METHOD STATEMENT PANEL BOARD INSTALLATION AND POWER CABLE TERMINATION

METHOD STATEMENT PANEL BOARD INSTALLATION AND POWER CABLE TERMINATION

MATERIAL TO BE USED:-

1.       PANEL BOARDS are all metallic enclosures with completely insulated bus bar, protected Neutral bars. Earth and Neutral terminal with knock outs at top and bottom removable gland plates, and with zinc coated metal sheet 1 .2mm without any welding joints and flush mounted type. (The manufacturer, equipment data, drawing, accessories, etc will be summitted for approval and will be as per approval).

EQUIPMENT AND TOOLS:-

o   Spanner Sets

o  Concrete Cutting Grinder

o   Spirit level

o   Screw driver Set

o   Measuring Tape, knife etc.

o   Multimeter , Megger

o   Cable tie, wire marker

o   Fish tape

INSTALLATION :-

a) Fixing Generally:

(1 ) Align , level and securely fasten panelboards to structure.

(2) Do not use connecting conduits to support panelboards.

(3) Close unused openings in the panelboard cabinets.

b) Panelboard interiors: Do not install in cabinets until all conduit connections to cabinet have been completed.

c) Wiring Inside Panelboards: Neatly arranged, accessible and strapped to prevent tension on circuit breaker terminals. Tap-off connections are to be split and bolted type, fully insulated.

d) Trim: fix plumb and square prior to painting. Fix trim for flush mounted cabinets Flush with wall surface finish.

e) Protection: Treat concealed surfaces of recessed cabinets with heavy field application of waterproof compound prior to installation.

f)  Mounting Heights: Top of trim 1800 mm above finished floor, unless otherwise indicated.

g) Mounting: Plumb and rigid without distortion of box. Mount recessed

panelboards with fronts uniformaly flush with wall finish,

 h) Circuit Directory: Create a directory to indicate installed circuit loads

after balancing panelboards loads. Obtain approval before instaling.

Use a computer or typewriter to creat directory not handwritten

directories.

i)  Install filler plates in unused spaces.

 j)  Cut the wall Blocks carefully and neatly avoiding cracking or other

     damage to surrounding structure,

 k) Cut 15cm depth of masonry wall and install the panel board with all

      its components and cover removed.

1)  Check for the horizontal, vertical levels and the top height of the panel

board is 1800mm from finished level,

 m) The conduit connections to panel board is completed with suitable

      lock nut and washer,

 n) Adjust the panel board with respect to plaster guide so as to be in

flush with the wall finish.

o) Directory is created to indicate the installed circuit loads,

 p) Close unused opening in the panel board,

q) The panel board is labelled.

 r)  The masonry wall is refinished and repaired with finishing materials

to match adjacent undisturbed surface of wall,

s) The panel board is protected by plastic cover to prevent the entry of

debris and to protect from paint and other work.

IDENTIFICATION:-

A. Identify   field-installed   conductors ,interconnecting   wiring,   and components: provide warning signs.

B. Panel boards Nameplates: Label each panel board with engraved metal or laminated-plastic nameplate mounted with corrosion-resistant screws.

CONNECTION:-

A. Install equipment-grounding connections for panel boards with

ground continuity to earthing pit.

B. Tighten electrical connectors and terminals according to

manufacturer’s published torque-tightening values.

POWER CABLE TERMINATION:-

Materials Used:-

Power Cables are multi core XLPE insulated feeder cables 0.6/1KV compacted, XLPE insulated for conductor temperature of 90°C and PVC over sheathed, color black, RIYADH Cables are used. The following are the

sizes used.

I.  4c x 35mm² CU/XLPE/PVC-1C 16mm² CU/PVC 

II.  4cx 150mm-CU/XLPE/PVC-1C 95mm^; CU/PVC

EQUIPMENT AND TOOLS:-

o   Cable Cutter, Hock Saw

0   Crimping Tool

0   Screw driver set

0  Spanner set and ratchet set

0  Measuring tape

0   Electrical Knife .Cable tie

0   Plastic Hammer

Preparation:-

1. Confirm that the correct Cable size is installed with exact routing layout.

2. Confirm that the cable end is dry and properly insulated.

 Installation:-

1) Cables generally are run through duct-banks, or special recesses, clamped to steel racks or cable trays.

2) Fixing: Single cables are run in PVC conduit (inside concrete ) or metallic conduit (exposed). Where two or more cables are run in parallel, they are fixed on galvanized steel perforated trays and protecting arrangement.

3) Clamps: Where cables are fixed to steel trays or supporting structures, approved galvanized cast steel clamps are used at distances not exceeding 20 diameters.

4) Joints or splices will not be used on feeders. Cables are supplied in lengths sufficient for straight-through un-jointed termination pull.

5) Directly buried cables, crossing pipe banks or other services, are laid in heavy duty PVC duct banks. In no case are cables to be directly buired in concrete, in masonry or in floor finishing.

6) Buired Cables liable to mechanical damage are to be drawn through PVC conduit or asbestos cement pipe. If steel conduit is used, all three-phase conductors, neutral and protective earth circuits are to be in the same conduit.

7) Exposure to Heat: Route wires and cables to prevent exposure to excessive heat or to corrosive agents. If such condition is unavoidable, cables are type designed for particular condition.

8) Insulating covers are to be applied to prevent exposure of bare cable connections. Insulating cover is to be purpose made and is to provide minimum insulation level equal to that of conductor insulation.

9) Glands for various single-core and multi-core cables are purpose made and suitable for rigid mounting to equipment enclosure.

10)     Cables and wires pulled inside high conduit riser are supported at the upper end of risers and at intermediate points by split rubber grommets,

11) Seal around cables penetrating fire-rated elements using approved fire-stopping materials.

12)     Confirm the 2″ male adopter with bushing and locknut is fixed _to the panel board for 35mm² cable (and for 150 mm² will be 2.5″ male adopter).

13)     Cut the cable to the required length and carefully remove the outer  sheath PVC cover. Care is taken not to damage the PVC core insulation.

14)     Remove the rubber bedding insulation and neatly bend the core of the cable to bring it up to the terminal of the MCCB’s. Care is taken that the cores are not crossing each other.

15)     The core insulation is removed according to the size of the lugs.

16)    All the strands of the cores are compacted with plastic hammer.

17) Lugs are fixed to the exposed bare stranded core. Fix it firmly with plastic hammer.

18)   Crimp the lugs with the crimping tool and wound insulation tape between the    end of the lugs and the phase core.

19)   Same procedure is followed for all 4 core of the cable.

20)    Proper size of Nuts and Bolts are used to fix the lugs to terminals of the MCCB’s.

21)   Bolts and Nuts with spring washer is used and tighten with ratchet, and required    torque is given to all the nuts and bolts.

22)  clean the area from insulation debris.     

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CONNECTIONS:-

1) Through joints will not be allowed in feeder cables where adequate manufacturer’s lengths are available.

2) Cutting tools for jointing and terminating cables are to be purpose made, to prevent damage to insulation in general.

3) Cleaning of lacquer on conductors is to be by use of ‘Scotch Bnte’ spongs and white spirite or equal approved.

4) Tighten electrical connectors and terminals including screws and bolts, in accordance with manufacturers published torque-tightening values. Where manufacturer’s torquing requirements are not indicated, tighten connectors and terminals to comply with international standards.

INSPECTION AND QUALITY CONTROL

Cable termination is inspected for correct termination and workmanship and

Megger test is conducted.

Note : The Procedure for Testing will be submitted separately.

END