METHOD STATEMENT FOR MV CABLE PULLING AND INSTALLATION

METHOD STATEMENT FOR MV Cable  Pulling  and  Installation

• TABLE OF CONTENTS

1. SCOPE

2. definitions

3. HEALTH  AND  SAFETY

4. OPERATION

5. installation  and  fIXATION

6. RESPONSIBILITIES

7. MANPOWER  REQUIRED

8. MATERIALS  REQUIREMENTS

9. EQUIPMENTs  REQUIREMENTs

10. WASTE MANAGEMENT

11. SPECIAL CONTROL MEASURES

12. SUPPORTING  DOCUMENTATION

13. DISTRIBUTION

1.SCOPE

• This procedure to clear the method of the supply, Installations and Pulling of MV Cable .
• This document details Installation and Pulling of MV Cable :
• Preparation of work.
• Delivery and inspection upon arrival of material at site.
• Installation of the system.

2. definitions

           PQP             : Project Quality Plan

PSP              : Project Safety Plan

QCP             : Quality Control Procedure

HSE             : Health, Safety and Environment

MS               : Method Statement

ITP               : Inspection Test Plan

QA/QC         : Quality Assurance / Quality Control Engineer.

WIR              : Inspection and Test Request

MIR              : Material Verification Record.

3. HEALTH  AND  SAFETY

• Strictly followed as per the manufacturer’s Health and Safety recommendations for handling and use of the materials.
• Ensure all involved personnel shall be aware of the same.
• Specific safety measures have to follow as applicable, and all the safety measures are covered separately in the project safety plan.

4. OPERATION

• Material:
• Material used will be as approved by the Engineer.
• The sizes and routes routing will be as per the approved Shop Drawings.
• Storage and Protection: 
• Deliver components parts to site, completely identified in accordance with shop and certified CAD Drawings prepared for this work.
• Store in accordance with the manufacturer’s instructions, above ground, properly protected from the weather and construction activities.

5. INSTALLATION and Fixation

• Pre-Installation:
• All materials and documentation relevant to this particular section of works will be checked and verified ensuring that  these are correct and approved type.
• Prior to the commencement of works, ensure that the areas for permanent installation are ready, accessible and in suitable condition.

• 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.

• 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.

• 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 jackedup 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.

• Termination:
• 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 part 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.

• 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.
• The continuity test and phase sequence tests would be carried out and results would be recorded for records and future reference.

• Technical Assistance:
• The installation supervising technician for the system trade shall instruct the CONSULTANT Engineer, and Construction Site Manager on the programming and correct operation of the system after the installation is completed.
• This instruction shall be scheduled at the convenience of the staff.
• All such instruction shall be properly recorded.
• WIR will be issued for Consultant approval upon making sure that the installation of the system equipment’s done as per approved shopdrawings, approved specs and manufacturer recommendations.

6. RESPONSIBILITIES

Ø  PROJECT MANAGER

1. To ensure that all the preparation and application works are carried out according to the Contract Specification and with the approved drawings.
   1. To ensure that the progressing of works is carried out according to the planned program and as per the approved method of statement.
   1. To ensure that all the equipment and material required executing the work are available according to the planned construction program.
   1. To co-ordinate with the Main contractor, MEP coordinator, Safety Officer for a safe and proper execution of the works.

Ø  SITE ENGINEER

1. To ensure that the works are carried out according to the Contract Specification, approved method statement and the shop drawings.
   1. To provide all necessary information and distribute responsibilities to his construction.
   1. To monitor the progress of work in relation with the work program and to report to the Project Manager.
   1. To co-ordinate with the safety officer and to ensure that the works are carried out in safe practicing method.

Ø  FOREMAN

1. The foreman will carry out his duties by maintaining continuous coordination with the site engineer on daily basis, and ensure proper distribution of the work force on the required and planned locations.
   1. To ensure that his assistant foreman/ charge hand are aware of the job requirements and they have enough information to carry out their duties properly.
   1. To ensure that the daily work is progressing as planned and advice the site engineer of any requirement for additional resources.
   1. To ensure in consultation with the site engineer that the manpower involved in the works are moving as agreed and planned for the work.
   1. To control disposal of waste materials according to the instructions received from the site engineer.
   1. To ensure full coordination with the safety officer to maintain safe working and proper house keeping of the site, following the proved safety measures and further ensure that all his working team are aware of the same to prevent accident and losses.
   1. To inform the site engineer regarding areas ready for inspection.
   1. Foreman and the storekeeper are responsible for the distribution and control of materials.

Ø  SAFETY ENGINEER

1. Ensure the implementation of all the safety measures in accordance with the HSE plan and everybody aware of it for it’s proper implementation.
   1. Ensure all the implemented safety measures are adequate to maintain safe working on the site.
   1. Inspect all the site activities and train the person to prevent accidents and it’s proper implementation.
   1. Ensure that the site is maintained clean and tidy.

Ø  TECHNICIAN FROM SUPPILER

1. The carrying-out of work and the proper distribution of all the available resources in coordination with the sub-contractor Site Engineer on a daily basis.
2. Daily reports of the works are achieved and coordinated for the future planning with the Site Engineer.
3. Complying with the sub-contractor basic design practices, particularly those related to safety and engineering
4. Meeting with any type of unforeseen incident or requirement and reporting the same to the Site Engineer immediately.

Ø  STORE KEEPER

1. Responsible for overall Store operations in making sure to store the material delivery to the site and keep it in suitable area that will keep the material in safe from rusty and damage.
2. One who will acknowledge the receiving of materials at site in coordination with QA/QC and concerned Engineer.

7. MANPOWER  REQUIRED

• Charge hand and Experienced Technicians

8. MATERIALS  REQUIREMENTS

• MV Cable Components and  Accessories.

9. EQUIPMENTs  REQUIREMENTs

• The Equipment  that will be engaged for Installation and Pulling of MV Cable will be as follows:
• 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

10. WASTE MANAGEMENT

• The Rubbish which would be created from our scope of works will be disposed to the designated dumping ground.

11. SPECIAL CONTROL MEASURES

• The following general control measures against Safety, Environment and Quality shall be required for our scope of work and special control measures are not applicable for us :
• Proper PPE must be worn at all time
• Permit to work at height > 2m where applicable
• Lifting operation permit (using crane) where applicable.
• Confined space permit where applicable.
• Approved work method statement and risk assessment will be made available to site.
• All workers doing the work shall be briefed on this method statement and risk assessment.

12. SUPPORTING  DOCUMENTATION

• This method Statement should be read in conjunction with the below referenced documentations:

• ITP for Anti – termite Treatment.
• Insulation Resistance and continuity Test Report.

13. DISTRIBUTION

• Copy of this method statement shall be issued to the following for information/ action/ comments:

1. Project Manager
2. Site Engineer
3. Foremen
4. Safety Engineer
5. Technician From Supplier
6. Store Keeper