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0 PURPOSE The purpose of this procedure is to describe the system of control for all activities and define the sequence of work for installation of HV, MV & LV Cables. This procedure also includes the interface activities, and responsibilities relating to HV, MV & LV Cables Installation & Testing activities, in compliance with project specifications and IFC drawings. 2.0 SCOPE The scope of this procedure covers the activities during the Installation & Testing of HV, MV & LV Cables and related inspection activities 3.0 REFERENCES 3.1 CUSTOMER / COMPANY DOCUMENTS: DEP 33.64.10.10-Gen – Electrical Engineering Guidelines DEP 33.64.10.33-Gen – Electromagnetic Compatibility (EMC) Requirements DEP 63.10.08.11-Gen – Field Commissioning & Maintenance of Electrical Installation & Equipment - Power, Control & Earthing Cables. - Electrical Requirement for Packaged Equipment-Water Injection Cluster. - Electrical Bulk Materials-Water Injection Cluster. - Hazardous Area Equipment and Electrical Bulk Materials. DEP 82.00.10.10 Gen – Project Quality Assurance - Material Identification & Traceability Procedure - Material Receipt Inspection Procedure - Preservation of Project Equipment & Material. 3.2 GALFAR DOCUMENTS: 3.2.1QA/QC Documents: - Project Quality Plan

5.10 QC : Quality Control 4.14 PQP : Project Quality Plan 4.1 PROJECT MANAGER:  Project Manager shall report to the Project Director  Shall be responsible for the execution of the project in line with the contractual requirements.Quality Control Procedure for Material Identification and Traceability 3. 5.7 ITP : Inspection and Test Plan 4.0 ROLES AND RESPONSIBILITIES Following are the roles and responsibilities of personnel involved in this scope of procedure.3 Sub Contractor 4.2 QA/QC MANAGER: .9 QA : Quality Assurance 4.13 NCR : Non Conformance Report 4.2 HSE Document: . 5.Inspection and Test Plan for Electrical Installation.11 RFI : Request for Inspection 4. .2.2 Contractor : 4..0 ABBREVIATIONS 4.1 Company : 4.10 HSE : Health Safety & Environment.Project HSE plan 4.

PLANNING ENGINEER:  Planning Engineer shall report to the Project Manager. He shall maintain the status of documents like revisions. man power.  Shall be responsible for ensuring the Project Quality requirements and shall monitor all the Quality related issues throughout the project. 5.  Shall be responsible for controlling & issuing all the Project related documents throughout the Project.6. He shall be key point to receive and transmit documents from the CONTRACTOR and to the CONTRACTOR. erection.5 CONSTRUCTION MANAGER:  Construction manager shall report to the Project Manager  Shall be responsible for arranging necessary equipment. approvals etc. He shall be responsible for planning the field erection activities including but not limited to the materials. consumables. machinery and manpower. areas for storage. 5.7 CONSTRUCTION ENGINEER: . 5. 5.3 HSE MANAGER:  HSE Manager shall report to the Project Manager  Shall be responsible for ensuring the Project HSE requirements and shall monitor all the HSE related issues throughout the project. preservation and ensuring that the procedure is implemented and complied with all specifications and HSE requirements. 5.4 PROJECT DOCUMENT CONTROLLER:  Document controller shall report to the Project Manager. QAQC Manager shall report to the Project Manager.  Shall be responsible for monitoring the equipment receipt and erection activities in line with the schedule / targets given by the CONTRACTOR’s Project controls department.

5. 5.8 STORE KEEPER:  Shall report to Material controller. quality requirement for the timely . Shall report to the Construction Manager. 5. gaskets.9 QA/QC ENGINEER: .  Stages of inspections and surveillance in accordance with ITP and assurance of quality of work as per specification and Installation procedure. bolts & nuts and other accessories received with equipments. to identify and intimate the CONTRACTOR for the hold.  Shall inspect the incoming equipment and verify the materials received are confirming to the AFC Drawings. work method / instructions.11 ELECTRICAL SUPERVISOR / FORMAN  Shall be report to Electrical Engineer  Aware all procedures. as per the manufacture’s recommendations. monitoring the drawing revisions and modifications if any to meet the progress target set by the Project controls.  Shall be responsible for proper storage and issue of special tools. 5.  Shall ensure the preparation of daily reports.  Shall be responsible for quality control & documentations. He shall interface and coordinate with the CONTRACTOR’S Lead QC Manager to resolve the issues related to quality and shall monitor the Implementation of procedure at site.  Shall coordinate and interface with Contractor’s construction engineer to ensure the work front availability at site. He shall be responsible for arranging the tools & tackles.  Shall report to the QC Manager  Shall be responsible to ensure that works carried out at site are complied with project quality requirements.10 QC INSPECTOR ELECTRICAL:  Shall report to the QC Engineer. issue of drawings for erection. witness and review points as described in the inspection and test plan for Electrical Installation.

8. Manufacturer’s instructions and monitor the job as per the schedule.  Execute all activities as per the contract requirements.  The Supervisor / Foreman shall ensure that the equipment & accessories used are suitable for the job and are in good working condition to complete the electrical work shall be as per good engineering practices. applicable code of practice. 7. 5. the Construction Department shall request the equipment from the Store. slings and other necessary tools and tackles for rigging & material handling operation shall be calibrated & colour coded as per HSE requirement  Hand tools & calibrated all testing Equipments suitable for HV. After receiving the Issued for Construction Drawings. The Store shall issue the Material issue Slip with equipment stated. MV & LV Cables installation and testing. Fork Lifts. safety equipments. lifting belts. proper tools & tackles are ready at the point of use  Shall be responsible for to oversee & monitor the site activities on a continuous basis and ensure all control measures as stated in PTW are implemented.0 DRAWING RECEIPT & ISSUE OF EQUIPMENT The Engineering Department shall issue to construction department the Issued for Construction Drawings provided with Material Traceability List complete with information such as identified profile and description to corresponding material items.completion of the job and explains to the task force for the installation of HV.0 CALIBRATION CONTROL .12 JOB PERFORMER  Shall report to Electrical Supervisor  Ensure all permit to work.0 CONSTRUCTION EQUIPMENTS  Cranes. 6. MV & LV Cables.

1.11-Gen. rain corrosion etc as per material preservation procedure 9.0 QUALITY CONTROL 9. dust.5 Verify the Test certificate of cable is available for reference.4 Verify the quality. 9. 9.1 RECEIVING INSPECTION: 9.1.2. Multimeter.6 Proper protection will be provided against wind. spirit level. Hi-pot Tester. measuring tape etc. 9.1.1 Check and verify the installation Procedure and make sure the proper method of installation is being used as per the approved Method Statement 9.1.1. 9.3 All Material Receiving Inspection to be completed before installation in position and if any discrepancy found. Insulation resistance shall not be less than as per DEP 63. 9. year of manufacturing (if any) and country of origin.08.2.2 INSPECTION PRIOR TO INSTALLATION: 9.1. 9. size.The measuring instruments like Insulation tester.1 Check the availability of “IFC” drawings. item will be entered in the punch list and maintain a record further inform to site Engineer immediately.3 Continuity & Insulation resistance test on drum.2. colour and route of the cables are as per the approved drawing & cable schedule. material identification & traceability and manufacturer’s instruction. 9.10. A12.2 Verify the cable type. Phase sequence meter. vendor manuals and instructions etc.2 All material received shall be stored according to the installation schedule. deployed during installation & inspection activities shall be calibrated periodically once in six months at certified laboratory and the certificates may be submitted for review The certificates are to be made available at site during various stages of inspection. surveying instruments.2 (10 x kV / km) in MΩ .

9.3. 9.1.1.3.6 Follow and adhere to the manufacturer’s permissible pulling force for cable pulling. 9. Three Core Unarmoured – 15 D.3.4 Follow the direction shown in the cable drum for the rotation of cable drum.7 Maintain the minimum bending radius as Single Core Unarmoured – 20 D. 9. Single Core Armoured – 15 D.1.1. 9.3 QUALITY CONTROL CHECKS DURING INSTALLATION 9.3. 9.3.2.1.3.5 Make sure the cable coming from the top of the drum and cable shall not drag on the floor.9 Cable crossing under road shall be through reinforced concrete duct bank.4 Cable roller shall be placed at the span of every 10 meters and angle roller at all turning points where there is a change in direction.8 Each set of single core cables comprising a three phase circuit shall be run close together in trefoil formation.3.1 Under Ground cables 9. .9.2 Check and verify the installation Procedure and make sure the proper method of installation is being used as per the approved Method statement for installation of cables 9.3 Verify actual cable length against the cable schedule. 9.3. 9. 9.1.3. (D – Diameter of Cable).3.1.5 Ensure trained. 132 kV 100 mm & all other cable 75 mm 9.2. well experienced and skilled persons do the cable pulling. Three Core Armoured – 12 D.1. ie.1.4 Verify cable trench & sand bedding as per project specification.1.1 Verify the laying sequence of the cables to avoid crossing and over lapping.3.

3.3. 9.3.3 Cable identification shall be for underground and above ground application.1 All cable joints / termination shall be strictly in accordance with cable manufacturer’s recommendation 9. all entry point to JB and along the route shall not exceed 10 M for under ground cabling.4.1 9.11-Gen.2.4 QUALITY CONTROL CHECK DURING CABLE JOINTING & TERMINATION 9. at each end.3.11 Appendix A 11.2. .2.08. 9.2 before and after installation of every length of cable.3.2.4. 9. The test voltage & timing of Hi-pot test shall be as per DEP 63. Cable shall also be numbered where they branch off from main route.10.4 Witness & verify continuity & insulation resistance test are carried out as acceptable critical DEP 63. engraved stainless steel cable tags. For above ground cabling the spacing between cable number shall be at every 25 meters.4 Qualified and well experienced person shall be engaged for cable jointing / termination 9.2 All cable joints / termination kits shall be compatible to the cable and shall be Confirmed by the cable manufacturer.3 At most care shall be taken while preparing the cable for jointing / termination 9.2.5 Witness & verify the Hi-pot test for HV & MV Cables. 9.1 Cable shall be laid on trays in accordance with laying pattern indicated on AFC layout drawings.10.9.1.3.08.4. 9.5 Check continuity & insulation resistance with calibrated instrument before cable jointing / termination.2 Above Ground Cables 9.4.4. A 12. at both ends of sleeves.2 The cut end of the cable shall be protected from moisture entry.

9. MV & LV cables • Continuity & Insulation Resistance Test of the cable on Drum • Continuity & Insulation Resistance Test of the cable before backfilling • Hi-pot Test for MV & HV Cables • Continuity & Insulation Resistance Test of the cable after backfilling 11.0 HEALTH AND SAFETY REQUIREMENTS 12. EE xe cable glanding and termination shall be done by trained technician 10.6 Check and ensure the cable jointing / termination kit is complete with all materials as per the packing list.7 All cable conductor shall be fitted with company approved make & correct size ferrule / leg. 9.9 All EE xd.4.9. The ferrule / leg shall be crimped compression type as specified by the manufacturer. .4.1 Hazards:  Accidents during loading & unlading cable drums from storage yard to the point of installation  Personal injury during cable pulling and using torch blower for heating during cable termination & joining.8 Cable glands shall be double sealed compression type with earth clamping features to IP55.4. 9.0 REQUEST FOR INSPECTION RFI shall be raised 24 hours before the actual schedule for inspection as per approved ITP 12.0 TESTING Following electrical test shall be conducted for HV.4.

all personnel involved on the job shall attend the project HSE Induction training.2 control measures:  Strictly ensure that the entire activities of cable laying. Equipment will be regularly checked and inspected by the safety officer. In the case of major hazards. shall be inspected by competent personnel prior to use at site. Work shall stop and area secured until approved  The Construction Engineer / Supervisor shall immediately correct any hazards observed or reported to him. Electric shock during megger testing / Hi-pot testing.  All equipment like Cranes.  Any accident / Injury / near miss shall be reported immediately to appropriate authorities.  Toolbox talk shall be carried out to keep the team-mates aware of job activities before starting any work. 12. warning devices and signboards shall be in position at work site. Fork lifts.3 Safety Precautions:  Prior to commencement of any activity. slings and other necessary tools and tackles for rigging & material handling operation.  All work performing personal’s shall be provided with PPE and ensure proper use of it. lifting belts. electrical equipment etc.  Safety equipments.  The site management.  Pollution due to excess & waste materials.  Emergency evacuation contingency plan shall be known to work performing crew members. identification of all hazards including hidden one and control measures of it. termination & joininting shall be carried out under consolidated Permit to Work system. work shall be stopped and appropriate and satisfactory permanent action to remove the hazards shall be taken. 12.  Good housekeeping shall be maintained at all times  All activities reflected to HSE shall be carried out according to the approved documents a) Project HSE Plan – b) Contractor HSE Plan – . Chain pulley blocks. supervisors and safety officers will closely supervise and monitor all phases of activities in connection with the compliance of safe working models.

– Insulation Resistance & Continuity test record-Electrical cable on trench. Before backfilling. – Inspection of cables in trench before final backfilling. ..0 DOCUMENTATION & RECORDS Mateerial Receipt Inspection Checklist – Material Receipt & Inspection Repor (MRIR) – Excess. – Cable jointing certificate for LV/MV/HV cables.13. – Insulation resistance & continuity test record-Low voltage cables after Glanding and termination – Hi-Pot test of MV / HV cables. – Inspection of electrical cables after installation. Shortage and Damage Report (ESDR) – List of Critical Items for Material Receipt Checking – Receipt & Shotage Checklist – – Insulation Resistance & Continuity test record-Electrical cable on drum (before installation) – Cable trench & duct bank inspection before cable pulling. NOTE: Sample copies of above are as attachments of this procedure. glanding and termination.

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