Lessons Learnt Part 2

Feb 2016Panel Design Issues

Introduction• Last year we went through a hard and tough

panel- one of the largest built• To make matters worse the panel build was

accelerated, we decided to use a new untested panel build method

• To make matters even worse the panel field cabling was rigid, thick cables and loads of it.....

• The following are the lessons learnt from this experience – with more

Bottom or top Entry of PanelMore time to be spent on analysis by Design

department, together with commissioning and installation to determine if top or bottom entry is to be used.

This issue is to be studied in greater detail - And all options properly weighted and assessed involving all persons

Bottom entry panels - positioning of panel on siteThe positioned panel did not have enough space behind

to pass the cables comfortablyWhen designing the location of panel consider the space

required and the canalisation down drops required

Panel SizingPanel was too small for what was put into it.Proper sizing to be looked into before ordering of

panel. Size of panel should be calculated in the quotation phase. An estimate panel size can be made, after a parts list is made.

Panel terminationsNo space for laying of cable inside the panel.Space should be left between the top/bottom of

the panel and terminal blocks to allow adequate space for cable dressing.

No ventilation or fans installed.To create two big air ventilation holes and prepare

holes for a fan to be fitted - ALWAYS. If heat generating equipment (eg VSDS) is to be

installed in the panel - then a fan should be fitted. Panel cables are not labelledFault finding will involve removing several cables within

the trunking- this is time consumingLabel with adequate toolsInadequate label toolsLabels fall off, only a few days after fittedLabel with adequate tools

Size of panel trunking not suitable for amount of cables install

From design stage to panel installation stage additions were implemented and different types of cables were pulled.

Every one needs to be made aware of any changes from the original design and someone will need to be responsible to follow up on the effects that these changes will cause

Motor CBs under ratedDuring testing - it resulted that motor CBs were under rated as

motors were changed from original specifications.Every one needs to be made aware of any changes from the

original design and some one will need to be responsible to follow up on the effects that these changes will cause.

Space between panel devices (Terminal block rail) and cable entry

More space needed between the first row of devices in the panel and the cable entry point (either top or bottom)

At design stage more required space for cable entry needs to be taken in consideration

Socket outlet in panelSocket outlet installed too far from UPSDesign needs to be made aware of the site needs. In this

case the main purpose of this socket outlet is to be used to bypass the UPS in case the UPS goes faulty, so it needs to be installed closer to the UPS.

HMI openingHMI did not fit in the openingAt panel build stage, on fitting such devices one needs

to check that the device actually fits in the opening.

Panel drawing hard copyOne hard copy of panel drawing was supplied at time

we had to wait after each other to use it For large panels at least two hard copies of the panel

drawings need to be supplied subject to that all site updates will be updated on the same one copy