PT. _____
/ VERSION NO.: 1
REVISION NO.: FIELD CHANGE
FIELD CODE:
DATE:
PAGES: 1 OF 22
WORK INSTRUCTION PROCESS FOR INSPECTION, TESTING & COMMISSIONING OF ELECTRICAL SWITCH BOARD & SWITCHYARD
PREPARED BY
/ LEGALIZED BY
______
PROJECT DIRECTOR / ______
QMR
SIGNATURE: / SIGNATURE:
DATE: / DATE:
APPROVED BY:
SIGNATURE:
DATE: / ______
ELECTRICAL DIVISION MANAGER
2 APRIL 1998
Amendment record
Page No. / Rev. No. / Description of Amendment / Date of issue / QMR Legalized Date / Electrical Authorized Date
N/A / N/A / First Issue of WI016, Ver. 1 & Rev. 0 for
PT ______
N/A / N/A / Page 2/10/11 & 15 OF 22
Revision 1
PM-P-21 Battery & Battery Charger Inspection Record Incorporated

DISTRIBUTION TO:

1)ALL MANUAL HOLDER

WI015

WORK INSTRUCTION OF ELECTRICAL INSTALLATION

PURPOSE

SCOPE

RESPONSIBILITIES

DEFINITIONS

PROCEDURES

5.1U/G CABLE

5.2INCOMING SWITCHGEAR 20 KV

5.3OUTGOING SWTICHGEAR 20 KV

5.4TRANSFORMER

5.5SUPPLY CABLE FROM PLN’S RELAY STATION

5.6SYPPLY CABLE FOR TRANSFORMER

5.7GROUNDING SYSTEM

5.8INSTALLATION LVMDB’S

5.9CABLE FOR LVMDB’S

5.10GROUNDING SYSTEM LVDBM’S

5.11TERMINATION CABLE

5.12TERMINATION FOR GROUNDING SYSTEM AT TX AND LVMDB’S

5.13INSTALLATION SUB DISTRIBUTION BOARD

5.14PIPE INSTALLATION (CONDUIT)

5.15SMALL POWER AND LIGHTING

5.16CABLE SUPPORT

QUALITY RECORDS

1.0PURPOSE

This procedure is made to carry out the necessary electrical installation works accordingly and to ensure that the installation process is carried out and controlled in accordance with quality standard stipulated by the company.

2.0SCOPE

This procedure is used at all projects, such as electrical installation for industry and building construction.

3.0RESPONSIBILITIES

3.1Project Manager shall be responsible for and ensure that the electrical installation works are properly carried out in accordance with the stipulated quality standards.

3.2Supervisor shall be responsible for supervising the implementation of electrical installation in accordance with quality standard and specification in the contract and make a report to Project Manager.

3.3Foreman shall be responsible for and carry out the electrical installation works at the location at which they work and then foreman should make a report to supervisor.

3.4Electrician is to carry out the installation works in accordance with his supervisor’s instruction, quality standard and contract specification, and then the foreman should make a report to foreman at which he is assigned.

4.0DEFINITIONS

P.U.I.L 87The 1987 Indonesian electrical installation general codes, and electrical installation regulation issued by PUIL and LIPI committee. So all new installations, change and installation extension must meet the 1987 PUIL.

LVMDBLow voltage main distribution board

SWGRSwitchgear

SUB DBSub distribution board

HVHigh Voltage

TXTransformer

5.0PROCEDURES

5.1U/G Cable

5.1.1Check the location drawing at which the U/G Conduit will be planted. The cable that will be planted under ground must be protected against possible mechanical and chemical disturbance. In general cases the protection against the building will be considered safe if the cable is planted in a certain depth.

  • At least 80 cm under ground at vehicle road.
  • At least 60 cm under ground at non-vehicle road.

5.1.2Cable must be laid in a peat type of soil or sand free from stones, and above steps, strong and flat ground. Peat sand or soil layer at least 10 cm around the cable must be placed. Concrete or brick may be laid around the cable as additional protective material.

5.1.3Ground cable comes out of ground outside building must be protected with steel pipe or other strong material until it is beyond the reach of hand, except it is already provided with the same degree of protective material. Any ground cables joint protected or covered with metal must be treated as follows:

  • Must be made in ground cable joint box. Protective or covered material must also be put into the joint box until certain extent and the box must be filled with damp proof insulation component.
  • Must be made in a lead box covered at outside the cable.
  • Made in other acceptable manner.

5.1.4Ground cable must be treated carefully, cannot be wound or bent. So if a cable must be taken out from its haspel must be carried out by winding the haspel, and do not use mechanical pull and pressure. Ground cable must be lifted up and kept in the haspel in standing position. For protected cable must be used a haspel with minimum 25 x outside cable diameter. If it must be laid above ground, the cable must be laid by taking the form of figure 8 (eight) which dimension is quite large. Land must be flat and free from stones and other material

5.1.5The end of the ground cable may not be left open but must be covered with appropriate manner to keep water from entering into it and from being dampened. For cable testing and inspection see test form _____.

5.2Incoming Switchgear 20 KV

Check the working drawing at which incoming switchgear will be placed. Put the incoming switchgear at its place in level and perpendicular position. Afterwards the lower part of the body of switchgear is lifted to floor with Dynabolt or other tool of a kind.

5.3Outgoing Switchgear 20 KV

5.3.1In most cases it is installed next to the incoming SWGR, close to incoming with level and perpendicular position, and then the lower part of the switchgear is lifted to the floor by using Dynabolt or other tool of a kind. Next step is to tie the incoming body and outgoing switch using bolt and nut firmly.

5.3.2Connect the poles R, S and T of the incoming and outgoing after testing. Same thing to be done if outgoing switch is more than one units. Installation method would be same as the first outgoing.

5.4Transformer

Check the space drawing in which transformer will be placed, place the transformer in level and perpendicular position. When the proper position is obtained, turn off the four wheels under transformer to prevent friction.

5.5Supply Cable from PLN’s relay Station

In general, the type of cable used is a three-cored N2XSEBY or shielded thermoplastic ground cable with capacity of 20KV. See the item 5.1 above for installation manner. For monitoring inspection use form ____. To measure the insulation resistance use the form. When the testing result is good, the end of cable may be connected.

5.6Supply cable for transformer

In Most cases, a single-cored N2XSBY is used between the outgoing SWGR and transformer. The cable is installed through available trench and be taken up to HV connection terminal through cable rack attached to the wall of the transformer relay station. And then the end of the at the outgoing is put with cable lug or termination kit in accordance with required specification (Raychem, 3M or other tool of a kind) and the end of the cable at transformer HV terminal is provided with cable lug or termination kit which normally uses Elastimold type or the same type. Afterwards the cable is tested using form ____. If the testing result is good, the cable tip may be terminated.

5.7Grounding System

5.7.1Whole Body of the electrical equipment made of metal, such as TR panel, illumination, capacity, etc, must be provided with proper grounding system and manhole.

5.7.2Grounding electrode is made of Cooper Metal Clad with 20 mm diameter which is planted until it reaches grounding resistance of maximum 1 ohm, and minimum depth of 6 m or otherwise stated in the contract specification. Where electrode has connection, this must be carried out using tread system, by using an appropriate size of copper brodile. The end of the tread is to be tinned in such a manner so it serves and inseparable item leaving no space to keep air from entering into it which may lead to oxidation at the connection.

5.7.3Each connection/joint must use galvanized or treated clamp as determined in the specification to prevent process if it is in contact with other type of metal. Conductor bar available at the new connection point must be tinned.

5.7.4Any connections must be covered with certain material such as epoxy or other material of a kind. If the whole length of the Electrode is already planted at all points, make a test using form _____. Connect all points of electrode with B Conductor according to appropriate size. Repeat the test using form _____ and ____. Connect all grounding pole to the grounding system outside conductor.

5.8Installation of LVMDB’s

Check the drawing to find the location of the LVMDB, put it on a flat and stable ground in perpendicular position. When the position is good, lower part of the body is lifted to floor using Dynabolt or other tool of a kind. For testing use form _____.

5.9Cable for LVMDB’s

5.9.1Check the drawing to find the cable to be installed or pulled from switch room leading to LVMDB both its size and lane. Possible lane to pass through, such as through cable ladder or through underground PVC pipe and directly underground.

5.9.2If the lane to pass as stated above, uses shielded thermoplastic ground cable, installed according to determined cable drawing and number. The installed cable will be attached to cable ladder firmly to prevent frictions. Grounding cable is also installed with the same manner as power cable pulled from grounding main terminal in the switch room.

5.10Grounding System at LVMDB’s

Installation of electrode bar is same as the above point 5.7. After testing with a good result see Form ____. The tip of the conductor available at the LVMDB is properly connected to grounding terminal in the LVMDB.

5.11Termination Cable

5.11.1There are twenty (20) KV supply PLN cables (from PLN relay station to Incoming SWGR).

The installed cable is the N2XSEBY type for copper conductor or NA2XSEBY for aluminum conductor. For termination equipment, a method suitable to the installation would be in accordance with termination procedure to be used, such as Raychem, 3m, Cell Pack, etc.

5.11.2There are 20 KV supply cable from outgoing swtichgear to transformer.

The installed cable, can be of N2XSY type for copper conductor or NA2XSY for aluminum conductor. The installation of the terminal at the end available at the outgoing switchgear uses Heatshrink type o terminal kit such as Raychem, 3M, or other of a kind. The installation of terminal at the end of the cable available at transformer, uses special terminal such as Elastimold or type of terminal kit which is tailored to the transformer maker.

5.11.3Termination cable from transformer to LVMBD.

The installed cable, in accordance with required capacity, most cables used are of NYFGBY type (four-cored shielded thermoplastic cable). The installation of cable at end of cable at the transformer must have its cover be removed according to the need. Each of end of the cable core will be matched with cable scun or cable shoe using Hydraulic Crimper to strengthen the part between the end of the core and cable shoe. Mark each shod cable end for easy reference at the time of termination to poles LV at the transformer.

5.12Termination for grounding system at TX and LVMBD’s

When grounding system has already been tested and inspected in accordance with Form ___, ___ and ___, termination may be executed which includes:

  • Grounding Pole at SWGR which is connected to the grounding main terminal in the switch room.
  • Grounding system outside switch room consisting of electrodes stuck on the ground are connected to and electrode or other electrode and the end of its conductor is terminated to the grounding main terminal.
  • The Conducting cable leading to LVMBD is terminated to the main terminal.
  • All doors and ventilation made of metal are connected to conducting system through conductor.

5.13Installation of Sub Distribution Board

At every electrical works there will be many sub distribution boards installed, which are frequently called small scale distributing network. The installation work is carried out by Supervisor with the assistance of electrician as of the installation of sub distribution board until it functions. The works would include:

5.13.1Electrician would choose one of sub DB to be installed according to working drawing.

5.13.2Supervisor/Foreman to mark on the sub DB for the purpose of making hole for cable coming into and going out from sub DB that will be installed. Electricians make cable hole according to instruction by supervisor/foreman. After making hole, sub DB is installed at the point determined in the drawing, on the wall or close to Equipment requiring electrical power.

5.13.3After sub DB is installed properly, firmly and perpendicularly the works are continued with cable pulling. Check the drawing to find out where the cable supply comes from or incoming and type of cable, size of cable. Here the cable is installed as form LVMBD to sub DB. If the cable goes through cable ladder, at 90 cm interval the must be tied to cable ladder radius in good order and be firm.

5.13.4Before cable is put into the LVMBD/SUBDB install cable gland according to the size of the cable to be installed. The cable is put into the LVMBD/SUBDB by removing its outer cover and shield. Make the cable number on both ends according to the drawing and list of cable. Make a test and inspection on the cable in accordance with form ___ Cable Continuity Test.

5.13.5After the cable test is declared good and correct, works are continued with putting on the cable lug on both ends at the LVMBD and SUBDB. Go ahead with test insulation of the cable which is already installed in accordance with form Test Insulation ___. If the insulation resistance meets requirements, the cable is connected on both LVMBD and SUBDB.

5.14Pipe Installation (Conduit)

5.14.1For cable installation in a building cables are mostly used and installed in the installation pipe. Installation pipe is classified as follows:

  • Steel pipe painted with foundation pain
  • PVC pipe
  • Flexible pipe

5.14.2In general practice, installation pipes are sold in three-meter long each with different diameter. Installation pipe must have sufficient resistance against thermal mechanical pressure and may not flare. Out side/inside surface must be smooth and level and protected from being rusty. PVC installation pipe has some characteristics such as:

  • Good installation resistance, minimize soil effect,
  • Chemical proof,
  • Does not cause a flare,
  • Easy to use.

5.14.3PVC pipe must be protected from other mechanical damage such as, at the place where pipe has to go through floor. While steel pipe within the reach of hand and installed in open area must be planted into ground properly, except steel pipe used to cover double-insulation pipe or to cover grounding cable.

5.14.4At the end of the steel must be provided with Bushing, durable and suitable size. Bending of installation pipe must be carried out in correct manner to prevent damage (being dented). The bend radius must be measured until the inside part of the bend which at least:

  • 3 diameter for PVC pipe
  • 4 diameter for steel pipe up to 16 mm (5/8’’)
  • 6 diameter for steel pipe of more than 16 mm (5/8’’)

Note: D-Outside diameter of installation pipe.

5.14.5Installation pipe which is not plated must be installed in correct manner by using an appropriate clamp or support. The space between the supports must be more than 1 meters. For steel pipe must be provided with open wrap as follows:

  • Pipe is not to be bent,
  • At a horizontal installation the groove part of the warp must be positioned beneath, and at vertical installation the groove must face the wall.

5.14.6Auxiliary tool must be used to joint the installation pipe. For a long channel must be provided with many pulling box used to pull cable. Note the length of electrical sprint (available in 10 meters or 20 meters long that we can buy). The space between the pulling box may not be longer than four bends.

5.14.7For PVC pipe installation, joint and bend are seldom used. Bend can be made on PVC pipe itself, and that there is no bending material released at the time the cable is pulled into the pipe. To make joint on pipe installation branch box must be used, such as three branch T box or four-branch box. Branch box is also a pulling box, easy to reach, not placed behind wall layer which is difficult to be released.

5.14.8Cable joint in a pipe installation can only be carried out in the branch box or pulling box. Joint must be firm and good, by winding the nuts and cover it with lasdop. Any lasdop may not be connected with more than five cables. The number of joints in the connecting and pulling box must be restricted to allow proper cover.

5.15Small Power and Lighting

5.15.1Small Power

Small Power is often called outlet. Outlet would include one or three phases. Check working drawing to make sure the location of the outlet in one site. Supervisor to determine the location of the outlet in one site. Supervisor to determine or pre-determined in the working drawing from which the electrical current come for such outlet.

At building, installation pipe is normally planted in the wall. Electrician would pull cable from LVMDB or SUBDB to outlet that will be installed. Cable entering into the PVC pipe is installed and attached to a concrete plate or cable support. When the supporting cable is installed up to the outlet, the cable is tested using form ___-0852. If the cable is good, the outlet would be installed. Afterwards MC is turned on at LVMDB or SUBDB. Check tension at the outlet 220 V or 380 V for three phases. If in one circuit is more than one outlet, cable connection can only be made at connection box, planting box. To check the proper connection of the three-plates outlet phase rotation tester must be used.

At industrial building outlets sometime are installed outside wall. The installation pipe are of metal and supported to the wall at 90 cm interval.

5.15.2Lighting

5.15.2.1Light installation would be stated by installing installation pipe, cable pulling, switch and other control tool, light and testing until the light is on. Supervisor must check with drawing and list of cable and list of circuit at LVMDB or SUBDB. Workers to pull cable from LVMDB and SUBDB to the switch or light control tool at the position as determined in the working drawing. And then, from the switch or light control tool to the light armature. All cables are put into the installation pipe clamped with concrete plate or ceiling.

5.15.2.2In case branches are needed, branch box may be used according to the size of pipe used. Cable connection can only b e made at the connection box and light armature. After installing the cable, test can be held in accordance with test form ___. If the cable is declared good, tray to conduct the tension to test the switch or other light control tool: For full testing use form ___.