing to be available during installation and inspection.
Contractor’s QA/QC department will forward WIR to consultant/client for inspection and approval in accordance with ITP.
All the equipment’s engaged for testing shall have valid calibration certificates.
Sequence of Work for Control Panel Installation
Receiving Inspections and Storage:
Make sure that the MCC, ACB, Control Panel and it’s accessories are as per the approved material submittal prior to movement to site installation location.
Equipment’s are new and without any damages to enclosure and metering devices.
Type and Ratings of all the Panels are as per the Approved shop drawings and Approved technical submittals.
All material received at store shall be inspected by the engineer’s representative for conformance to Material approval, and then handled & stored properly upon receipt.
Panels shall be kept in shaded and covered area or the main panels can be moved to the electrical rooms if the location is ready for the installation activities.
Keep all the panels covered properly till the actual start of the electrical installation activities.
Ensure type of Storage and handling of the Materials are acceptable to consultant and easily accessible.
All the panels shall be handled with proper mobile trolley and hoisting equipment’s as applicable on the site conditions.
RFIA to be raised and ensure its approval prior to start installation and assembling of the MCC, ACB and Control Panels.
Approved Drawings and Co ordination
Ensure approved shop drawings and approved method statements are available with installation team, (distributed competent workforce) in the required and planned locations.
Make sure that approved MEP coordination drawings are available for the confirmation of the final location of MCC, ACB and Control Panels.
Ensure full coordination with the safety officer to maintain safe working and proper housekeeping of the site, following the approved safety measures and further ensure that all working team are aware of the same to prevent accident and losses.
Work progress is coordinated with the Main contractor, MEP Coordinator and Safety Officer, for a safe and proper execution of the works.
Pre Installation Requirements:
Project engineer shall make sure that approved materials required to carry out the electrical panel installation activities are available at site.
Prior to commencement of work, work areas and access shall be inspected to confirm that site is ready to commence the installation Activities.
Verification of equipment layout from relevant construction drawings shall be completed.
All relevant documentation (Approved Shop drawings and materials), for a particular section of the works, will be checked prior to commencement of work.
The site engineer/supervisor/Foreman will give necessary instructions to tradesmen and provide necessary construction/fabrication schedule.
Site engineer /supervisor/ Foreman will also check that available tools and equipment’s are suitable for the Installation of MCC, ACB and Control Panels.
Make sure that all power tools are having necessary safe guards / covers.
Installation of MCC Panels
Prior to proceeding with the installation of MCC Panel, make sure that the surface/area for electrical installation has been cleared/released by main contractor for commencement of installation work.
Shift the panel from stores to the installation spot using fork lift.
For floor mounted panels, the exact location of the panel and fixing holes to be marked on the concrete plinth provided by main contractor for the installation.
Remove the packing and ensure that the panel is free from transportation damages.
For wall mounted panels, the exact location of the panel and fixing holes to be marked based on approved shop drawings keeping panel in place and will be fixed in an approved manner.
Provide fixing arrangement in an approved manner in the marked location.
Install the panel on the plinth, align and fix properly.
Gland the cables ( Power / earthing ) on the glanding plate of the panel and terminate properly.
Tighten all the connections as required.
Access around the panel to be checked for future maintenance as per regulations.
Make sure that any services containing water is away from the panel or properly protected against any accidental leakages.
Identification of panel and outgoing breaker shall be provided and checked against approved shop drawings.
Incoming and Outgoing cables shall be marked / identified as per approved shop drawings.
All components of the panel such as MCCB, MCB, Relays, Fuses, Meters, CTs, Contractors, Terminal s, etc. shall be verified against the approved panel drawings for correct rating and size.
Any internal connections / modification will be carried out only by the manufacturer representative of the particular switchgear panel.
All breakers (incoming / outgoing) shall be in “OFF” position and to be locked to prevent mishandling.
Check and ensure adequate space is available for maintenance.
After installation panel shall be properly cleaned and protected to prevent dust and contamination.
Inspection request shall be raised for internal QA/QC verification, after which work inspection request WIR shall be raised for Consultant’s inspection and sign off.
Installation of ACB Panel
Installation works shall be carried out only with respect to approved shop drawings of latest revision.
All components of ACB shall be verified as per the approved material submittal.
Ensure the floor surface is ready with base frames grouted to install the ACB panel.
Minimum clearance of 800 mm shall be maintained at rear side of the panel so that easy access for termination of cables and other maintenance works can be carried out.
Panel boards shall be installed serially and with Level Verticality in accordance with the Manufacturer’s recommendations, approved site layout and as per site requirements.
Check cabinet interconnections, bus bar connections, control wire connections between the cubicles after proper alignment of the sections cubical as per manufacturer’s drawing and approved shop drawing.
All knockouts made on the panel covers shall be filed and provided with grommets to avoid sharp edges and unused knockouts shall be covered.
The connection of bus bar trunking with all panel boards shall be done rigidly with proper supports.
Cables bending radius should be less than the 8 times of the cable diameter in line with the Manufacturer’s recommendations.
Cable pulling, termination & crimping shall be done as per cabling method statement.
Termination of cables shall be done using approved material submittal for cable glands and lugs.
Glanding and connections should be done only by competent technicians / electricians under supervision of electrical site Engineer.
All panel boards and switch gears shall be provided with proper earthing connections as per approved shop drawings.
Manufacturer recommendations are to be followed for all relay, timer and other breaker current settings, as per the total connected loads and the discrimination study of the system.
Identification labels of approved type shall be fixed on all panel boards.
MEP contractor shall coordinate with the main contractor to ensure provision of chequer plates on the open trenches inside the LV Room and Electrical rooms.
Ensure that all cable entries and other openings of Electrical / LV Room, Wall / Floor are carried out with proper approved sealant.
The manufacturer’s representative to verify the site installations and provide acceptance of same prior to energization of Panel boards after approval from authorities as applicable.
Inspection request will be issued for installation of Panel Boards along with glanding and termination to consultant for final approval.
Installation of Control Panels
Verify equipment layout from relevant construction drawings. Check drawings are of current revised status.
Make sure that installation site is released for panel installation, i.e. confirm readiness of the area.
Location of the Panels / Equipment shall be determined and the covered false flooring shall be removed to expose the main structural steel, this will however be done in phases depending on the panel that is going to be installed.
Installation supervisor shall review vendor drawings of the Panels and familiarize the installation method recommended by the manufacturer/vendor.
Check the availability of adequate space for unloading the panels / components. Also confirm the Height and Width of the entrances.
Personnel involved in the activity are made aware of the risks and the steps to be taken to mitigate any hazard or unsafe situation.
The tentative sequence for the Panel / Equipment erection will be as per the project schedule.
Supports required, if any, for the installation of the Panels will be prefabricated in accordance with the drawings and vendor recommendations.
Equipment packages shall be unpacked outside the substation room just prior to the installation.
Shortages or damages if any shall be brought to the attention of the main contractor / consultant engineer immediately.
Each and every loose item shall be properly identified before installation.
Panels shall be lifted by the Crane and off-loaded on the platform outside the entrance of the respective Sub-stations / Rooms.
It shall be ensured that the Crane lifting range will be within the specified limited capacity, due to angular position at the entrance of the main door especially during lifting of the heaviest panel, from here the Panels will be slid on pipe rollers and or Tran’s pallets over Plywood sheets and taken to exact location.
Panels will then be placed in position over the foundation frame already installed, after that panels will be aligned using Spirit level & Water level.
Installation of interconnection of wires or Bus-Bars between panels shall be completed and Bus Bars will be tightened with suitable Torque Wrench.
Insulation tests will be carried out as well as all pre-commissioning testing as applicable.
Inspection request will be issued for installation of Panel Boards along with glanding and termination to consultant.
Cable Terminations Method
Cable termination in the LV Switchgear Panels shall be done as per the approved method statement for the cable laying and terminations.
Openings for the Cable Glanding in the Gland plates shall be as per the number of cables to the terminals and its gland sizes.
Earth connections for the enclosures shall be done as per the approved Earthing shop drawings.
Use suitable Cable glands and cable lugs for the cable termination and secure the terminals with suitable bolts and nuts.
After termination of the cables and primary testing all the panels and enclosures shall be closed and secured properly.
Ensure all the panels are clean and safe for the others to do their activities.
Test and Inspections
Assembled splited panels, and MCC’s Shall be tested as per the Manufacturer recommendation and project requirements.
Testing and commissioning of the ACB, Control Panels shall be as per the Recommendation of the manufacturer.
Disconnect the control wiring prior to insulation resistance test.
Insulation Resistance test shall be done with 1000 Volts Megger for one minutes and resistance should be 2Mega Ohms Minimum.
Check all the bus for the continuity performance.
Operate Each switch and breakers for 3 times minimum to check the performance.
Functional test shall be done for all the breakers and relays.
Ensure the continuity of protective conductors.
Labels and Markers
All the temporary markers and labels to be removed if not required.
Identification Tags and permanent markers shall be provided for all the modules and devices as per the Requirement and approval of the project and authorities.
Tag all equipment, stations and other components at which tests have been satisfactorily completed.
Cable numbering Tags and marker shall be provided as per the Engineer’s approval (According to the size of the cables, Stickers or Cable marker carrier strip with ties).
Update/mark the drawings for the as built purpose if there are any changes from approved shop drawings done at site as per the site requirements with the approval of consultant.