Project Title
ESNAAD Main Gate Complex
Document Title
Method Statement for Cable Pulling & Termination of MV Cables
Revision and Approval History Re v. No. Date Descripti on / Remarks CONTRACTOR EMPLOYER Approva l Status Prepar ed Reviewe d Approve d Approved
1.0 PURPOSE 2.0 SCOPE 3.0 REFERENCES 4.0 DEFINITIONS 5.0 RESPONSIBILITIES 6.0 EQUIPMENT
7.0 HEALTH AND SAFETY ARRANGEMENTS 8.0 PROCEDURE
8.3 CABLE TERMINATION & INSTALLATION 8.4 TESTING & COMMISSIONING
1.0 PURPOSE
This method statement is applicable for laying & termination of MV Cables for ESNAAD MAIN GATE TRUCK X-RAY COMPLEX in accordance with the specified standards and regulations in project specifications.
2.0 SCOPE
The Scope of works includes the delivery to site, installation, pre-commissioning, testing, commissioning and guarantee of the system as described in the specification/contract documents and drawings.
3.0 REFERENCES
3.1 Project Contract Specifications
3.2 Approved Project Quality Plan: EMG-PQP-01 Rev.01 3.3 Approved Project HSE Plan: EMG-HSE-01 Rev.00 3.4 ESNAAD HSE Procedures
3.5 Approved AFC Drawings 3.6 Approved Materials 4.0 DEFINITIONS
Employer/ Client : ATS Group/Advanced Integrated Systems(ATS/AIS)
Customer : CICPA
Operating Company
Contractor/Contractor :: ESNAADAegis Contracting L.L.C. (Aegis).
Subcontractor/Sub-tiers : Organization employed by Contractor forexecuting part of the works
Supplier : Organization used by Contractor and /or
subcontractors for supply of approved Materials.
HSE : Health, Safety and Environment 5.0 RESPONSIBILITIES
5.1 The Project Manager is over all responsible for implementation of this Method Statement and to ensure that his site team of
Engineers and Foremen are aware of this Method Statement and all resources, manpower, material and equipment are available to carry out the work as planned and without any delay.
5.2 The Construction Manager/Site Engineer will co-ordinate with the MEP Sub contractors and the Safety Officer, Foreman for a safe and proper execution of works.
5.3 The Site Supervisor/General Foreman along with Foreman will ensure that, the installation is carried out according to the Specifications/Drawings and the Method Statement.
5.4 Lead QA/QC Engineer, in close interaction with MEP Site personnel, will ensure that, the works are carried out as per the project
requirements. He is also responsible for the implementation of QA/QC related to works as detailed in this procedure and for completing Quality Documents for the Installation works. 5.5 Lead Safety Engineer will ensure implementation of all safety
procedures, Safety measures related to the nature of works being carried out in accordance with Project HSE Plan “ EMG-HSE-01 Rev.00
6.0 EQUIPMENT
Cable Rollers Cable Pulling Grip Hand Cable cutter Manual Cable Crimpers Hacksaw blade
Power Tools Tool Box
Measuring Tape
Ladders / Scaffoldings/Platform Hand tools Hilti Drill Machine
Hilti Concrete Bit (6mm to 16 mm) Anchor Bolt/Screw Screw Driver Adjustable Spanner Hammer Electrician’s Knife Multi Meter 1 KV / 5 KV IR Test Kit Continuity Tester Torque wrench VLF – Test Kit
7.0 HEALTH AND SAFETY ARRANGEMENTS
The hazards associated with the Cable Pulling & Termination of MV Cables have documented (Ref: Job Hazard analysis Doc. No.
HSE/RA/__. Control measures as identified in the documents will be complied with the approved Project HSE Plan.
8.0 PROCEDURE 8.1 Preparation
8.1.1 Excavation
Permit to Work (PTW) shall be raised for the excavation clearly mentioning the location of work, size of excavation and levels. Excavations area shall be surveyed and marked to the lines and
levels as shown on the drawings.
The area of excavation will be cordoned off using safety devices. Ensure the working area at any confined space is free from any
Hazardous Gas by proper Gas testing using the Gas testing instrument.
8.1.2 Materials
Not necessary for the construction shall be removed carefully and stored neatly for reinstating after the construction works.
The material received from the client shall be stored in designated area of store.
Arrangements shall be made to protect against effects of weather and environment.
8.2 Cable Pulling
Insulation resistance of the cables shall be checked before laying cables.
After the test, the end of the cable shall be sealed to prevent the ingress of moisture.
Location of the panels / equipment shall be identified.
Cables shall be lubricated if bends in conduits are encountered in a run to facilitate drawing in.
Cables must not be bent to a radius of less than 12 times the overall diameter of the cable.
Rollers must be used where cables are installed in an open trench using a pulling rope and eye; cable rollers are to be used at frequent intervals to support the cables and must never be more than 3 meters apart.
The rollers are to be placed securely to prevent movement. The pulling rope must be equipped with a swivel and be
attached to the cable by a stocking grip with pulling eye.
The cable drum intended for cable pulling shall be identified as per that indicated in the drum schedule.
The cable drums shall be un-packed and placed on a cable roller, as required.
Cable laying will generally start from one end of the route length or at any suitable point, as necessary.
Depending on the weight and size of the drum, suitable size of the cable rolling shaft (Spindle) shall be placed inside the central axis of the drum.
Suitable jacks shall be placed firmly on the ground and jacked-up to allow clearance from the ground depending on the size of the cable drum.
The drum shall be lifted by required equipment and placed on the jacks.
The cable drum will be correctly positioned and the direction of cable pulling as indicated by arrow on the drum shall be complied.
The cable shall be drawn into the trench smoothly with a minimum of stops and at an average speed of between 9-12 meters per minute, to avoid irregular movement.
8.3 Cable Termination & Installation
Termination point inside the panels / equipment shall be considered for suitable spare length to be left available during pulling of cable termination.
After cutting the cable to the required length the termination work will be conducted as per ADDC Standard.
Jointing and Termination will be carried out as per ADDC standards. All jointing and termination work will be carried out by trained technicians, experienced in such work for the operating voltage concerned.
Proper crimping tools shall be used compression type lugs. All cables are to be terminated used glands of proper type and size as per area classification.
The gland shall be assembled strictly in accordance with manufacturer’s instruction, particular attention being paid to ensure good mechanical and electrical contact between parts without excessive strain or distortion of cable.
The entire body of the cable must enter the gland. The cable shall be on a straight axis from a point at least six diameter before entering the gland. Seals shall be checked for correct size at the point of application.
Unused cable entries shall be closed with plug suitable for the degree of protection classification.
After completion of indoor and outdoor termination the cable is ready for Testing.
8.4 Testing & Commissioning
The following calibrated testing instruments will be used: 1 KV / 5 KV IR Test Kit - 1 no.
Multi Meter - 1 no. Continuity Tester - 1 no. Continuity Tester - 1 no. Torque wrench - 1 no. VLF - Test Kit
Before starting the test, the corresponding Circuit Breakers at both ends of the cables are racked out and earthed properly. Test will be conducted at the MV panel end. The opposite end of
the cable termination will be secured & protected. Testing engineer will be at the end where high voltage is applied and another Engineer to monitor at the opposite end of the cable. Insulation Resistance will be done first: (a) between termination
lugs; (b) Phase, Neutral and Earth termination lug; (c) conductor to termination lug. This will be done one minute each at 5kV, and the results are noted as per approved test report format.
Note: The cables and conductors must discharged per test.
The continuity test and phase sequence tests would be carried out and results would be recorded for records and future reference.
9.0 DOCUMENTATION
9.1 Request of Inspections will be issued for all hold and witness points as indicated on the Quality Control Plans
9.2 QC Forms will be jointly completed and signed off at the end of Inspection.
9.3 Attachment:
Quality Checklist - Cable Pulling & Termination of MV Cables Inspection
