ELECTRICAL

1
 CONTENTS

¾Objective of Presentation

¾Electrical Milestone Projects

¾Work & Material Flow

¾Different Systems of Electrical

¾QC Plan

¾Tools & Tackles at Glance

¾Safety Key Functions

2
 OBJECTIVE

To share knowledge and interact about

the Electrical construction
methodologygy and Procedures

3
 OVERALL WORK FLOW CHART

CLIENT

APPROVED RFI
(Next Phase)
Document Review
PROCUREMENT PROJECT Technical Information CLIENT QA/QC

mitted
DEPARTMENT MANAGER Job Execution Procedure ENGINEER

port,
Project Requirement

Apprroved Document Subm

hedule & Progress Rep

INFORMATION
Invoice Submittal
Material Requirement
Material Approval

Material Availability
Material Issuance
Reports

QA//QC Clearance &

Materiall Testing Reports

E ACTION MEMO
MATERIALS /

OMPLIANCE/
STORE
SAFETY
Material Distribution DEPARTMENT

NON CO
and Control

CORRECTIVE
Sch
ADMIN PLANNING Daily Reports E&I RESULTS/CONFORMANCE QA/QC
Resources Availability
DEPARTMENT DEPARTMENT MANAGER DEPARTMENT
Return Superceded
Resource Requirement
q Drawings &
Documents Quality Work Assurance
Work Programme
Site Inspection
EQUIPMENT Construction Procedure
PLANNING Material Testing & Review
QA/QC
CONTROLLER
Material Approval
ENGINEER ENGINEER QA/QC Documentation & ENGINEER
Interim Progress Report
System Filling
Progress Monitoring
Equipment Schedule
Invoice
Mobilization and SUPERVISOR RFI
Demobilization of Equipment
Utili ti Record
Utilization R d
Quantity Surveying QUANTITY NON COMPLIANCE
TIME KEEPER/ Actual Progress Quantification
SURVEYOR FOREMAN
PMENT, RESOURCE
GRAMME PRIORITY
MATION ON WORK

Final Remeasurement
HUMAN Quantity & Manpower
RESOURCE Allocation Analysis Direct Work Execution
Site Physical Planning
Daily Reports
Daily Manpower Record Documentation DOCUMENT Work Supervision
Manpower Allocation Record Control
CONTROLLER MAIN ACTIVITY
C - BLACK
C
INFORM
DEVELOP
& PROG

Extra Time and Overtime System Filling MATERIAL ACTIVITY B- LUE

Evaluation Distribution of Drawings & QA/QC ACTIVITY -RED
Field Instructions
RESOURCE ACTIVITY GREEN
-
CLIENT ACTIVITY
MATERIAL INFORMATION
CONTROLLER INTER DEPT. COMMUNICATIONS
 QA/QC PROGRAMME

Understanding the scope Measuring and testing

instruments Calibration
and specifications &
controls
Identifications of QC Plans
and Procedures
Maintenance of records
related to work

QUALITY
ASSURANCE
• Inspections Compile
activities from documents into
receiving to final Final Dossiers
as per approved and Handover
ITP’ &
ITP’s
SATISFIED
maintenance of CLIENT
records

¾ Establishing
g
inspection test
plans and ¾ Periodic audits
recording
formats
¾ Key performance
analysis
¾ Materials and
Subcontract ¾ Handling discrepancies
approvals and resolving Non
conformances
IN-HOUSE MATERIAL
Material Requirement

Purchase Request
raised by Supervisor/QS

Verification
Requireed
Not Project
Approved Manager

CORPORATE PURCHASE Centralized LOCAL PURCHASE

Procurement
FROM HO

>5,000 SR < 5,000 SR

Value /
RFQ RFQ
Or Not Urgent
g Requirement
q Or Urgent
g
Required Required

Verify Quote Verify Quote

Material Delivered

P.O for Supply

pp y P.O for Supply
pp y
Site Inspect

BAD BAD
Condition

GOOD

Use on Site
 CLIENT SUPPLIED MATERIAL

Client Function

E&I

Stage Inspections will

Packing List & be carried out where
Material ever applicable

Function

Data Entry BY Stack Material in

Planning/Material Section Store/Lay down Area

Store/ Material
Reconciliation
Controller

Field Fabrication Shop Fabricated items

Use material on Site

EXECUTION STRUCTURE
Drawings & Specification
Materials, Supports • Materials Issue Notes PLANNING
DEPARTMENT

• Drawings & Specification

• Release notes for Erection

EXECUTION TEAM STUDY OF TYPICAL

ENGR. / SUP. DRAWING DETAILS

ADDITIONAL •No CO
CONFIRMATION
O OF
O
WORK SCOPE OF WORK CHECK FOR LATEST
REVISION DRAWING
• Yes

MOS / ITP

DOCUMENT
INTER CONTROLLER
DEPARTMENT
COORDINATION

• Daily Progress Report

• Materials FIELD WORK
MATERIAL CONTROL • Supports, EXECUTION
Final Verification of Supports, materials
etc.
t for
f Material
M t i l SpecEtc.
S Et
Material Verification &
Confirmation QA/QC
8
DIFFERENT SYSTEMS

1. GROUNDING SYSTEM

2. CATHODIC PROTECTION SYSTEM

3. LIGHTING SYSTEM

4. POWER SYSTEM

5 COMMUNICATION SYSTEM
5.

6. FIRE ALARM SYSTEM

7. HEAT TRACING SYSTEM

STANDARDS

1. NEC – National Electrical Codes

2. IEC – International Electrical Codes

3. NFPA – NATIONAL
3 O FIRE PROTECTION
O C O ASSOCIATION
SSOC O

4. NEMA – NATIONAL ELECTRICAL MANUFACTURERS

ASSOCIATON

5. UL – UNDERWRITERS LABOURATORY
GROUNDING SYSTEM
GROUNDING SYSTEM [PURPOSE – PROTECTION]
BURRIED CABLES

TYPES
¾ Copper
¾ PVC Insulated Copper

Excavation Depth: 400mm From ground level

Copper Cable
NON BURRIED CABLES

TYPES
¾ Full Green [Common Ground)
¾ Yellow Green [ Panel ground]

Precautions:
¾ Detailed study of drawing
¾ Co-ordination
PVC Insulated Copper cable
12
Yellow Green Cable

Full Green Cable

Excavation

Excavation depth 13
TYPES OF GROUND

Electro-Static Ground

The equipments, tanks and vessels shall be grounded to discharge the

static electricity
electricity. The Ground conductor from the main grid line shall be
connected to the stainless steel ground lugs welded in the containers,
piping and structure.

Structural Grounding Ladder Grounding

EQUIPTMENT GROUNDING

¾STATIC EQUIPTMENTS

¾ROTARY EQUIPMTENT

Static Rotary
HUMAN SAFETY GROUND

The enclosure of the equipment and N.G.R shall be connected with the
main grid of the grounding system. The low voltage electrical equipments
and panels shall be connected to the grounding system by looping from
main grid grounding system. All layers of cable tray and supports shall be
bonded every 30 meters.
SYSTEM EARTHING

The medium
Th di voltage
lt electrical
l t i l equipments
i t shall
h ll be
b connected
t d with
ith low
l
resistance grounding system for the protection. The low resistance grounding
system shall be formed by connecting the neutral point of the equipment with
Neutral g
ground resistor and the N.G.R shall be connected with individual
ground wells.

Motor Grounding Panel Grounding

17
INSTRUMENT EARTHING

All the instruments shall be connected with intrinsically safety grounding to avoid the direct
secondary current flow to the instruments. This can protect the instruments from component
degradation and physical damage.

18
CAD WELDING

Procedure

The cad weld connection is made by dumping a container of weld

metal copper oxide and aluminum) into a semi permanent graphite
mold housing the conductor with a flint igniter. The exothermic
reaction produces molten cavity and weld the conductor to pipes.

CAD Welding Mould

19
CAD WELDING AT A GLANCE

Fixing Mould Fixing Mould Powder Filling

Igniting Bitumin Coating Looping 20

 EARTH PIT

Rod Length: 3m

Resistance value:

¾ 1 Ohms for Grid Type

¾ 5 Ohms for Rod type

Earth Rod Clamp Cable Connection C-Clamp Cable Lug

21
LIGHTNING ARRESTOR SYSTEM
CLASSIFICATION

1.External Lightning
¾ Lightning Protection System (LPS)
¾ For Protecting Structures from direct lightning strikes

2.Internal Lightning Protection

¾ Protection against Lightning Electromagnetic Pulse
¾ For Protecting sensitive Equipments inside the
building
Air Termination

LPZ OA
LPZ OB

Side Flash Structure representing shield 1

External LPS

LPZ 1 Room representing shield 2

Metallic
Down Conductor

Water Bonding bar 1

Local bonding bar
at the boundary
Tank 2 at the boundary
of LPZ Oa , Ob
LPZ 2
of LPZ 1 & LPZ 2
& LPZ 1
D

e.g Computer
Cables, Lines
Related Pipe Room
Works Bonding of shield 2
Example for dividing a structure into several LPZ s 22
and adequate bonding
CATHODIC PROTECTION SYSTEM

23
CATHODIC PROTECTION

Purpose

To Protect Cathode ((Tanks,, Pipes,

p , Underground
g Structures)) from rusting
g

Types of Bedding

¾ Vertical
¾ Horizontal

Classification

¾ Impressed Current system

¾ Sacrificial Anode System

Plant and Equipment

Drilling Machine (Deep bore well system) - for boring anode bed holes

24
CATHODIC PROTECTION SYSYTEM

25
WORK METHODOLOGY
¾ Cad Welding

¾ Cable Laying

¾ Installation of Ref. Anode And Test Boxes

In Tanks
Under Ground Pipe Line

¾ Installation of Anodes

¾ Installation
I t ll ti off Tr.
T Rectifiers
R tifi

Materials Used

Anodes - High silicone cast iron / Ag /Agcl

Junction boxes - Weather proof
Cables 600V
600V - HMWPE
Steel & P
Pvc
c Casing - 200
200mm
mm dia
Pipe - Rsc
Cad weld metal - CA
CA--15.
15. 26
LIGHTING SYSTEM

27
LIGHTING SYSTEM
TYPES OF FIXTURES

1. Industrial Type

¾ Indoor a) Explosion Proof Fluorescent

¾ Outdoor b) Weather Proof Flood Light
c) Common Type High Bay Light
Street Light
Emergency Exit Light

2 Commercial Type
2.

¾ Recessed Type
¾ Surface Type

Indoor Fluorescent
Outdoor Flood Light
High Bay Light
Street Light
Emergency Exit Light
28
MOUNDING SCHEME

Conduiting

¾ Exposed Conduiting

a.) G.I & E.M.T Conduiting G.I Conduit

¾ Concealed
C C
Conduiting

a.) P.V.C or E.M.T with all accessories

¾ Trunking system
E.M.T
¾ Common Materials Used
¾ End
E dB Bush
h
¾ Condulets (Fitiings)
¾ Clamps
¾ Supporting
pp g Channels
¾ Fixing Hardware

PVC Conduit 29
General Tips for Conduiting

¾ In a closed Circuit only two 90 Deg bends allowed

¾ 30% should be Kept

p free
Megger
¾ Usage of end bushes

¾ Avoid Sharpe edges

¾ Method of conduit vary according to area classification

T t Equipments
Test E i t I
Insulation
l i T Tester

¾Lux Meter – Intensity of Light

¾Megger - Resistance check of cable

¾Insulation Tester – Insulation Resistance check of cable

¾Multimeter – Continuity check

Multimeter
30
 Wall Mounting Indoor Type Fixture

Outdoor Weather Proof Mounted on Poles

31
Typical Wall Top Mounting Type Fixture

Conduits

Junction Box Lighting Fixtures

32
Indoor Surface Mounting Type Fixture

Flexible Conduits

Hanging Support

33
Flood Lights

34
Recess Mounting

High Bay Light

Street Light
g

35
Explosion Proof Light Fixture Exit Light

Lighting Receptacle Socket Lighting Junction Box

36
POWER SYSTEM

37
POWER SYSTEM

TRANSFORMER INSTALLATION

1.
1 Execution
E ti plan
l and
d rigging
i i plan
l
2. Lifting arrangements
3. Transportation
4. Installation
sta at o

Rigging Plan

38
T
Transportation
t ti Transportation

Sign Boards

Erection
39
TRANSFORMER ASSEMBLY

Conservator

Cooling Fans

Radiator

40
MV Termination

Before Sleeving After Sleeving

41
DIESEL GENERATOR SET

42
¾ Oil Filteration & Filling

For maintaining insulation grade oil has to be filtered through

heating until achieving the stipulated breakdown voltage
(Removing moisture and foreign materials)

¾ Precommissioning & Commissioning

¾ BDV of oil.

ƒ Voltage ratio at all taps & tap continuity test.

ƒ DC winding resistance test.
ƒ Vector group test.
test
ƒ Magnetic balance test.
ƒ Magnetizing inrush current test.
ƒ Primary injection test for neutral CT (Including winding
resistance & insulation resistance).
ƒ Resistance value check for NGR.
ƒ Conformity test for buchchholz relay. WTI & OTI Alarm & trip
contacts upto Marshalling boxbox.
ƒ Transformer winding High Voltage test.
ƒ Any other tests indicated by the vendor to charge the transformer.
43
Solo Run Test

No load test for 2 – 3 Hours dry run for Performance check of motor

Measuring Parameters

¾Temperature
¾Vibration
¾Speed
¾Voltage ½ Hour Duration Value Check
¾Starting Current for each parameters
¾Running Current
¾Rotation
¾Noise

MV Cable Test

¾Hi-Potential Test (Hi-Pot Test)

To Find rate of Leakage current

¾Megger
Insulation Test
44
HV, MV & LV SWITCHGEARS
PLANNING • Materials Issue Notes EXECUTION TEAM
DEPARTMENT ENGINEER / SUPERVISOR

• Drawings & Specification • Drawings & Specification

• Release notes for Erection
PANEL BASE
PREPERATION
wings & Specificatiion

erials, Supports

DOCUMENT
PREPERATION OF
CONTROLLER
RIGGING PLAN

PERMIT SYSTEM
Draw

Mate

TRANSPORTATION/ APPROVAL FROM

ARRANGEMENT OF CLIENT
MATERIAL CONTROL TOOLS

VISUAL
INSPECTION
Final Verification of Supports, materials
p
etc. for Material SpecEtc.
•Precommisiioning, Commissioning
• Yes
QA/QC DAMAGES

•No
CABLING
C G/
Material Verification &
FIELD WORK TERMINATION
Confirmation
EXECUTION
• Daily Progress Report 45
PANELS

Switch Gears Switch Gears

SF6 Breaker Bus Bar Chamber

46
Battery Unit MCC

LCS LCS with Motor

47
Panel Grounding Panel Grounding

Panel Grounding Panel Grounding 48

Precommissioning
g & Commissioning
g

¾Complete scheme check as per the final approved drawing.

¾HV busbar insulation resistance & High voltage test.
¾Cold charging of HV busbar by applying 480V supply (to ensure the
voltage on all points).
¾Up stream & down stream interlock check.
¾Differential stability test for motor.

Testing & Commissioning Of 480V SWGR Incoming & B/C - Testing

¾Primary injection test for CT & PT (Including winding resistance &

insulation resistance).
¾Knee point voltage test for PS class CT.
¾Secondary injection test for all relays.
¾Ci
¾Circuiti breaker
b k tripping
i i & closing
l i time i test.
¾Circuit breaker closing & tripping coil test at 80% & 120& of rated
voltage.
¾Circuit breaker mechanical & electrical operation check (with all
interlocks).

49
 RISK ASSESSMENT
EQUIPMENT INSTALLATION(TRANSFORMERS & PANELS)

¾Material Checking, Shifting From Store

Personal Injury
Fall of Objects

¾Support Fabrication, Painting and Erection

Fire hazard to flammables stored near to the welding area
Burn Injury
Danger of flying particles
Eye injury due to hazardous rays from welding

¾Panel Erection, Alignment Of Panels, Termination And Connection

Personal Injury
F ll off erection
Fall ti material
t i l due
d tot unsafe
f lifting
lifti

¾Earthing Work For Panel, Testing And Commissioning, Panel Energization

Personal Injury
j y
Electric Shock

50
CABLE PULLING FLOW
PLANNING • Materials Issue Notes EXECUTION TEAM
DEPARTMENT ENGINEER / SUPERVISOR
• Drawings & Specification • Drawings & Specification
• Release notes for Erection
CABLE DRUM
IDENTIFICATION &
RECEIVING
wings & Specificatiion

PREPERATION OF
METHOD STATEMENT
erials, Supports

PREPERATION OF
CABLE ROUTE
DOCUMENT
Draw

Mate

PERMIT SYSTEM CONTROLLER

TRANSPORTATION/
ARRANGEMENT OF APPROVAL FROM
MATERIAL CONTROL
TOOLS CLIENT

Final Verification of Supports, materials MEGGERING

etc. for Material SpecEtc/
• Precommissioning.
P i i i ,C
Commissioning
i i i

•No
(cables will not be
QA/QC CONTINUITY pulled by machines)
CHECK

• Yes DRESSING, GLANDING

DRESSING
Material Verification & & TERMINATION
Confirmation FIELD WORK
EXECUTION
• Daily Progress Report 51
 CABLE DRUM
IDENTIFICATION & RECEIVING

PREPARATION OF
CABLE ROUTE

52
 Duct Bank Manhole

Ladder Tray Punch Tray 53

 Cable Drum Kept on Shaft arrangement

Corner Roller

Cable Kept Rolled as 8 Type Cable Rollers

54
CABLE DRESSING

The installed cables shall be dressed tidily with cable tie for each 6 meters in
horizontal run and each 2 meters in vertical run. The power cables shall be
grouped according to the voltage rating, insulation level, and dressed with
cable
bl titie and
d the
th control
t l cables
bl shall
h ll b
be grouped d accordingly.
di l

Dressed Cables
55
CABLE TERMINATION

¾ The color coding and wire numbers are identified with suitable ferrules and
bunched if required. Then the connections are given to the terminals as
per wiring diagrams with suitable Lugs.

¾ Ensured that all the terminal Junctions are properly connected without any
loose contacts.

¾ The shielded cables are properly wired and the shield is seperated and
provided suitable sleeve and connected to the Busbars.

Cable Sleeves Cable Crimping

56
CABLE TAGGING

All the cables shall be identified with PVC band tags at both ends

Tagging Glanding Pin Type Bootless Lug

Ring Type boot lugs U Type Lug Sleeves

57
Single Core & Multicore Cables

58
Lugs & Glands S.S Cable Glands Cable Glands Cable Glands

Cable Lugs Cable Lugs Cable Lugs Cable Lugs

59
RISK ASSESSMENT

CABLE INSTALLATION

Excavation For Underground Cable Trench

¾Dust Generation
¾Fall of Objects and materials and personal
¾Cavitational soil subsidence due to inadequate sloping.

Under Ground Conduiting For Cable Laying

¾Body injury due to sharp edged materials and tools.

¾Fall hazard of cable drum and stand

Cable Drum Setting, Cable Roll Setting

¾Body injury.
¾Fall hazard of cable drum.

60
¾Cable
C bl Drum
D and
d Cable
C bl Stand
St d Lifting,
Lifti Cable
C bl Pulling
P lli By
B Hand
H d

Fatigue

¾Cable Dressing And Tying, Cable Tagging, Cable Glanding, Cable

Termination And Connection, Cable Meggering and Continuity Check

Body hurt due to pointed materials.

materials
Electrical Shock.

¾Cable Trench And Filling, Cable Tiles Laying

Dust Generation
Heavy equipment hazards.
Body Hurt.
Hurt

61
COMMUNICATION SYSTEM

¾Public Address
¾Paging
¾Telephone
¾Data System

FIRE ALARM SYSTEM Push button

¾Addressable
¾Conventional System
Photoelectric
Ionization
Heat Detector
Gas Detector

Remote Detector
62
 Smoke Detector Fire Extinguisher

Fire Alarm Panel Fire Alarm

63
HEAT TRACING SYSTEM

To maintain certain temperature in pipe lines and vessels using

resistive and conductive materials

Series ΔV

ΔV
Parallel r r r r r

Σ
I I
=
R r
64
¾ Typically Consists of:
z 500′′
Piping Runs Less Than 500
z Multiple Pipe Diameters
z Numerous Inline Equipment
• Valves
• Pumpsp
• Strainers

65
 MI Cables Polymer Zone Heating Self Regulating Power-Limiting Skin Effect
Insulated Cables Cables Current Tracing
Cables
Cables

Uses: Freeze Protection and Low

to Moderate Temperature Uses: Process Temperature Uses: Process Temperature
Maintenance Maintenance and Freeze Protection Maintenance and Freeze Protection

Max. Maintain Temp: 150°F Max. Maintain Temp: 250°F Max. Maintain Temp: 300°F

Max. Exposure Temp: 185°F Max. Exposure Temp: 375°F Max. Exposure Temp: 450°F
T-Rating: T6 T-Rating: T3 T-Rating: T3
66
TOOLS & TACKLES A GLANCE

67
Hydraulic Crimping Tool Contact Resistance Tester

Threading Machine Conduit Bender

68
Ordinary Crimping Tool

69
 I
Insulation
l ti Tape
T Manual Crimping Tool Cutter

Spanner & Cutting players Spanner Set Player knife

Player, knife, Cutter

70
 Hole Saw Kit Tongue Tester

Drilling machine Grinding Machine

71
SAFETY AT A GLANCE

72
 SAFETY KEY FUNCTIONS

1.Good housekeeping and material stacking policy

2.Complete the Project with accident and incident free.

3.Provision of good health and well being at work.

4.Create Safe working environment through out the project.

Carelessness

Scaffolding planks got fired during preheating jobs.

Incident area Live cables below accident area

74
 Subject to damage
from other activities in
th vicinity
the i i it

Electrical cord in
Contact with the
cylinder

Cylinder laying
in a horizontal
position.

75
 HOUSE KEEPING

¾ Slips, trips & falls account for 80

80%% of all accidents.

¾ These are mainly due to poor housekeeping habits.

¾ You, (Yes
(Yes YOU!
YOU!) are responsible for keeping your work area clean & tidy
at all times.

¾ D ’t block
Don’t bl k access ways, doorways
d etc.
t

¾ Don’t leave cables where people can trip over them.

¾ Don’t leave your mess for others to clean up.

76
THANK YOU

77