The purpose of generating this method statement is to implement the correct practices for the installation of main distribution board MDB, Sub main distribution boar SMDB, distribution board DB, Motor Control Center MCC and capacitor bank. By following the guidelines contained herein the installation team shall ensure that the job execution complies with project specifications and electrical installations serve the intended function to satisfactory level of the client and end users.
This method statement covers all processes related to installation of MDB, SMDB, DB, MCC and CB.
Below procedure is to be read in conjunction with the relevant ITP outlining the inspection and testing responsibility and the quality verification requirements by various parties.
Definitions / Abbreviations
PQP: Project Quality Plan
PSP: Project Safety Plan
QCP: Quality Control Procedure
HSE: Health, Safety and Environment
MS: Method Statement
ITP: Inspection & Testing Plan
QA/QC: Quality Assurance / Quality Control
SK: Store Keeper
WIR: Work Inspection Request
MIR: Material Inspection Request
MDB: Main Distribution Board
SMDB: Sub Main Distribution Board
DB: Distribution Board
MCC: Motor Control Center
CB: Capacitor Bank – Power factor corrector
Roles and Responsibilities
Project Manager
Project Manager is overall responsible for the project in terms of work execution, safety, planning & quality.
The Project Manager will maintain the planning progress and coordination of works with the main contractor.
He shall ensure that work progress is achieved as per planned program and all the equipment’s required to execute the works are available and in good condition as per the project plan.
Also he shall ensure that specific attention is paid to all safety measures and quality control requirements in coordination with Safety Engineer and QA/QC Engineer and in line with PSP and PQP.
Construction Manager
Construction Manager is responsible to supervise and control the work on site.
Coordinating with QA/QC Engineer and site Team and foremen for all activities on site.
Control and sign all WIR’s before issuing to Consultant approval.
Site Engineer
He shall make sure that method of statement is implemented according to the consultant requirements, project specifications and approved shop drawings.
Responsible for the provision of all necessary information and distribution of responsibilities to his construction team.
Monitor the work progress in accordance with the planned work program and he will provide reports to his superiors.
The constant coordination with the Safety Engineer to ensure that the works are carried out in safe working atmosphere.
Constant coordination with the QA/QC Engineer for any works to be carried out and initiate WIR for the completed / finished works.
He will ensure the implementation of any work / change request that might be raised by the consultant.
Make sure that daily progress target is achieved for all the equipment and manpower.
He will engage in the work and check the same against the daily report received from the Foremen.
Responsible to convey all the instructions/information to the Foremen and to ensure that its being carried out properly.
QA/QC Engineer
Monitoring of executions of works at site, to ensure that it is as per the approved shop drawings and project specifications.
Ensure WIRs and MIRs are being raised for activities timely manner and inspected by the consultant.
Check and ensure that all activities / work done / completed prior to offering for consultant inspection.
Follow the testing activities to ensure that these are carried out as per project specifications.
Obtain the required clearance prior to Consultant’s inspections.
Should acquire any necessary civil works clearances and coordination.
Coordinate with site construction team.
One who will assist the Consultant Engineer / Inspector during inspection.
Site Foreman
Carrying out of work and ensure proper distribution of all the available resources in coordination with the Site Engineer on daily basis.
Ensuring that daily targets of the works are achieved and coordinated for the future planning with the Site Engineer.
Incorporate all the QA/QC and safety requirements as requested by the concerned Engineer.
Meeting with any type of unforeseen incident or requirement and reporting the same to the Site Engineer immediately.
Safety Officer
Implementation of all safety measures in accordance with the project HSE plan and ensure that whole work force is aware of its proper implementation.
Make sure that safety measures are adequate to maintain safe working environment on the work activity.
Inspection of all the site activities and where necessary training the personnel about accident prevention and proper reporting to the Construction Manager and the Project Manager.
To make sure that the site is maintained in clean and tidy manner.
Ensure only trained persons shall operate the power tools.
Make sure that all workers are using suitable PPE and all other items as required depending on the nature of work.
Ensure adequate lighting is provided in the working area all the time.
Make sure that all the high risk elevated areas are provided barricade, warning tape, safety nets and ladders etc. as applicable
Ensure service area/inspection area openings are provided with barricade, tape, and safety nets.
Responsible to provide and ensure safe access to site work at all times.
Store Keeper (SK)
Responsible for overall Store operations.
Make sure that material delivered to the site are kept in suitable area that will keep the material safe from any kind of damage.
One who will acknowledge the receiving of materials at site in coordination with QA/QC and concerned Engineer.
Ensure that store procedure is suitably implemented for all activities i.e. issuing and receiving the materials on daily basis.
Necessary Tools & Equipment for Electrical Panels Installation
MDB’s, SMDB’s, FDB’s, MCC’s & CB’s shall be in line with approved material submittals and as per approved shop drawings.
Other tools include but not limited to:
- Portable Hand Tools
- Portable Drilling Machine
- Grinding Machine
- Insulation Testing Equipment
- Digital Multimeter
- Measuring Tape
- Ladder/ Scaffolding
- Safety requirements tools such as safety shoes, safety helmet, safety glasses, fluorescent vest, safety gloves and dust mask to ensure maximum ability of safe work.
Switchgear Installation Methodology
Handling and Storage
On receipt of MDB’s, SMDB’s, FDB’s, MCC’s, CB’s and accessories at site, necessary precautions shall be taken for unloading, shifting and storage, as follows:
Material shall be stored in a covered / dry space at all the time.
All materials received at site shall be inspected and ensured that the materials are as per approved material submittal.
Any discrepancies, damage etc. found will be notified and reported for further action.
Site Engineer has to ensure that all panel boards used at site are free from any damage or deformity of any kind.
Any minor damages observed shall be repaired suitably and in case if the repairs could not be done properly, the panel boards are to be sent to assembler for rectification, after all formalities are carried out.
HSE Requirements
Ensure only trained/ Authorised & licensed persons shall operate the power tools.
Make sure that temporary live cable management plan is developed and implemented.
Necessary PPE to be worn while working on energized equipment’s and circuits.
Safe lifting and shifting of LV switch gear panels shall be ensured and related hazards and risks shall be identified.
Ensure service area/work area openings are provided with barricade, tape, safety nets and warning signage.
Make sure LOTO procedure shall be followed and implemented during execution of work.
Emergency response plan & procedure shall be developed and established as per the site condition during the execution of activity.
Ensure that training cards are issued to identify the power tools operatives.
PTW to be applied and obtained to start work on the required area.
Calibrated Instruments only to be used.
Work Sequence and Methodology
Check all material delivered to site is inspected properly by QA/QC Engineer and check if it is stored properly as per manufacturer’s recommendations.
MIR shall be raised for the inspection of materials received at site by subcontractor QA/QC Engineer to the Consultant Engineer.
Work shall be carried out by the site staff under strict supervision and guidance of the concerned Supervisors / Foremen / Engineers.
The Subcontractor QA/QC Engineer shall check all the installations as per the installation check list.
WIR shall be prepared by Subcontractor QA/QC Engineer and will be submitted to Consultant for their inspection and approval.
Electrical subcontractor QA/QC Engineer shall coordinate with other contractors and arrange inspection for installation of switchgear to the consultant.
MEP QA/QC Engineer is responsible for all installation activities for getting the work inspected and approved by Consultant / Engineer.
General Installation Requirements
Ensure that the work area is ready and safe to start the installation of MDB’s, SMDB’s, FDB’s, MCC’s, CB’s and accessories.
Make sure that the installation of MDB’s, SMDB’s, FDB’s, MCC’s, CB’s & accessories are carried out in accordance with manufacturer’s installation recommendations, requirement of applicable standards and in accordance with recognized industrial practices.
Make sure all components and equipment are as per the specified in project specification to ensure that installation complies with requirements (i.e. Make, Size, Model / Type etc.)
Prior to start the switchgear installation work, refer to the approved shop drawings related to the area of installation and ensure that required materials are available at site as per approved material submittals.
Ensure the materials are stored properly and there is no mark of damage or deformity of any kind before issuing the material from site store, all materials and accessories should also be free of dust, scale, or oil.
Installation Procedure for MCC, CB & MDB
Installation works shall be carried out only with respect to approved shop drawings of latest revision.
All components of MCC, CB &MDB such as relays, fuses, CT’s, meters etc. shall be verified against the approved material submittal.
Ensure the floor surface is ready with base frames grouted to install the switch gear panels.
Minimum clearance of 800 mm shall be maintained at rear side of the panel for easy access for termination of cables and other maintenance works.
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 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 cable manufacturer’s recommendation.
Cable pulling, termination & crimping shall be done as per cables method statement.
Termination of cables shall be done using approved 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.
Coordinate with the Main Contractor and 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 sealed by using proper and approved sealant.
The manufacturer’s representative to verify the site installations and provide installation acceptance certificate, before energization of Panel boards.
Raise (WIR) for installation of Panel Boards including the approval of glanding and termination to consultant.
Installation Procedure for SMDB &FDB
Installation works shall be carried out only in accordance to approved shop drawings of latest revision.
Ensure all civil and finishing works are completed and area is released and cleared by civil section to proceed with Distribution Board installations.
Also make sure that the work area is clean and safe to undertake the installation activities.
Ensure the floor/ wall surface is ready to install the distribution boards.
Clearances are to be maintained between the SMDB’s and FDB’s, as specified in the approved shop drawings.
Height of the Distribution Boards shall be maintained as per approved shop drawings in order to ensure easy access for termination of cables and other maintenance works.
Connection of cable trays / cable trunking with all distribution boards shall be done rigidly with proper supports.
All knockouts made on the panel covers shall be filed and provided with grommets to avoid sharp edges and unused knockouts shall be covered.
Cable entries shall be closed and sealed in proper way using suitable sealants as applicable on the site.
Termination of cables shall be done using approved cable glands and lugs, glanding and connections should be done by only competent technicians / electricians as per the approved shop drawing.
SMDB’s and FDB’s shall be provided with proper earthing connections as per approved shop drawings.
Doors of SMDB’s and FDB’s are to be earthed using the flexible connections.
Identification labels of approved type shall be fixed on SMDB’s and FDB’s.
Raise (WIR) for installation of SMDB’s and FDB’s along with glanding and termination to Consultant.
ATTACHMENTS
Inspection and Testing Plan
Check List for Installation of FDB
Check List for Installation of SMDB
Check List for Installation of MDB
Check List for Installation of MCC & CB
Risk Assessment
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