NSG Group Copyright Confidential

VGI 3 FLOAT
ELECTRICAL INSTALLATION CABLING AND EARTHING
Document No. 4693-507-H00-002

This document, and all copyright in it, is the property of Pilkington Group Limited, and its contents shall not be reproduced in whole or in part without the consent of Pilkington Group Limited. Use of this document and the information herein shall be regarded as an acceptance on the part of the user that it is obliged to treat all the data and information in this document as secret and confidential and that it is obliged to use such data and information only for the purposes authorised by Pilkington Group Limited. Neither Pilkington Group Limited nor any other member of the NSG Group (Nippon Sheet Glass Company Limited and its subsidiaries) shall accept any liability in respect of any claims, whether by the recipient or any third party, arising out of or in connection with any use of this document or any of the technical data or information contained herein or of any advice furnished in connection herewith.

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DOCUMENT HISTORY Revision No. 00 00 Date of Issue Issued For 19/08/2011 8th Jan 2013 Revision Description Based on Master Rev 04 Update Document No. Review Figure 1 (Separation along cable runs) .Change the distance between ladder (500m 400mm) Author Y. Funatsuka K.Uetsuki

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CONTENTS
DOCUMENT HISTORY
1. 2. 3. 4. SCOPE STANDARDS SUPPLY SYSTEMS CABLING 4.1 General 4.2 Cable Construction 4.2.1 Conductor 4.2.2 Insulation 4.2.3 Core Identification 4.2.4 Sheath 4.3 Rating 4.4 Armouring 4.5 Mineral Insulated Copper Sheathed Cable (with copper conductors) 4.6 Polymeric Cables (unarmoured) 4.7 Polymeric Cables (armoured) 4.8 Screened Cables 4.9 Enclosed Trenches 4.10 Cabling for Moving Machinery 4.11 Cable Identification Markers 4.12 Cable Glands 4.13 Termination of Cores 4.14 Bend Radii 4.15 Cable Routes 4.16 Cable Segregation CONDUITS AND METAL TRUNKING CABLE TRAYS AND LADDERS PLASTER DEPTH INSTALLATIONS LIGHTING INSTALLATIONS 8.1 High Bay Lighting and General Lighting 8.2 Wiring 8.3 Fixings 8.4 Switching SOCKET OUTLETS EARTHING 10.1 Protective Earth DISTRIBUTION BOARDS 11.1 General 11.2 Circuit Breaker and Isolator 11.3 Busbars 11.4 Neutral and Earthing Links 11.5 Load Balancing 11.6 Circuit Identification ISOLATORS SUPPORTS AND FIXINGS MISCELLANEOUS LABELLING QUALIFICATIONS

2
5 5 6 6 6 6 6 6 6 7 7 7 7 8 9 9 9 10 10 10 10 10 10 11 11 13 13 13 13 14 15 15 16 16 16 17 17 18 18 18 18 19 19 19 19 19

5. 6. 7. 8.

9. 10. 11.

12. 13. 14. 15.

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16. 17. 18.

MATERIALS FAULTY WORKMANSHIP AND MATERIALS TESTS

20 20 20 20 21 21 22 22

19. FINISHING, PAINTING AND CLEANING APPENDIX A MINIMUM CABLE SEGREGATION ARRANGEMENTS Figure 1 - Separation along Cable Runs Figure 2 - Separation at Cubicle Entry

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1.

SCOPE This document sets out the general requirements for Electrical Equipment installations, cabling and earthing for the VGI -3 Float glass Plant in My Xuan, Ba Ria, Vietnam. This standard relates to the supply and installation of cables and electrical equipment rated up to 1000V (Low Voltage) and the earthing of apparatus and electronic systems. The cables required and special routing information are listed in separate contract documents, (e.g. cable schedules). ASBESTOS Asbestos-containing material (ACM) is defined as any material containing 1% or more asbestos and shall not be supplied, used or contained in equipment for new installations or repair work. All applicable national, state regulations and company rules for removal, handling and disposal of ACM shall be followed. ACM can include, but is not limited to: insulation floor tiles roofing felts, mastics or flashing fireproofing gaskets The composition of any unknown materials to be installed, removed or otherwise disturbed shall be determined before any supply or work starts. Any task involving materials listed above will require training or certification of personnel, specialised PPE and competent (or qualified) supervision. Other workers in the area must be alerted to the work being performed.

2.

STANDARDS The design, manufacture, testing installation and commissioning shall comply with the requirements of the latest editions, with amendments, of the relevant European, British and Vietnamese laws, Regulations and Standards, which ever is the more onerous, including. i. ii. iii. iv. v. 89/654/EEC 89/655/EEC 90/270/EEC 92/58/EEC 89/392/EEC Directive Concerning the Minimum Safety and Health Requirements for the Workplace Directive Concerning the Minimum Safety and Health Requirements for the Use of Work Equipment by Workers at Work Directive Concerning the Minimum Safety and Health Requirements for the Work with Display Screen Equipment Directive Concerning the Minimum Safety and Health Requirements for the Provision of Safety and /or health Signs at Works As amended by 91/368/368 Directive on the Approximation of the laws of Member States Relating to Machinery.

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vi. vii. viii.

89/336/EEC EN1938 EN 60598

Directive on the Approximation of the Laws of Member States Relating to Electromagnetic Compatibility (EMC) Lighting Application Emergency Lighting Luminaires

3.

SUPPLY SYSTEMS The supply arrangement and voltages are as listed in section 3 of specification 4693-407H00-555.

4.

CABLING 4.1 General Cable shall be run in continuous lengths between terminations. Multi-core cable for control circuits shall have the nearest standard number of cores in excess of the number required including any spares that may be specified. Spare cores shall be earthed at both ends to avoid EMC interference. Care shall be taken when using single core cables on AC power circuits to ensure that harmful circulating currents cannot be induced at gland plates, etc, it may be necessary to use non-ferrous gland plates (e.g. above 50A). Cables shall be secured to cable ladder by approved cable ties to the satisfaction of the Pilkington Electrical Engineer. Speech communication cables and electronic signal cables shall be screened and separated from power cables (see Section 4.15). 4.2 Cable Construction 4.2.1 Conductor All conductors shall be high conductivity annealed stranded copper to Class 2 minimum IEC228 4.2.2 Insulation The cable shall be insulated to 0.6/1 kV. PVC, XLPE or EPR materials are accepted, to IEC 60502-1 or Vietnamese equivalent. 4.2.3 Core Identification Power cable cores shall be colour identified as listed in section 4 of specification 4693-407-H00-555 Multi-core control cable cores shall be numerically identified with numbers on the insulation at intervals not exceeding 300 mm.

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4.2.4

Sheath The cable shall be sheathed with extruded PVC or PE (as appropriate) to IEC 60502-1 or Vietnamese equivalent.

4.3

Rating Cable sizes are to comply with the current rating tables of the IEE Wiring Regulations for Electrical Installations, BS7671, or Vietnamese equivalent. The operating conditions laid down in IEE Wiring Regulation 522, referring to current-carrying capacity, voltage drop, minimum cross-sectional area of neutral conductors and electro mechanical stresses shall be complied with by the Contractor. All cables shall be rated and cleated to withstand the relative prospective short circuit current and for the maximum design time the protection needs to clear the fault. The minimum size of cable used shall be 1.5 mm. Screened cables shall normally have a 0.5 mm cross-section. The cable sizes of protective conductors shall be determined by the methods described in the relevant sections of the IEE Wiring Regulations or Vietnamese equivalent.

4.4

Armouring Unless stated otherwise, armoured cables shall be used for routes that are prone to mechanical damage during or after installation. Armouring may be in wire or tape. AC power circuits, using single core armoured cables shall have non-magnetic armouring.

4.5

Mineral Insulated Copper Sheathed Cable (with copper conductors) Rating for all MICS cable to be heavy duty and comply with BS.6207. The installation of this type of cable shall only be carried out by competent workmen who have received instructions in the special technique involved. The termination of all MICS cables shall be made with screw-on pot type seals and glands. Where it is necessary on long runs to join two lengths of cable, the appropriate coupling shall be used. MICS cables, which terminate at motor terminal boxes or at other equipment where some degree of movement is required, or where the termination may be subjected to vibration, shall be formed into a loop adjacent to the termination. The radius of the loop shall be suitable to permit belt tensioning, etc.

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MICS cables shall be fixed with clips, saddles or spacing saddles on walls or run on cable tray as specified. Where there is a likelihood of corrosion of the sheathing as a result of cables being in direct contact with the fixing surface, PVC spacing saddles shall be used. Where cables pass through walls or floors, or where they are exposed and liable to damage near floor level, or elsewhere, they shall be protected by sleeves or sheet steel guards, the ends of which shall be bushed or similarly finished to prevent abrasion of the cable. For installations in corrosive atmospheres, MICS cables and terminations shall, where specified, be sheathed overall with PVC, cable trays and fixing saddles shall be suitable for the corrosive agent and its concentration. PVC sheaths shall be coloured orange for security systems. For flameproof installations, the glands shall be of flameproof type and conduit boxes shall be of certified flameproof construction to BS.5501 for the gas group specified by the Pilkington Electrical Engineer. Unless otherwise specified, the seals shall be made with cold sealing compound and coloured identification shall be used to distinguish between the respective phases and neutral. 4.6 Polymeric Cables (unarmoured) Cables of this type can be run on the surface without any additional protection, but where possibility of mechanical damage exists, they shall be suitably protected. In order to avoid the risk of damage at low temperatures, cables of this type shall not be installed in ambient temperatures below 0C. The wiring system shall employ metal junction boxes and accessories, and the cables shall contain an earth continuity conductor. The earth continuity conductor shall be continuous and shall be bonded to all non-current-carrying metalwork in the wiring system and to the earth terminal of socket outlets. The cables shall be fixed with approved cable ties on cable ladder. In corrosive atmospheres, fixing clips shall be either non-metallic or coated with PVC or polythene as specified. Where cables pass through walls or floors or where they are exposed and liable to damage near floor level, they shall be protected by sleeves or sheet steel guards, the ends of which shall be bushed, or similarly finished to prevent abrasion with the cables. All terminals shall be by means of suitable glands and the cable sheath taken into the box or accessory.

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4.7

Polymeric Cables (armoured) In addition to the requirements of the preceding section, the following is also relevant. Terminating glands shall be of the type indicated on the drawings or schedules and shall be suitably protected against corrosion, where specified. For outdoor installations, the protective PVC sheaths shall be brought into the gland and the wire armouring securely clamped and a shroud fitted. A shroud shall also be fitted on indoor installations where the armouring is visible.

4.8

Screened Cables Cables of this type shall comply with DEF STAN 61-12 (Part 5)/1. When screened cable is used, the screen shall be insulated from earth and, at one end, made off into a suitable 360 gland which shall be bonded to an earth bar. The other end of the screen shall be left "floating". Both ends of the screen shall be taken as close to the terminal board in the equipment as practicable and then taped off to contain al loose wisps of braid. The screen terminal is to be specified on the cable schedule and shall be connected internally in the equipment to signal ground, i.e. the designated common reference point for all signal voltages. When there are several connections they shall be run in overall copper braid screened, PVC insulated, stranded, multi-core cable, or in overall screened DEF STAN 61-12 (part 5)/1 cable, in heavy gauge steel conduit or heavy gauge steel trunking with a tightly fitting steel lid, with the conduit or trunking bonded together throughout its length. Connections for digital control signals, analogue control signals and data transfer signals shall not be run together in the same multi-core cable or conduit, except in special situations such as cable reeling drums or similar. To comply with EMC guidelines all inverter controlled motor cables shall be installed such that the armour/screen is connected to earth, using a suitable 360 metal gland at each end.

4.9

Enclosed Trenches Cabling in prepared concrete or masonry trenches shall comply with the recommendation given in the IEE Wiring Regulations Appendix 4. The lids shall be of suitable design as to protect the trench and its cables under all working conditions. The cables shall be secured by cleats and fire-breaks shall be provided at suitable places, e.g. near transformers and at suitable intervals along the trench lengths. All trenches shall be adequately drained. The trenches shall be complete and clean before cables are laid.

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4.10

Cabling for Moving Machinery Due consideration shall be given to the long term effects of vibration on to the cable installation. Sheathed cables shall be used where a flexible conduit system is impracticable. Flexible conduit and sheathed cables shall be fitted in such a manner that there is neither mechanical strain on the connection point, nor any sharp flexing. The minimum radius of any bend shall be ten times its outside diameter. Flexible and pliable conduits and sheathed cables shall have a minimum length consistent with the required movement. They shall be made in a U-form to eliminate flexing at the termination and ensure that liquids drain away from the terminations.

4.11

Cable Identification Markers Cable tags shall be used at each end of each cable, bearing the relevant cable identification number as indicated in the cable schedule, or wiring diagram. Clip-on or self-adhesive types shall not be accepted.

4.12

Cable Glands All cables shall be provided with a recommended cable gland on entry to any cubicle or junction box.

4.13

Termination of Cores Where possible, pre-insulated crimped lugs shall be used. In clamp type terminals (e.g. Klippon) lipped lugs shall be used wherever possible. For termination under screws, lugs with an annular contact portion shall be used unless an alternative is approved by the Pilkington Electrical Engineer. Each core shall be identified with a wire number which shall be a full circle interlocking ferrule. Saddle type ferrules shall not be accepted. Larger power cable shall be terminated in crimped lugs.

4.14

Bend Radii The radii of bends in cables shall not be less than the cable manufacturers recommended bending radii.

4.15

Cable Routes The routing of all cables shall be submitted prior to installation for approval. Cable routes shall be selected bearing in mind the following: a) The most direct route between items of equipment connected together, taking into consideration the structure of the building. The most efficient use of cable trays, trunking, ducts, trenches, etc.

b)

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c)

Avoidance of steam, hot and cold water and gas services. Drawings shall be prepared indicating the route of all main cables, including any builders work requirements. The routing of screened cables shall be arranged to avoid main power cable routes wherever possible.

d)

4.16

Cable Segregation If routing of electronic signal cables cannot avoid main power cable routes, the segregation shown in Appendix A of this specification shall be observed, as a minimum requirement. Where it is possible, metal box conduits shall be used to reduce interference.

5.

CONDUITS AND METAL TRUNKING All conduit shall be heavy gauge screwed steel, galvanised and of 20 mm minimum size. Adaptable boxes shall be heavy gauge sheet steel where used with conduit. Conduit boxes shall be of the malleable iron circular pattern, screwed and complete with cover fixed by brass screws. For surface work the standard pattern boxes shall be used. Top inspection elbows and tees are not to be used. Standard bends, elbows and tees are to be used wherever possible. Where conduit is to be run between joists beams, etc, the size of conduit shall be selected such that there is no noticeable sag in the conduit. The minimum size to be used for such installations shall be 25 mm. Conduit connections shall be made as follows: Adapter boxes and spout entry boxes - conduit tube screwed up solid. Conduits shall be threaded to butt close together in couplings and sockets and the ends filed square, carefully reamed to remove burrs and traces of oil or grease. No threads shall be exposed except at running couplings and where running couplings are used they shall be complete with lock nuts and shall be neatly painted with cold galvanising paint. Joints in galvanised conduit runs shall be made watertight using this paint. The joints shall be partially screwed up before application of the paint to ensure that continuity is maintained. All unused entries in the conduit system shall be stopped with plugs to prevent the ingress of moisture, dust or other harmful substance. Conduit shall be installed so as to drain all condensed moisture without injury to end connections. For situations where condensation is anticipated drainage points shall be provided where necessary. In all concealed or surface conduit risers and down drops a coupling shall be provided at a distance of 300 mm from the floor or ceiling as applicable. Bends and sets shall be made cold without altering the section on an approved bending machine using formers and guides for short radius bends where necessary.

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Sufficient conduit boxes shall be provided to facilitate complete rewiring of the system at a future date and hence particular attention shall be paid to the position of boxes to ensure easy access. No boxes shall be installed in inaccessible positions. Unless otherwise specified, all conduit shall be run on the surface and fixed by means of heavy duty pattern spacing saddles for parallel runs of two or more conduits multiple saddles screwed between each way shall be used. Where conduit and boxes are concealed in walls or run in floors, it shall be programmed such that installation is complete before plastering and screening is complete. Chases are to be sufficiently deep that the full depth of plaster covers the conduit. Suitable outlets shall be made to enable the cables to be drawn in at a later date. All sections of the conduit system, including all conduit fittings shall be finally fixed in position prior to the drawing in of cables. Cables shall be drawn into adaptable boxes of ample capacity. In single phase and neutral circuits the wiring shall be arranged so that the phase conductor and neutral or switch wire and return are drawn into the same conduit. Similarly, for 3 phase or 3 phase and neutral circuits, all the phase conductors (and neutral where applicable) shall be drawn into the same conduit to avoid eddy current heating. Flexible metallic conduit shall be used to provide the final connection to a motor terminal box or to other apparatus where some degree of movement is required. The length of flexible steel conduit used for such purposes shall be kept as short as possible. The method of securing the ends of flexible steel conduit into the adapters shall be such as to provide sound mechanical joint. To obviate several conduits running to and from the same point, sheet metal trunking may be used with conduit branches taken off as necessary. Trunking shall be run as neatly as possible, and where a change of direction of trunking is required, suitably manufactured bends or tees, etc shall make such changes. Conduit branches shall be made via suitable means for ensuring mechanical security and good earth continuity. Wiring in conduit installations shall be PVC insulated. Where trunking passes through a wall or floor, the hole shall be made good to the full thickness of the wall or floor, etc, to prevent the spread of fire. In addition, suitable fire-resisting barriers shall be provided and secured inside the trunking where it passes through the wall or floor. Cabling of extra low voltage systems or of fire alarm, radio, telephone, bell and call systems, sound distribution or emergency lighting shall be segregated in conduits and trunking.

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In offices, welfare areas and laboratories, plastic conduit and trunking may be used where these are appropriate to the location and conditions. In the offices, multi compartment trunking shall be used, to cater for telephone and computer cables (installed by others) in addition to mains voltage services.

6.

CABLE TRAYS AND LADDERS The cables shall be laid on steel cable tray or ladder. Trays and cable ladders shall be heavy-duty steel type. Trays and ladders installed outdoors shall be hot dip galvanised and ladders installed indoors shall be galvanised; cold galvanised types shall be acceptable or other agreed treatment to suit the environment. Cable trays and ladders shall be supported to the manufacturer's recommendations. Metallic tray work shall be earthed and joints shall be made to form a continuous metallic bond. In offices, welfare areas and laboratories, plastic or wire trays may be used where these are appropriate to the location and conditions. Cable trays and ladders shall be designed to leave 40% minimum spare space for future additional cables.

7.

PLASTER DEPTH INSTALLATIONS Installations on plastered walls shall comprise PVC cable to IEC.227 or Vietnamese equivalent, with integral earth core and protected by steel capping. Since the plaster depth may not be greater than 12 mm, allowance shall be made for sinking all boxes into the walls.

8.

LIGHTING INSTALLATIONS 8.1 High Bay Lighting and General Lighting High bay fittings shall be suspended from the roof structure. Additionally, a safety chain shall be fitted, attached at independent points. Each fitting shall be equipped with a length of 3 core, 1.5 sq mm, 85C rated, BS 6500 (IEC 227, IEC 245, or Vietnamese equivalent) flexible cord, terminated in a fused connector, fused at 13A. Wiring from the supply shall be terminated in a roof-mounted junction box, fitted with the female part of the connector.

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All sodium high-pressure discharge light fittings shall have lamps and integral control gear. All light fitting shall have good colour rendering. All fittings shall have plug and socket for ease of maintenance, except those for external use. All light fittings shall be suitable for the environmental conditions where they are installed. Fluorescent light fittings shall be compatible with T8 krypton filled triphosphor lamps of 26 mm (or 38 mm for higher wattage) diameter. For the ease of maintenance the different range of wattage of lamps shall be kept to minimum. The use of tungsten filament lamps shall be strongly discouraged because of high cost of replacement and low lamp life. All emergency lighting fitting shall be self-contained with local test key-switch. The lighting level from the emergency lighting system shall be 1 lux on average, however, where there is light risk in any industrial hazard areas like tin baths, rotating machinery, conveyors, acid baths and the lighting level shall be 10% of the normal lighting levels or 15 lux which ever is the higher. 8.2 Wiring The minimum size of conductor used in any part of a lighting installation shall be: 1.5 mm for fixed wiring 0.75 mm for flexible cords A factor of 1.25 shall normally be applied to the rating of distribution cables. Fluorescent tube circuits produce a certain amount of harmonic distortion, which increases the neutral current in a 3 phase 4-wire system. Where the fluorescent lighting forms a large part of the electrical load, a full size neutral conductor shall be used and the main 4 core distribution cable derated 17%. For all lighting final sub-circuits, a separate neutral conductor shall be used for each phase. At the lighting distribution board, numbered cable ferrules or markers shall be fitted to the outgoing phase and neutral cables to enable each single phase circuit to be readily identified. Where lighting fittings are installed on lighting trunking, a 1.5 mm earth continuity conductor shall be used per run of lighting-trunking and shall be terminated at a suitable earth terminal in the lighting distribution board. Where fixed wiring cables or flexible cords, other than those designed for high temperature operation, are brought into a fluorescent lighting fitting, suitable heat resisting sleeving shall be fitted in the vicinity of the ballasts and control gear.

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For Tungsten and high pressure discharge lighting fittings not provided with a cool wiring terminal box, fixed wiring shall be terminated at a conduit box adjacent to the fitting, and final connections to the lighting fitting shall be made with flexible cords insulated with glass fibre. Any terminal block used shall be of a porcelain construction. 8.3 Fixings Surface or pendant mounted tungsten or high pressure discharge lighting fittings shall have one suspension point. Tubular fluorescent luminaries over 1200 mm in length shall have two suspension points. Conduit pendants shall not exceed 1800 mm in length, and shall be suspended from ball socket fittings. Rod suspensions for individual lighting fittings shall be 6 mm diameter rod minimum, and not exceed 3m in length. Hook and eye couplings shall be used at the top of a rod suspension. Die cast hooks and eyes are not permitted. Rod suspensions for lighting trunking shall be similar to those described in the above paragraph, but shall be 8 mm diameter rod minimum, and the fixing centres shall not exceed 4 metres apart. The actual spacing depends on the suspended load and shall be such as to keep sag to less than 3 mm. Surface mounted fittings shall be installed either on lighting trunking, using the appropriate suspension bushes or on surface or flush mounted conduit boxes using two brass screws per box. Wall mounted fittings shall be fixed direct to the wall surface, i.e. not on surface conduit boxes or lighting trunking. Unless a recessed conduit box is available for fixing, screws or Hilti bolts of suitable length shall be used. Chain shall not be used for suspending or fixing any part of a lighting installation. 8.4 Switching Unless otherwise specified, all lighting switches shall be rated at 15 amps, and shall not carry a running current exceeding half their rating. Where single pole switches are specified, these shall be connected in the phase conductor of the supply. Where 3 phase switches are specified, these shall be clearly marked 380 volts. Under no circumstances shall more than one phase of the supply be taken into a switchbox unless it is either a 3 phase switch, or a switch of the barrier box type. Flameproof lighting installations shall be controlled by double pole switches. Contactors controlling lighting installations shall not carry a running current exceeding half their normal rating. The contactors shall be fitted with AC coils operating at the single-phase voltage, and arranged for 2-wire remote control. Where contractors are installed in the incoming supply to a distribution board, they shall be fitted with an internal HRC fuse for the control circuit.

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9.

SOCKET OUTLETS 380V general purpose socket outlets shall be 63 Amp, 3 phase, neutral, and earth, RCD protected, in metal or plastic boxes, to BS.4343 / IEC 309 / EN 60309-2, or Vietnamese equivalent, IP.44 minimum. 220V single-phase socket outlets in offices etc. shall be 15 amp, 2 pole and earth, to BS.4343 / IEC 309 / EN 60309-2, or Vietnamese equivalent standards. Portable tool socket outlets shall be 16 amp, 2-pole and earth, switched, to IEC309 / EN 60309-2, or Vietnamese equivalent industrial type, with 30 mA RCD protection at the distribution board.

10.

EARTHING 10.1 Protective Earth Protective earth systems shall comply with the IEE Wiring Regulations, Chapter 54 and with BS Code of Practice CP.1013. All circuits shall include an earth continuity conductor colour green/yellow, except that for extra low voltage circuits special arrangements may apply, such as screening. All metalwork (other than current carrying parts) associated with the installation shall be earthed by means of an earth continuity conductor. Copper earth continuity conductors shall, unless otherwise specified, be tinned at joints and connection points and the size shall be chosen in accordance with IEE Wiring Regulation 543-1. Earthing tapes shall be fixed by means of bronze spacer bar cleats. The armour and lead sheaths on single core AC cables and on other cables as specified in Section 4.7 shall be earthed at one end only. On all other cables the armour and lead sheath shall be earthed at both ends. Armour shall be earthed by clamping it in a suitable armour clamping gland bonded to the metalwork of the apparatus. Lead sheaths shall be earthed by plumbing to a cable gland or by gripping in a lead or lead alloy cone bonded to the metalwork of the apparatus. When an insulated gland or insulation material gland plate is used the cable gland shall be bonded to the metalwork. When single ended earthing is specified and a gland plate of insulation material is not included, an insulated gland shall be used at the unearthed end, or, the PVC sheath containing the armour shall be passed through and clamped in the gland with the armour cut back and taped so that no rough ends protrude.

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Metal conduit and ducting shall be bonded throughout its length and (unless earthing at one end only is specified) shall be bonded to the metalwork of the apparatus or to the installation earth at each end. Cable trays shall be bonded to the installation earth at each end. Earth couplings shall be fitted to adaptable boxes and between conduit and trunking. In corrosive situations, separate earth continuity conductors shall be PVC sheathed unless otherwise specified. All joints, connections and terminations in conduit, trunking, etc, shall be such as to ensure effective earth continuity and shall be adequately protected against corrosion. Joints in trunking shall be thoroughly cleaned before making off in order to ensure good metal to metal contact. Where conduit runs across expansion joints, suitable earth bonds shall be fitted. Where flexible metal conduit is used, a separate earth continuity conductor is required. The minimum size shall be 2.5 mm and the conductor shall be bonded to the adapter or apparatus at each end. Earthing for EMC compliance shall be by the use of flat braided cable and shall be in addition to any protective earth installation.

11.

DISTRIBUTION BOARDS 11.1 General The switchboard shall be a sheet metal enclosure fitted with lockable doors. The doors shall be dust sealed by neoprene gaskets and ventilation openings (if used) shall be gauze screened to prevent dust and insect entry. External identification label, engraved with 10 mm black characters on white background, affixed with screws. All conduits and ducts as applicable shall be securely attached to the switchboard(s). Provide pre-punched conduit knockouts or removable gland plate. All distribution boards shall have 25 to 30% spare capacity for future use. Spare ways of circuit breaker boards shall have at least one breaker of each different size in place and marked spare plus remaining unused ways as blanks Where space is provided for future breakers, fuses, etc., the switchboard(s) shall be fitted with necessary busbars and connections to facilitate the future fitting of additional equipment without disturbance to the existing installation. Where this involves provision of unused lengths of busbar, this busbar shall be adequately supported. The escutcheon (if any) shall be cut for the future equipment and suitable filler pieces provided.

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Equipment shall be symmetrically and neatly mounted, firmly supported and all wiring shall be neatly run and supported. Connections between various pieces of equipment shall be copper busbar or insulated cable. Where cables terminate under heads of screws and nuts suitable cable lugs shall be used. All incoming/outgoing cables shall be terminated using cable lugs or tunnel type terminals. The colour of distribution boards shall be ascertained from the Pilkington Electrical Engineer. Wall mounted switchboard(s) shall be mounted approximately 2m from top of board to floor. 11.2 Circuit Breaker and Isolator All circuit breakers shall be fitted with thermal and instantaneous overload protection on all phases. The incoming supply shall be controlled by a defeatable isolator which shall be capable of operating on load to the rating of the busbar. The frame size of the circuit breakers shall be such that three (3) single phase breakers shall be capable of being used in the same space as three phase breaker.

11.3

Busbars Busbars shall be copper and mounted on a chassis so that circuit breakers may be clipped on to the chassis and connected directly to bus tabs.

11.4

Neutral and Earthing Links Separate neutral and earthing links of adequate rating. Each link shall be provided with a number of connection points equal to the total number of switchboard single pole positions plus 30%. The neutral link shall not be earthed.

11.5

Load Balancing In every switchboard the load shall be balanced as evenly as possible across all three (3) phases.

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11.6

Circuit Identification On every switchboard each switch, fuse, circuit breaker or other device shall have an engraved multi-layer durable laminate label fixed on or adjacent thereto as appropriate. The fuses or circuit breakers shall be numbered and a neatly typed circuit list giving number, rating and circuit function shall be mounted in the card index holder in the cubicle door for each board. The circuit index shall be provided with a clear perspex cover. Numbering shall be as per drawings, but fixed details may be updated during execution of the electrical work.

12.

ISOLATORS Isolators supplied by the Contractor shall be fitted with a label engraved in 10 mm, red characters on a yellow background and affixed by screws. Legends shall be as shown on the drawings or agreed with the Pilkington Electrical Engineer.

13.

SUPPORTS AND FIXINGS All equipment brackets, clips and the like to be fastened to poured concrete structures shall be secured with concrete anchors of a size which shall adequately support the components. Timber shall not be used to mount or fasten equipment unless the timber forms part of the building structure. All screws, bolts and other hardware shall be galvanised or cadmium plated. Cold galvanising compound shall be painted on newly cut ferrous metal surfaces. No cutting or drilling of pre-stressed or steel beams, columns or structural members shall be permitted, without the approval of the Pilkington Electrical Engineer.

14.

MISCELLANEOUS LABELLING All junction boxes, self-contained starters and similar items of equipment supplied by the Contractor shall be fitted with a label, engraved in 6 mm black characters on a white background and affixed by screws. Legends shall be as shown on the drawings or agreed with the Pilkington Electrical Engineer.

15.

QUALIFICATIONS The work shall be performed and supervised by fully qualified and certified craftsmen to the satisfaction of the Pilkington Electrical Engineer. Certification shall be available for inspection by the Pilkington Electrical Engineer at any time.

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16.

MATERIALS All materials used by the Contractor necessary to carry out the installation shall conform to relevant Vietnamese standards and regulations. All materials shall be new.

17.

FAULTY WORKMANSHIP AND MATERIALS Should the presence of faulty workmanship or materials associated with installation be disclosed, then the Contractor shall arrange to have the parts concerned replaced at the Contractors expense, to the approval of the Engineer. Should the presence of faulty materials be disclosed and if the size of the part or parts affected warrant that testing of the materials shall be carried out, and/or the Engineer so directs, then the Contractor shall arrange to provide the part or samples representative of the part or parts affected. Dimensions of samples, method of testing and adequacy of results shall be in accordance with the relevant standard for the material. The whole of such testing, including the selection of test samples shall be carried out by the Contractor or other authorised person under the supervision of the Engineer. Should the results of such tests show that part or parts of the work do not satisfy the requirements of this Specification, then the Contractor shall replace such parts. The Contractor shall bear the costs of all sampling, testing and replacement.

18.

TESTS The Contractor shall make all tests, as required by the regulations on all equipment, cabling and systems covered by this specification and scope at any time as requested by the Pilkington Electrical Engineer. The Contractor shall supply all meters, instruments, materials and personnel required to carry out these tests. If any failure of any part of the system occurs during testing, the contractor shall take immediate steps to correct the fault at his own expense, except for failure of any pre-purchased equipment due to manufacturing defects. The work shall not be considered complete until the system has successfully passed all tests. Extreme care shall be exercised to ensure that all semi-conductor devices such as rectifiers and transistors will not be damaged to over-voltage originating from tests. The Contractor shall programme with and carry out all tests in the presence of the Pilkington Electrical Engineer. On completion, the Contractor shall supply in duplicate to the Pilkington Electrical Engineer, test/ completion certificates.

19.

FINISHING, PAINTING AND CLEANING The Contractor shall refinish all metal cut, or any finish damaged on the work Site. All enclosed equipment such as panels and switchgear boxes shall be vacuum cleaned by the Contractor, prior to acceptance of the work.

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APPENDIX A MINIMUM CABLE SEGREGATION ARRANGEMENTS

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Figure 1 - Separation along Cable Runs Signal cables 800mm

Medium power cables 400mm

High power cables

Figure 2 - Separation at Cubicle Entry

CUBICLE

200mm Power cables Signal cables

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