1. What is Method Statement for SMDB, DB, and Feeder Pillar Installation and Testing?
This Method Statement describes the sequential approach for installation and testing of SMDB, DB, Feeder Pillar in accordance with the project specifications, HSE, and quality requirements.
This method statement shall ensure that the installation is executed safely. This method statement aims to ensure that quality assurance and quality control activities are adopted by the contractor for the project so that the job execution complies with the requirements and serves the intended function to a satisfactory level.
This method statement is subject to the requirements as stated in the following regulatory & statutory documents, applicable standards/specifications/building codes:
Relevant Sections of IEC/BS.
Project approved materials/shop drawings/IFC drawings
Approved Project HSE Plan
Approved Project Emergency Response Plan
Approved Project Waste Management Plan
Occupational Health and Safety
Works will be started or carried out only when all associated main contractors procedures are completed and by ensuring safe access to work areas will be available through hoist lifts/access ladders to carry out the work where ever main contractor site engineer’s & safety officers clearance available.
MEP Subcontractor will deploy a dedicated team for the required logistics and material movement in –out of the project.
5. HEALTH & SAFETY HAZARDS
Extreme Heat and Humidity
Mobile Equipment- Crane, forklift, etc. for material loading/offloading, transfer of materials to work locations o Temporary electrical supply for lighting, use of power tools, etc.
Improper Stacking of materials DB, SMDB, Feeder pillars, etc.
Manual Handling / Offloading & Installation of DB, SMDB, Feeder pillars, etc.
Working on the unsafe scaffold for the installation of DB, SMDB, Feeder pillars, etc.
Damaged Hand Tools – Installation of DB, SMDB, Feeder pillars, etc.
Uninspected Power Tools
Unsafe working on Ladders
Poor Housekeeping& waste management
6. HEALTH, SAFETY AND ENVIRONMENT GUIDELINES
HSE Site Safety Inductions
Work supervisors shall ensure STARRT and RAMS are discussed with the workgroup prior to works commencing
Safety toolbox talks
Environmental toolbox talks
Training courses (Internal and Third-party Training)
HSE Bulletin/HSE Site Notice Boards
Site Engineers, Site Supervisors, and Site Foreman
7. PERMITS AND CERTIFICATES
Hot work permit (Cutting/grinding)
Working at heights/working on scaffolding – Supervisor to be trained by a third party.
Third-party certification for the operator and the equipment. Competence certification for workers.
MS – Method Statement
QCP – Quality Control Procedures
ITP – Inspection and Test Plan
ITA – Independent Testing Agency
DB -Distribution Board
SMDB – Sub Main Distribution Board
MEP – Mechanical Electrical & Plumbing
HSE – Health, Safety, and Environment
FP – Feeder Pillar
RAMS – Risk Assessment Method Statement
STARRT – Safety Task Analysis Risk Reduction Talk
The project manager shall be responsible for overall project planning, procurement, technical submissions, and drawing submissions.
The project manager shall coordinate activities within the site team and with the management for the timely completion of activity in accordance with contract requirements.
The construction manager is responsible for the work execution in compliance with the approved method statement, HSE Risk Assessment, project specification, issued for construction drawings, section, and details
The site engineer is responsible to carry out the work as per approved shop drawings and method statements. He is also responsible to ensure adequate tool kits required for the works are in place prior to the starting of work. The site engineer reports to the Construction Manager.
The site Engineer is responsible to ensure work has been done as per the specification and drawings; inspections are carried out based on ITP and quality control procedure and coordinate with QA/QC department for inspections.
The site engineer is responsible to ensure that all safety precautions are ensured in place and that all personnel on-site are using the required personal protective equipment like helmets, gloves, shoes, and reflective jackets. The site engineer in coordination with safety officers will ensure all relevant permissions are taken prior to commencement of works.
The site engineers shall ensure that the works are supervised by a competent supervisor till the completion of the task.
The QA /QC department will be responsible for overseeing the quality requirements and quality control measures for the project in coordination with the project engineer and construction manager.
The SHE officer will be responsible for the safety, health, and environmental aspects on site as per the project safety and environmental requirements/safety standards in coordination with the project engineer and construction manager.
10. PROCEDURE / METHODS TO BE EMPLOYED:
10.1 Site Planning & Preparation
Before installation takes place, the following pre-installation task is essential:
Identify and ensure that the pertinent document (e.g. approval for shop drawings, MEP coordination drawings, wiring diagrams, (SMDB, DB & FP) load schedules, Schematic diagram & site development overall plan power layout shall be available on the site) are approved.
Permits shall be applied prior to commencement of works.
Please ensure to obtain necessary PTW (Permit to Work), prior to allowing to work. Frequently training should be conducted by the site supervisor/foreman. A daily safety briefing should be conducted.
HIRA Compliance of control measures as stated on HIRA. Close monitoring of the activity to identify any hidden hazards. The pre-task briefing shall be developed prior to commencing the activity.
Applicable permits shall be applied prior to the commencement of works.
The start of DB, SMDB, and Feeder Pillar installation shall be done in accordance with approved shop drawings and properly coordinated with site engineers for the exact locations and levels. Marking on-site to be carried out prior to commencement of installation works.
Conduct site safety briefing prior to commencement of work.
Identify and obtain appropriate installation tools and equipment.
Determine the staffing required and assign tasks to team members.
Perform lockout/tag-out procedures (where applicable) during installations.
10.2 Handling of Materials
Upon receiving the materials, all must be inspected and ensured that there are no manufacturing defects and delivery damages.
Loading and unloading of the material shall be performed as per the manufacturer’s recommendation. Use appropriate lifting equipment (e.g. crane, forklift, etc.) in unloading and stacking/storing materials to and from the site stores/warehouse.
Ensure relevant Manufacturer’s Routine Test Certificates are available prior to/during delivery and inspection.
Store DB, SMDB, Feeder Pillar, and MCC and its associated fittings/accessories in a clean and dry area to prevent condensation. Do not allow the materials to contact with corrosive fumes, liquids, salts, or concrete. It must be stored off the ground and securely covered to provide protection from dirt and moisture. DB, SMDB, and Feeder Pillar location, as possible, keep the packaging/pallet intact and lift using proper lifting equipment or manually with an adequate number of people. Handle with care to avoid damage to internal components and the enclosures. (Follow handling guidelines recommended by the manufacturer).
DB, SMDB, Feeder Pillar, and accessories shall be properly supported and stacked on a flat surface (follow manufacturer manner of stacking), should not be laid directly to soil/ floor.
Store the materials in the manufacturer’s original packaging in the manner that labels are so arranged for easy identification, to avoid mismatches of loose components.
Only required materials to be shifted to site and store temporarily ensure extra materials are not dumped to site and congest the working area.
Once work is completed extra materials and tools are to be returned back to stores, work is to be kept clean.
10.3 Pre-installation Work
All workers to attend safety induction training on the safe installation methods by the safety department.
Ensure that Distribution Boards, Feeder Pillar & Main Distribution Board is as per approved material schedule.
Ensure all Distribution Board, Feeder Pillar & Sub Main Distribution Board received are inspected from Consultant and found acceptable as per approved materials submittal
Ensure all drawings are the latest revision, approved for construction issue, and are fully co-coordinated with all other services and installations
Confirm that the type, schedule, and rating of distribution boards are correct and as per project specification and approved material submittal before commencing the installation works.
Make arrangements to provide manufacturer’s installation manuals prior to starting the installation work.
Prior to commencing any works, a risk assessment must be conducted, taking into account all possible risks and the appropriate precautions put in place, i.e. fire extinguishers, fire blankets, safety harnesses, etc. Refer to the risk assessment/risk management section of this method statement.
Ensure DB, Feeder Pillar & SMDB installation shall be done exactly as per the approved construction drawings
Coordinate with the civil scope contractor due to the requirement of the wall and surface finishing.
All works shall be undertaken in a neat and workmanlike manner to ensure a quality installation.
Immediately before being installed, Distribution Boards will be checked for damages.
Permit to work system to be followed if required Proper PPE to be worn by all operatives always on site.
10.4 Installation of SMDB, Feeder Pillar, and DB
Ensure the installation of the Distribution Board, Feeder Pillar, and Sub Main Distribution Board are as per approved shop drawings and coordinated with other services.
Ensure prior to installation all DB/SMDB/Feeder Pillar is approved from the consultant and is free of damages.
The location should be marked for the installation of the DB/SMDB/Feeder pillar as per approved shop drawings.
Ensure that the area is clear and barricaded off from other construction activities and that are overhead installations are completed.
Verify the DB/SMDB/Feeder pillar are tagged correctly before they are prepared for site installation as per project specification.
Mount DB at a height not less than 1200mm from finished floor level to bottom of the DB and the maximum height of this DB shall be 2200mm from finished floor level to top of DB unless shown otherwise on approved drawings/schedules.
Other Panelboards, Feeder pillar / SMDB elevation should be conforming to the approved detail/drawings.
Drill holes on the wall and install the bolts. The size of bolts should depend upon the size of the distribution boards and should be as approved detail drawing.
Proper DB dressing shall be made so that there are no free cables hanging inside the DB.
10.5 Installation of surface mounted DB, SMDB
Drill holes on the gypsum wall/masonry wall (as per site requirement) and install the channels place DB and SMDB to be fixed against the wall with bolts /nuts/washer and tight properly. The size of support should depend upon the size of the distribution board and SMDB.
Fix mounting bolts through the DB/SMDB and secure them in place (ensure mounting height meet the approved/specified).
Adjust for proper level and alignment. A distance of not less than 750 mm shall be provided and maintained in front of every switchboard (SMDB) for the purpose of safely and effectively operating and adjusting all equipment mounted thereon.
Trunking/cable tray may be fixed between the DB/SMDB and ceiling or floor level to dressed and accommodate the entry of wire/cables to the panel (refer to the approved detail drawings) ensuring the adequate earth continuity shall be made between the trunking/tray and the DB/SMDB enclosure.
Carefully pull wires and cables within the panel board.
Install DB/SMDB internal components, making sure that wires/cables are not to be damaged and vice versa.
Ensure wires/cables are to be dressed and should conform to the approved DB/SMDB schedule.
Ensure MCB/MCCB are correctly labeled as per corresponding approved schedules.
Install panelboard front cover trim. Adjust trim for proper alignment with building lines.
Identification labels should be applied correspondingly to all DB/SMDB as per approved shop drawings.
Appropriate touch-up paints (approved/manufacturer supplied) should be applied for any surfaces damaged during the installation process to restore the integrity of the panel’s surfaces in a neat and acceptable process.
10.6 Flush (Recessed) Installation
Drill holes on the Gypsum wall and install the channels to be fixed against the wall with bolts /nuts/washer and tight properly support the DB and SMDB. The size of support should depend upon the size of the distribution board and SMDB.
Flushing preparatory works should be stringently done in order to avoid rework or unnecessary concrete cutting (or chipping) that may affect the integrity of the wall structure. Hence it is advisable to provide only block-outs (thru styrofoam) with acceptable allowance (ensure very minimal gap should be provided) to accommodate the flush type DB/SMDB enclosure within this designated final location.
Remove the temporary block-out, and clean the surfaces not to damage the concrete and expose the wall reinforcement bar.
In order to protect internal components, it is advisable to remove them properly and layout the enclosure to the flush/block out. Carefully protect the dismantled internal components and store them in secure storage away from water contamination and properly label it for easy reference.
Install appropriate bracketing (strut channel, stud, threaded rod, etc. recommended by the manufacturer), ensure approval and civil discipline (as applicable). Check leveling and orientation as per approved shop drawing and project specification.
Appropriate plastic coverings should be provided to ensure the DB enclosure will not be damaged, contaminated by concrete, and/or deformation. Final adjustment is to be done as per approved elevation, provide as possible support holding the DB enclosure during mortar fill application.
Dressed properly the containment entry to the panel, provide appropriate sleeves between DB and home runs.
10.7 Feeder Pillar
Installation area shall be isolated and only authorized persons to be allowed, barricades and warning signs shall be provided for the same.
Loading/unloading of the panels shall be as per manufacturer recommendations. Use appropriate lifting equipment in bringing the materials from the storage to the permanent base/location.
Plywood (or appropriate floor protection) shall be placed on the floor in order to protect the floor from possible damage while moving.
Installation works shall be carried out only with respect to the approved shop drawing of the latest revision. It shall be supervised by a competent Engineer/specialist and/or manufacturer’s representative.
All components of Feeder Pillar such relays, fuses, CT’s meter, etc. shall be verified against the approved material submittal and relevant shop drawing.
Ensure the floor surface is ready with base frames/accessories properly coordinated with the panel base dedicated fixation point.
Mark support fixation as per approved method and shop drawing.
For external feeder pillar-based panel boards, coordinate sizes and locations of concrete bases with actual equipment provided. Cast anchor-bolt inserts into bases. Concrete, reinforcement, and formwork requirements are specified with concrete as per the approved drawing.
Install the panel, lift it and place it on its dedicated base using appropriate equipment, following manufacturer recommendation.
Ensure minimal/specified surrounding clearances shall be maintained specifically at the access side of the panel for easy accessibility for termination of cables and other maintenance works can be carried out.
Check cabinet interconnections, Busbar connections, control connections between cubicles after proper alignment of the sections as per manufacturer’s drawing and approved shop drawing.
All knockouts made on the panel covers shall be cleaned from burs/sharp edges and appropriate touches up are applied. Fix firmly the corresponding cable with suitable approved glands and ensure earthing connectivity.
Ensure allowable bending radius for all cables being gland are followed as per cables’ manufacturer recommendation (normally 8 times the cable diameter) and cables are rigidly fixed with proper support to avoid unwanted exertion of force and deform the Panelboard coverings
Cable pulling, termination, and crimping should be done as per the cables/wires method statement.
All feeder pillars shall be provided with proper earthing connections as per approved shop drawings.
The manufacturer’s representative to verify the site installation and provide acceptance of the same prior to final Testing and Commissioning/Energization.
Necessary covering/warning signs and tapes should be provided once the installation is completed to protect the panels from dust, water contamination, concrete, etc. that may cause early deterioration or damage on it.
Mark the location of isolator or disconnect switch on wall or ceiling. The location shall be as per the approved drawings and has been coordinated with other services.
Fix the channel support on the wall then fix the isolator or disconnected switch as per approved standards and coordinate with other services.
Ensure that the isolator switch is aligned and fixed properly. Terminate the incoming and outgoing cables using approved accessories.
Terminate the earthing of isolator brackets and other metallic parts and ensure that earthing has continuity up to the final sub-circuit.
A continuity test shall be conducted to ensure the proper working operation of the isolator. Isolator shall be chosen depending on the installation is (outdoor or indoor). Ensure that the isolator intended for outdoor shall minimum of an IP65 rating and shall comply with the requirements as per project specifications.
Cover or protect all installed isolators to prevent the accumulation of dust and debris during construction.
Ensure that workmanship is neat and clean and complying with good construction practices.
Where enclosure is installed in direct sunlight sunshades of an approved design shall be provided.
Raise inspection request when work is completed (per sections/areas) for installation of wiring accessories.
10.9 Identification and Termination
Identify field-installed wiring, and components; provide warning signs as specified as per relevant sections.
Sub Main Distribution Board (SMDB) Nameplates: Label each Sub Main Distribution Board compartment with engraved metal or laminated-plastic nameplate mounted with corrosion-resistant screws.
Install cable entries of DB, feeder pillar & SMDB panel shall be either bottom or top or both as per the requirement and site condition.
Brass compression type cable glands shall be used for glanding cables.
Internal & external compression cable glands shall be provided with PVC shrouds.
The number of strands of the cable core shall not be reduced at the termination point.
Compression-type cable lugs shall be used for termination.
Lugs shall be insulated with an approved type of insulation tape or heat shrinkable sleeve after crimping the lugs before termination.
The insulation tape or heat shrinkable tube shall have equal or better electrical and mechanical properties than those of the original insulation removed.
Sufficient spare cable shall be allowed to remake the termination.
SMDB, DB, & FP Nameplates should comply with requirements for identification specified in project specifications, approved material, and shop drawing.
Cable terminations are accessible and cable identification tags shall be provided at both ends of the cable.
Cables shall be tested for continuity and insulation resistance test before and after termination.
Install equipment-earthing connections for Distribution Board, Feeder Pillar & Sub Main Distribution Boards with earth continuity to main electrical earth bus.
Tighten electrical connectors and terminals, including screws and bolts, according to manufacturer-recommended torque-tightening values. If the manufacturer’s torque values are not indicated, use those specified in applicable standards.
The cable gland, termination lug, heat shrinkable, etc. all the cable/wire termination and labeling material shall be as per approved materials and project specification.
On completion of installation, inspect interior and exterior of panels and all system components. Remove paint splatters and other spots. Vacuum dirt and debris; do not use compressed air to assist in cleaning.
Repair exposed surfaces to match the original finish. Clean components internally using methods and materials recommended by the manufacturer.
All required training for stipulated installation activities are provided to all technical staff for ensuring a quality workmanship
12. WORKING HOURS
Site operational time shall be followed as per project progress requirements, all relevant local authority schedules of holidays are to be observed. Comply with regulations regarding summer working hours (Working in direct sunlight during hot weather conditions).
Working areas will be kept clean by disposing of the waste materials at the designated areas. At the end of the days’ work, the installation supervisor will ensure that the debris is disposed of during the course of the activity on regular basis.
Dust created by work e.g. drilling, of the slab, grinding, and polishing. The area must be isolated /protected by a green net and required additional PPE for the operatives.
Any materials stacked in the site shall neither obstruct the emergency evacuation route.
Subject to main contractors’ programmer and scope/area available for MEP activities, but not limited to below:
Electrical QA/QC Engineer
15. MATERIAL REQUIREMENTS
Distribution boards, Panelboards, Switchboards, Feeder pillar, ACB, MCCB, MCB, Relay, Pilot lamps, Volt Meter, Ammeter, etc.
Control cables/wires and accessories
Cables wires and accessories
Bolt, nuts, and washers
Plugs and screws
Anchor bolts/hammer set anchor
16. PERSONAL PROTECTIVE EQUIPMENT REQUIREMENTS
Full body harness
17. PLANT & EQUIPMENT REQUIREMENT
The following equipment’s and materials shall be used for the works:
Standard Electrician Tools
Electric Drill and set of bits
Set of wrenches
Set of files
Plumb bob/Spirit level
Air Blower/Vacuum Cleaner
Lifting Equipment (e.g. mobile crane, forklift for loading and unloading during delivery/shifting)
Cable termination kit
Third-party certification(competence certificates) for workers, operators, Equipment valid registration, insurance, and fitness certificates, operator daily inspection checklist should be available for Safety officer validation before commencing the works.
18. QA/QC APPROVAL
Follow approved Method Statement, ITP, QCP, HSE Plan, and Material Approval & Checklist.
19. SUPPORTING DOCUMENTS
This method statement is to be read in conjunction with the below-referenced documents
Project specification & approved drawings.
Project Quality Plan
Project HSE Plan
Inspection & Test Plan
Quality Control Checklist