Internal Power & Data Infrastructure Upgrade
Pick Shuttle Switch and PDP Electrical Connections
The Challenge
The client required the installation of new power distribution supplies to multiple panels, including the provision of local isolation and associated containment infrastructure. The works formed part of a wider system integration for automated equipment.
The scope involved cabling between distribution panels and field isolators, alongside the construction of suitable mounting frameworks to support the installation.
Key challenges included:
- System Integration: All new supplies needed to integrate with existing switchgear and panel boards without impacting ongoing operations.
- High Load Requirements: Large current ratings (up to 400A) required careful cable selection, routing, and termination methods.
- Compliance: All works were required to be carried out in accordance with current wiring regulations, ensuring full compliance and safety.
Our Solution
A structured and phased approach was implemented focusing on safety, reliability, and long-term performance for the installation of multiple high-capacity supplies.
Our approach:
- Installation of multiple new power supplies to distribution panels
- Provision of local isolators for safe and accessible power control
- High-quality cabling designed for heavy-duty industrial use
- Construction of a robust support framework for all electrical infrastructure
- Full testing and certification upon completion
The Technical Plan:
Power Supplies: Installation of three separate panel distribution supplies (PDP01, PDP02, PDP03), each with dedicated cabling and protection.
Cabling Infrastructure: Use of LSZH SWA cabling with appropriately sized CPC conductors to meet load and safety requirements.
Local Isolation: Installation of high-capacity, four-pole switched fused isolators to provide safe and accessible means of isolation.
Containment & Framework: Fabrication and installation of a Unistrut support framework, incorporating cable ladder and trunking systems.
Final Connections: Use of tri-rated, double insulated singles for final terminations between isolators and panel incomers.
Technical Execution
The installation works were carried out in accordance with BS7671, ensuring all aspects met current electrical standards.
For PDP01, a 250A supply was installed using 4-core 95mm LSZH SWA cabling with a 50mm CPC, feeding a 250A four-pole switched fused isolator. Final connections to the panel were completed using 120mm H07 LSZH cabling.
For PDP02, a higher capacity dual-feed arrangement was implemented, consisting of two parallel 4-core 120mm LSZH SWA cables with a 240mm CPC. A dual connection kit was utilised, with termination via a 250A four-pole isolator.
For PDP03, a 400A supply was installed using three runs of 4-core 120mm LSZH SWA with a 120mm CPC. The installation included twin 400A busbar chambers, with 185mm H07 LSZH cabling used for connections between the busbar system, isolator, and breaker.
A bespoke Unistrut framework was constructed to support isolators, cable ladder, and trunking systems, ensuring a secure and organised installation. All cabling was installed, dressed, and terminated to a high standard.
Following installation, all circuits were fully inspected, tested, and certified, with documentation provided for each supply to the panel system.
The Results
The project was successfully delivered, providing the client with a reliable and scalable power distribution system, designed to support critical operations.
Reliable Power Distribution: High-capacity supplies were installed to ensure consistent performance and support for demanding industrial loads.
Safe Isolation: Strategically positioned isolators provide clear and safe points of control for maintenance and emergencies.
Structured Installation: The use of bespoke framework and containment systems ensures long-term durability and organisation, and has been designed with capacity for future expansion.
Certified Compliance: Full testing and certification provide assurance that all works meet current regulatory standards.
