Date: 13-Apr-2023 MSD-DD-7600

METHOD STATEMENT OF PANEL

CONSTRUCTION
Rev. A Page 1 of 12

METHOD STATEMENT OF PANEL CONSTRUCTION

MSDP PROJECT
AUTHORIZED
STATUS
NAME SIGNATURE DATE
REVIEWED/
APPROVED

REVIEWED/
APPROVED WITH
COMMENTS AS
MARKED

NOT APPROVED TO
BE RESUBMITTED

(Not Applicable to IFIR)

REASON FOR NOT APPROVED

OWNER : PT. FREEPORT INDONESIA

CONTRACTOR : BLACK & VEATCH INTERNATIONAL
SUBCONTRACTOR : PT. TIGA PILAR ENERGI
MANYAR SMELTER DESALINATION PLANT PROJECT

A Issued For Internal Agustinus Agus Salim Deddy R.

Review Sitohang Harahap Sembiring
Rev. Description Date Prepared Reviewed Approved
 METHOD STATEMENT OF PANEL
Black & Veatch Intl. CONSTRUCTION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0003 2 of 12

TABLE OF CONTENT

Cover

Table of Content

1.0 Title 3 of 12

2.0 Purpose 3 of 12

3.0 Scope 3 of 12

4.0 Reference 3 of 12

5.0 Description of Procedure 3 of 12

6.0 Manpower 10 of 12

7.0 Equipments and Tools 10 of 12

8.0 Risk Safety Analysis 11 of 12

9.0 Attachment 12 of 12
 METHOD STATEMENT OF PANEL
Black & Veatch Intl. CONSTRUCTION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0003 3 of 12

1. TITLE

Panel Construction Procedure for Manyar Smelter Desalination Plant Project.

2. PURPOSE

This procedure is to describe as marginally of guidelines and requirements for installation of

shape steel on foundation, panel alignment, panel fixation, panel grounding and bus bar
installation.

3. SCOPE

The panel construction shall included installation, inspection and testing panel as construction
drawings and specifications. This construction procedure covers the following:

a. All switchboards, panelboards, and distribution boards installed for the control of light
and power circuits.
b. Battery-charging panels supplied from light or power circuits.

4. REFERENCES

a. Black and Veatch Specification and Construction Drawing

b. Black and Veatch, TPE Inspection and Test Plan (for Electrical)
c. National Electrical Code Article 408: Switchboards and Panelboards
d. Tiga Pilar Energi Engineering’s written practice procedure.

5. DESCRIPTION OF PROCEDURES

5.1 INSTALLATION OF 6 kV HV PANEL

A. Erection

1. Compare equipment nameplate data with drawings and specifications

2. Inspect location, elevation and level foundation, and dimension of mounting
structure to ensure that panel is installed in wet or damp location, in dust-
laden areas, outdoors, or in any hazardous area.
3. Verify appropriate anchorage, required area clearances, physical damage,
and correct alignment.
4. Fabricate and installed mounting base structures on foundation.
5. Verify that ground point and earth connection correspond to construction
drawings and specifications.
6. Inspect physical, electrical, and mechanical condition of 6 kV HV panel
before installation.
 METHOD STATEMENT OF PANEL
Black & Veatch Intl. CONSTRUCTION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0003 4 of 12

7. Mobilization, placement, alignment, and verify tightness of accessible bolted

by calibrated torque wrench method in accordance with manufacturer’s
published data for panel fixation on position.
8. Install ground point and earth connections.
9. Install bus-bar, bolting, and tightening bus-bar connections with calibrated
torque wrench method.
10.Inspect all doors, panels, and sections for paint, dents, scratches, fir, and
missing hardware in accordance with packing list.

B. Visual and Mechanical Inspection

1. Inspect all doors, panels, and section for pint, dents, scratches, fit, and
missing hardware in accordance with packing list or manufacturer’s
drawings and published data.
2. Verify that fuse and/or circuit breaker sizes and types correspond to
drawings.
3. Verify that current and potential transformer ratios correspond to drawings,
if necessary.
4. Verify tightness of accessible bolted electrical connections by calibrated
torque wrench method in accordance with manufacturer’s published data.
5. Confirm correct operation and sequencing of electrical and mechanical
interlock systems:
- Attempt closure on locked-open devices. Attempt to open locked-closed
devices.
- Make key exchange with devices operated in off-normal positions
6. Keep clean 6 kV HV panels.
7. Inspect insulators for evidence of physical damage or contaminated
surfaces.
8. Verify correct barrier and shutter installation and operation.

C. Electrical Tests

1. Perform resistance tests through all bus joints with a low-resistance ohm-
meter. Any joints that cannot be directly measured due to permanently
installed insulation wrap shall be indirectly measured from closest
accessible connection.
2. Perform insulation-resistance tests on each bus connection, phase-to-
phase and phase-to-ground.

5.2 INSTALLATION OF 380/220 V PANELBOARD.

5.2.1 Erection of 380/220 Panelboard

1. Compare equipment nameplate data with drawings and specifications
2. Inspect location, elevation and level foundation, and dimension of
mounting structure to ensure that panel is installed in wet or damp
location, in dust-laden areas, outdoors, or in any hazardous area.
 METHOD STATEMENT OF PANEL
Black & Veatch Intl. CONSTRUCTION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0003 5 of 12

3. Verify appropriate anchorage, required area clearances, physical damage,

and correct alignment.
4. Fabricate and installed mounting base structures on foundation.
5. Verify that ground point and earth connection correspond to construction
drawings and specifications.
6. Inspect physical, electrical, and mechanical condition of 380/220 V panel-
board before installation.
7. Mobilization, placement, alignment of panel with the following position:
- Vertically deviation < 1.5 mm
- Top deviation of two adjacent panels < 2 mm
- Top deviation of panels in line < 5 mm
- Edge deviation of two adjacent panels < 1 mm
- Panel surface deviation in line < 5 mm

8. Ensure tightness of accessible bolted by calibrated torque wrench method

in accordance with manufacturer’s published data for panel fixation on
position with joint clearance between panels < 2 mm.
9. Install ground point and earth connections.
10.Install bus-bur, bolting, and tightening bus-bar connections with calibrated
torque wrench method.
11.Inspect all doors, panels, and sections for paint, dents, scratches, fir, and
missing hardware in accordance with packing list.

5.2.2 Inspection and Tests

1. Inspect all doors, panels, and section for pint, dents, scratches, fit, and
missing hardware in accordance with packing list or manufacturer’s
drawings and published data.
2. Verify that fuse and/or circuit breaker sizes and types correspond to
drawings.
3. Verify that current and potential transformer ratios correspond to
drawings, if necessary.
4. Verify tightness of accessible bolted electrical connections by calibrated
torque wrench method in accordance with manufacturer’s published
data.
5. Confirm correct operation and sequencing of electrical and mechanical
interlock systems:
- Attempt closure on locked-open devices. Attempt to open locked-
closed devices.
- Make key exchange with devices operated in off-normal positions
6.Keep clean 380/220 V panel-board.
7.Inspect insulators for evidence of physical damage or contaminated
surfaces.
8.Verify correct barrier and shutter installation and operation.
9.Perform resistance tests through all bus joints with a low-resistance
ohm-meter. Any joints that cannot be directly measured due to
 METHOD STATEMENT OF PANEL
Black & Veatch Intl. CONSTRUCTION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0003 6 of 12

permanently installed insulation wrap shall be indirectly measured from

closest accessible connection.
10. Perform insulation-resistance tests on each bus connection, phase-to-
phase and phase-to-ground.

5.3 INSTALLATION OF L.V. AUXILIARY TRANSFORMER

5.3.1 Erection L.V. Auxiliary Transformer

1. Compare equipment nameplate data with drawings and specifications.

2. Inspect physical and mechanical condition of transformer.
3. Inspect location, elevation, level and dimension of foundation proper with
the pedestal of transformer.
4. Clean the surface foundation.
5. Mobilize placement, setting, alignment and bolting of transformer.
6. Install and connect grounding conductor to winding core, frame and
enclosure groundings.
7. Inspect bus-bar for physical damage and correct connection in
accordance with single-line diagram.
8. Check and survey for appropriate supports, bracing, and suspension.
9. Assembly, setting, and alignment bus-bar, for bolting and tightness
between bus-bars, and between bus-bar and equipment use calibrated
torque wrench with the following table:
Table 1
Bolt Torque for Bus Connections
Stainless Steel Fasteners
Bolt Diameter Uncoated
(Inches) (Foot Pounds)
5/16 14
3/8 25
½ 45
5/8 60
3/4 90

5.3.2 Inspection and Tests.

1. Inspect physical and mechanical condition.

 METHOD STATEMENT OF PANEL
Black & Veatch Intl. CONSTRUCTION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0003 7 of 12

2. Verify that control and alarm setting on temperature indicators are as

specified
3. Verify that cooling fans operate correctly and that fan motors have correct
over current protection.
4. Verify tightness of accessible bolted electrical connections by calibrated
torque-wrench method in accordance with manufacturer’s published data
or Table 1.
5. Verify that winding core, frame, and enclosure groundings are correct.
6. Perform insulation-resistance tests winding-to-winding and each winding-
to-ground, with test voltage in according with below table:

Table 2
Transformer Insulation-Resistance
Acceptance Test Voltage and Minimum Results

Resistance Minimum Insulation Resistance

(Mega-Ohm)
Transformer Minimum dc Test
Rating Type Voltage Liquid Filled Dry
(Volts)

0 – 600 1000 100 500

601 – 5000 2500 1000 5000
5001 – 15000 5000 5000 25000

7. Measure insulation resistance of each bus-bar, phase-to-phase and

phase-to-ground for one minute, in accordance with the below table.

Table 3
Insulation Resistance Tests
On
Electrical Apparatus and Systems

Maximum Rating of Minimum Test Voltage, dc Recommended Minimum

Equipment (Volts) Insulation Resistance
(Volts) (Mega-Ohm)
250 500 25
600 1,000 100
5,000 2,500 1,000
8,000 2,500 2,000
15,000 2,500 5,000
25,000 5,000 20,000
35,000 15,000 100,000
46,000 15,000 100,000
69,000 15,000 100,000
 METHOD STATEMENT OF PANEL
Black & Veatch Intl. CONSTRUCTION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0003 8 of 12

8. Perform contact-resistance test on each connection point of non-insulated

bus-bar, use micro-ohm-meter.

5.4 INSTALLATION OF MCC PANEL

5.4.1 Erection of MCC Panel

1. Compare equipment nameplate data with drawings and specifications

2. Inspect location, elevation and level foundation, and dimension of
mounting structure to ensure that MCC panel is installed in wet or damp
location, in dust-laden areas, outdoors, or in any hazardous area.
3. Verify appropriate anchorage, required area clearances, physical damage,
and correct alignment.
4. Fabricate and installed mounting base structures on foundation.
5. Verify that ground point and earth connection correspond to construction
drawings and specifications.
6. Inspect physical, electrical, and mechanical condition of MCC panel
before installation.
7. Mobilization, placement, alignment of panel with the following position:
- Vertically deviation < 1.5 mm
- Top deviation of two adjacent panels < 2 mm
- Top deviation of panels in line < 5 mm
- Edge deviation of two adjacent panels < 1 mm
- Panel surface deviation in line < 5 mm

8. Ensure tightness of accessible bolted by calibrated torque wrench method

in accordance with manufacturer’s published data for panel fixation on
position with joint clearance between MCC panels < 2 mm.
9. Install ground point and earth connections.
10.Install bus-bar, bolting, and tightening bus-bar connections with calibrated
torque wrench method.
11.Inspect all doors, panels, and sections for paint, dents, scratches, fit, and
missing hardware in accordance with packing list.

5.4.2 Inspection and Tests

1. Inspect all doors, panels, and section for pint, dents, scratches, fit, and
missing hardware in accordance with packing list or manufacturer’s
drawings and published data.
2. Motor running protection if necessary:
 METHOD STATEMENT OF PANEL
Black & Veatch Intl. CONSTRUCTION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0003 9 of 12

- Compare overload element rating with motor full-load current

rating to verify correct sizing.
- If power-factor correction capacitors are connected on the load
side of the overload protection, include the effect of the capacitive
reactance in determining appropriate overload element size.
- If motor-running protection is provided by fuses, verify correct
rating considering motor characteristics and power-factor correction
capacitors, if applicable.
3. Verify tightness of accessible bolted electrical connections by calibrated
torque wrench method in accordance with manufacturer’s published data.
4. Measure insulation resistance of each combination starter, phase-to-
phase and phase-to-ground, with the starter contacts closed and the
protective device open. Test voltage shall be in accordance with
manufacturer’s instructions.
5. Test circuit breakers in accordance with perform a contact-resistance
test and insulation-resistance test at 1000 V dc from pole-to-pole and from
each pole-to-ground with breaker closed and across open contacts of
each phase.
6. Inspect insulators for evidence of physical damage or contaminated
surfaces.
7. Perform resistance tests through all bus joints with a low-resistance
ohm-meter. Any joints that cannot be directly measured due to
permanently installed insulation wrap shall be indirectly measured from
closest accessible connection.
8. Test the motor overload relay elements by injecting primary current
through the overload circuit and monitoring trip time of overload elements.
9. Keep clean MCC panel

5.5 INSTALLATION OF DC PANEL AND CONTROL PANEL

5.5.1 Erection of DC Panel and Control Panel

1. Compare equipment nameplate data with drawings and specifications

2. Inspect location, elevation and level foundation, and dimension of
mounting structure to ensure that panel is installed in wet or damp
location, in dust-laden areas, outdoors, or in any hazardous area.
3. Verify appropriate anchorage, required area clearances, physical damage,
and correct alignment.
4. Fabricate and installed mounting base structures on foundation.
5. Verify that ground point and earth connection correspond to construction
drawings and specifications.
6. Inspect physical, electrical, and mechanical condition of DC panel before
installation.
7. Mobilization, placement, alignment of panel with the following position:
- Vertically deviation < 1.5 mm
- Top deviation of two adjacent panels < 2 mm
 METHOD STATEMENT OF PANEL
Black & Veatch Intl. CONSTRUCTION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0003 10 of 12

- Top deviation of panels in line < 5 mm

- Edge deviation of two adjacent panels < 1 mm
- Panel surface deviation in line < 5 mm

8. Ensure tightness of accessible bolted by calibrated torque wrench method

in accordance with manufacturer’s published data for panel fixation on
position with joint clearance between panels < 2 mm.
9. Install ground point and earth connections.
10.Install bus-bar, bolting, and tightening bus-bar connections with calibrated
torque wrench method.
11.Inspect all doors, panels, and sections for paint, dents, scratches, fir, and
missing hardware in accordance with packing list.
12.Keep clean inside and outside DC panel.

5.5.2 Inspection and Tests

1. Inspect all doors, panels, and section for pint, dents, scratches, fit, and
missing hardware in accordance with packing list or manufacturer’s
drawings and specifications.
2. Measure insulation resistance between bus-bar and ground is minimum
0.5 Mega-ohm.
3. Verify adequacy of mounting frame, anchorage and clearances.
4. Verify that fuse size and types correspond to drawings.

5.6 INSTALLATION OF LOCAL POWER CONTROL EQUIPMENT BOX

5.6.1 Erection of Local Power Control Equipment Box

1. Compare equipment nameplate data with drawings and specifications.

2. Inspect physical and mechanical condition before installation.
3. Verify location, elevation and leveling of control box.
4. Fabricate and install mounting support of control box
5. Install and alignment of control box.
6. Install and connection of earthing copper conductor to grounding
enclosure of control box.

6. MANPOWER

6.1 Supervisor = 1 Person

6.2 Foreman = 1 Persons
6.3 Rigger = 1 Persons
6.4 Electric skill = 5 Persons
6.5 Plate welder = 1 Persons
6.6 Un-skill = 6 Persons
6.7 Safety-man = 1 Person
 METHOD STATEMENT OF PANEL
Black & Veatch Intl. CONSTRUCTION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0003 11 of 12

7. EQUIPMENTS AND TOOLS

7.1 RT Crane 50 Ton = 1
Unit
7.2 Welding machine 400 A = 2
Unit
7.3 Hand pallet cap. 3 Ton = 2
Unit
7.4 Chain block 2 Ton = 4
Unit
7.5 Chain block 1.5 Ton = 4
Unit
7.6 Socket wrench set 10 ~ 32 mm = 2
Sets
7.7 Fire extinguisher cap. 3 kg = 2
Unit
7.8 Shackle ½” – ¾” = 4
Ea
7.9 Wire sling Ø 3/8” ~ ½” = 4
Sets
7.10 Vacuum cleaner 800 W = 1
Unit
7.11 DC Insulation-continuity tester = 1
Unit
7.12 Tool box 3 layer = 4
Units
7.13 Screw driver set +/- = 3
Sets
7.14 Hex key set 2 ~ 14 mm = 3
Sets
7.15 Level magnetic 230 mm = 3
Units
7.16 Electric grinder 4” = 2
Units
7.17 Electric drilling machine Ø 16 mm = 2
Units
7.18 Scaffolding pipe and clamps = 4
Sets
7.19 Square-meter 30 x 20 cm = 3 Ea
7.20 Measuring tape 5 m = 5 Ea
7.21 Electric speed cutting machine Ø 14” = 1
Unit
7.22 Micro-ohm meter AEMC Model 5600 = 1
Unit

8. RISK AND SAFETY ANALYSIS

 METHOD STATEMENT OF PANEL
Black & Veatch Intl. CONSTRUCTION PT. TPE

Document Number: Rev.: A

MANYAR SMELTER DESALINATION PLANT PROJECT Pages No.:
MSD-DD-7600-CONS-PRO-0003 12 of 12

a. Verify the electrical wiring and equipment (panel, transformer and control box) in
hazardous (classified) location before installation.
b. All tests be performed with apparatus de-energized except where otherwise specially
required.
c. The testing organization shall have a designated safety representative on the project
to supervise operations with respect to safety.
d. In cases where the panel installation present a fire hazard, one or more of the
following safeguards shall be applied according to the degree of hazard involved
e. Put LOTTO (Lockout-Tag out) to prevent accident which is caused by electric shock if
happen failure to de-energize electrical equipment during testing or inspection.
f. Inspection of all tools/equipment and its calibration certificate prior to used
g. Provision of appropriate barricade and signage
h. Floor/Cable trench opening should be identified and provided with physical barriers
and signage, cover it properly as necessary
i. Ensure proper illumination in the work area
j. Pre-work inspection, identify potential pinch/crush points and discuss with workers
during toolbox meeting.
k. Ensure tools and equipment used only for its intended purpose and according to
proper handling technique or manufacturer recommendation
l. Do not do any drill directly above head, always offset from body position.
m. Do not work on electrical tools or equipment when clothing is wet or any part of body
is in contact with water.
n. Disconnect equipment when not in use, but do not pull cable to disconnect; pull the
plug.
o. Provide additional fire extinguisher at hot work area and fire watch.

9. ATTACHMENT