POWERTECH ENGINEERING LLC

Construction Quality Procedure (QPR) for Cable Laying & Terminations - HV&LV
TABLE OF CONTENTS

Document Reference STST/QPR/PTECH/02 Rev. No Date 1 21.01.11

Sl. No 1.0 2.0 3.0 4.0 5.0 6.0 6.1 6.2 6.3 6.4 6.5 6.0 Purpose Scope Document Reference Responsibility Tools & Tackles Procedure

Description

Page 2 2 2 2 2 2 2 2-3 3-4 4 4-5 5

Approval of Documents and Inspection Personnel Preparation

Cable Laying

Cable Terminations Inspection Verification Documents / Records

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POWERTECH ENGINEERING LLC

Construction Quality Procedure (QPR) for Cable Laying & Terminations - HV&LV
1.0 PURPOSE

Document Reference STST/QPR/PTECH/02 Rev. No Date 1 21.01.11

The purpose of this procedure is to describe the method of installation of HV & LV cable laying and terminations. 2.0 SCOPE This procedure shall be applicable for installation of HV/LV cables and Terminations that are to be carried out under the Contract No: C31-1161 Engineering and Maintenance Contract - PDO North Oman at the sites of Fahud, Yibal, Lekhwair, Qarn Alam and Mina Al Fahal areas. 3.0 DOCUMENT REFERENCE 1. SP-1099 2. SP-1100 3. DEP-33.64.10.10 4. DEP-63.10.08.11 4.0 RESPONSIBLITY Electrical Engineer/supervisor is responsible for implementing this Procedure at work sites and QC inspector shall monitor compliance to the requirements. HSE Advisor shall monitor the HSE performance during execution of activities at site in compliance with the requirements stated in the approved HSE Plan and ensure that all works are carried out safely. 5.0 TOOLS & TACKLES 6.0 6.1 Vehicle mounted Crane Lifting Belts & D Shackles with appropriate colour code Trailer Hiab Truck Cable Drum Jack and Spindle Cable Rollers Tool Box with complete set of Tools Testing Equipment Electrical installation practice. Specification for Testing & Commissioning of Electrical Equipment Electrical Engineering Guidelines Field Commissioning & Maintenance of Electrical Installations & Equipment.

Procedure Approval of Documents and Inspection Personnel Prior to the start of activity at site, it shall be ensured that all relevant documents viz. Construction Quality Procedures, Inspection & Test Plans, Method Statement etc. as applicable are approved and Controlled copies available at site. The Inspection Personnel deployed at site should have sufficient knowledge and experience as per the Contract requirement and shall be ensured that they are approved by the Main Contractor / Client prior to deploy to the work site.

6.2

Preparation The cable drums shall be identified and transported to site with trailer or Hiab.

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Construction Quality Procedure (QPR) for Cable Laying & Terminations - HV&LV
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Document Reference STST/QPR/PTECH/02 Rev. No Date 1 21.01.11

Upon receipt of Cables, Glands, Joint kits and other materials at site, thorough inspection shall be carried out for any mechanical damage, type and size of cables. Material certificates shall be verified and accepted. All materials shall be stored under safe custody at appropriate locations where unauthorized entry of personnel restricted. Ensure that all cables ends are sealed to avoid entry of moisture Continuity and Insulation resistance shall be checked using equipment having valid calibration upon receipt of all Cables at site for the initial acceptance. The cable route shall be confirmed / verified with cable layout drawings and cable schedules as applicable. The details of the cable shall be verified against size, type and length with cable schedule.

6.3 Cable Laying Inspect the cable trench, trays for laying of cables as per approved drawing and Specifications. The cable drums shall be properly supported on suitable jacks in such a way that the cable leaves the drums from the top portion of the drum. Suitable cable rollers shall be located at regular intervals and at bends to prevent dragging of cables along the ground. Larger diameter of cables shall be laid with the assistance of a winch with the concurrence of the Client Representative. Cable trenches shall be checked for sand bedding, sizes against approved drawings and specification. Sufficient manpower shall be ensured for the laying of cables properly and to the satisfaction of the Customer. Sufficient spare length of cables for re termination shall be ensured while laying of HV, LV and control cables. Minimum 10M at either side shall be ensured while laying of HV cables. The single core cables shall be laid in trefoil formation. Cable running above the ground shall be secured with clamps / suitable cable ties as applicable. Clamping system for single core cables shall be ensured that all are non-magnetic materials. Physical separation of not less than 300mm shall be provided between HV and LV cables. Sufficient spacing between Cable Racks/Trays/Ladders/Structures/Walls & Columns shall be provided as per AFC drawings. Minimum 50mm shall be maintained. Underground cables shall avoid close proximity to pipe crossing and parallel pipe runs Cables bending radius shall be as per Manufacturers recommendations Single core HV cables shall be laid in Trefoil formation and secured with Non Magnetic clamps After laying of cables in trenches/trays/ladders, proper dressing of cables shall be carried out to avoid crossing of cables and easy identification etc.

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POWERTECH ENGINEERING LLC

Construction Quality Procedure (QPR) for Cable Laying & Terminations - HV&LV
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Document Reference STST/QPR/PTECH/02 Rev. No Date 1 21.01.11

All cable trays and trunkings shall be inspected and approved. Suitable supports and brackets shall be ensured. It shall be ensured that the cables in trunkings shall occupy not more than 45% of the available space. Cable numbering to be provided in distance of every 5mtr in the underground trenches. Sand bedding with clean & dry sand of 100mm below and above of cables shall be ensured for cables laid in UG trences. Protective tiles and warning tapes shall be installed as per AFC drawings. Continuity and Insulation Resistance test shall be carried out for all UG cables prior to the backfilling of cable trenches. Selected and approved backfill materials shall be used. Entire trench shall be rammed properly after backfilling and Cable route markers installed. After completion of cable laying, Client Representative shall be called for inspection before backfilling. Cable entries to building / built-up trenches shall be sealed with appropriate fire resistance materials. Multi Cable Transits shall be provided when cable enter hazardous area. Physical separation between HV, LV, Telecom and Instrument Cables laid in the same trench shall be in accordance with Standard Electrical Drawings.

6.4 Cable Termination Before termination of cable, continuity and insulation resistance shall be checked for cable core confirmation and healthiness. Qualified and experienced personnel shall only be employed for the cable termination works. Prior to termination of the cable, confirm that the equipment terminal where the cable is to be terminated is made dead and no damage, coatings which will act as insulator. Control cables are terminated with approved termination chart and cable identification provided. The cable termination shall normally be of the crimped type using compression type cable lugs. Proper dies and tools shall be used for crimping. Termination of the HV cables shall be carried out by PDO certified cable jointers using approved / suitable termination kits. Ensure that the armour of the cable is rigidly clamped inside the gland and the electrical continuity is established between armour of the cable and the earthing system through the gland body. Ensure that the gland plates for single core cable shall be of non-magnetic material and the armour is earthed only at one end of the cable. An adequate length of cable tail shall be left to allow remaking and termination of each core for all control, power cables. Cable identification, Phasing and core identification check shall be carried out before completing termination for HV, LV power cables. After completion of HV, LV power cable terminations pre-commissioning test to be carried out in presence of PDO representative Page 4 of 5

POWERTECH ENGINEERING LLC

Construction Quality Procedure (QPR) for Cable Laying & Terminations - HV&LV
6.5 Inspection

Document Reference STST/QPR/PTECH/02 Rev. No Date 1 21.01.11

Cables will be inspected for mechanical damage, cleanliness and it will be confirmed that cables are laid as per approved cable schedule, route drawings and project requirements. Cables will be checked and confirmed that they are supported with suitable support system and method as per approved drawings. Cables will be inspected for proper identification provided every 5mtr and marked as per layout drawings and segregated HV, LV and control cables. Inspection will be done for the spacing between HV, LV and control cables Checking will be done to confirm that terminal lugs are used for connection suitable for cables and connecting to equipment. Cable lugs are crimped and compressed well to make good contact and avoiding loose connection and arcing. Check on HV cable end termination, jointing shall use approved heat shrink or cold shrink termination kit. Check Armour earthing is done both side for multicore cables and one side for single core cables. Check and confirm that the used cable glands are all of approved type, make and suitable to designated zone areas. Check all heat tracing cable ends shall be sealed under all circumstances to prevent moisture ingress. Test Continuity of all cores using a calibrated Multimeter and Insulation resistance values for all cables using a calibrated Megger and record the values in respective forms. Acceptance value of Insulation Resistance of all cables shall be 10xkV/Length in KM mega Ohms. Check the earth loop continuity for all protective conductors, metal sheath, cable armour, cable trays, trunkings etc. Test and record high voltage test results for HV cable using a calibrated HV Test kit. The acceptance value of leakage current shall be less than 100mA/KM. Cables shall be energized only after completing all tests and Test Reports signed of by the representatives of main Contractor and Client.

7.0

Verification Documents / Records

Form No. 3 Form No. 4

Construction Test sheet for Electrical cables (HV & LV) Construction Test sheet for Cable installation Below ground

Form No. 4A Construction Test sheet for HV Cable terminations Form No. 5 Construction Test sheet for Cable installation Above ground

Form No. 33 Functional test sheet for HV cable Pressure test

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