Quality Control Procedure for HV, MV & LV Cables

1.0 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

- Inspection and Test Plan for Electrical Installation.

- Quality Control Procedure for Material Identification and Traceability

3.2.2 HSE Document:

- Project HSE plan

4.0 ABBREVIATIONS

4.1 Company :
4.2 Contractor :
4.3 Sub Contractor
4.7 ITP : Inspection and Test Plan
4.9 QA : Quality Assurance
4.10 QC : Quality Control
4.11 RFI : Request for Inspection
4.13 NCR : Non Conformance Report
4.14 PQP : Project Quality Plan
4.10 HSE : Health Safety & Environment.

5.0 ROLES AND RESPONSIBILITIES

Following are the roles and responsibilities of personnel involved in this scope of procedure.

5.1 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.

5.2 QA/QC MANAGER:

 QAQC Manager shall report to the Project Manager.

 Shall be responsible for ensuring the Project Quality requirements and shall monitor all the
Quality related issues throughout the project.

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.

5.4 PROJECT DOCUMENT CONTROLLER:

 Document controller shall report to the Project Manager.

 Shall be responsible for controlling & issuing all the Project related documents throughout the
Project. He shall be key point to receive and transmit documents from the CONTRACTOR and to
the CONTRACTOR. He shall maintain the status of documents like revisions, approvals etc.

5.5 CONSTRUCTION MANAGER:

 Construction manager shall report to the Project Manager
 Shall be responsible for arranging necessary equipment, man power, consumables, areas for
storage, erection, preservation and ensuring that the procedure is implemented and complied
with all specifications and HSE requirements.

5.6. PLANNING ENGINEER:

 Planning Engineer 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. He shall be
responsible for planning the field erection activities including but not limited to the materials,
machinery and manpower.

5.7 CONSTRUCTION ENGINEER:

 Shall report to the Construction Manager.

 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, issue of drawings for
erection, monitoring the drawing revisions and modifications if any to meet the progress target
set by the Project controls.
 Shall ensure the preparation of daily reports.

5.8 STORE KEEPER:

 Shall report to Material controller.

 Shall be responsible for proper storage and issue of special tools, gaskets, bolts & nuts and
other accessories received with equipments, as per the manufacture’s recommendations.
5.9 QA/QC ENGINEER:
.
 Shall report to the QC Manager
 Shall be responsible to ensure that works carried out at site are complied with project quality
requirements, to identify and intimate the CONTRACTOR for the hold, witness and review points
as described in the inspection and test plan for Electrical Installation. 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.

5.10 QC INSPECTOR ELECTRICAL:

 Shall report to the QC Engineer.

 Shall inspect the incoming equipment and verify the materials received are confirming to the
AFC Drawings.
 Shall be responsible for quality control & documentations.
 Stages of inspections and surveillance in accordance with ITP and assurance of quality of work
as per specification and Installation procedure.
5.11 ELECTRICAL SUPERVISOR / FORMAN

 Shall be report to Electrical Engineer

 Aware all procedures, work method / instructions, quality requirement for the timely
completion of the job and explains to the task force for the installation of HV, MV & LV Cables.
 Execute all activities as per the contract requirements, applicable code of practice.
Manufacturer’s instructions and monitor the job as per the schedule.

5.12 JOB PERFORMER

 Shall report to Electrical Supervisor

 Ensure all permit to work, safety equipments, 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.

6.0 CONSTRUCTION EQUIPMENTS

 Cranes, Fork Lifts, lifting belts, 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, MV & LV Cables installation
and testing.
 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.

7.0 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.

After receiving the Issued for Construction Drawings, the Construction Department shall request
the equipment from the Store. The Store shall issue the Material issue Slip with equipment
stated.

8.0 CALIBRATION CONTROL

The measuring instruments like Insulation tester, Multimeter, Phase sequence meter,
Hi-pot Tester, surveying instruments, spirit level, measuring tape etc. 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.
9.0 QUALITY CONTROL

9.1 RECEIVING INSPECTION:

9.1.1 Check the availability of “IFC” drawings, vendor manuals and instructions etc.

9.1.2 All material received shall be stored according to the installation schedule,
material identification & traceability and manufacturer’s instruction.

9.1.3 All Material Receiving Inspection to be completed before installation in position and if any
discrepancy found, item will be entered in the punch list and maintain a record further inform to
site Engineer immediately.

9.1.4 Verify the quality, year of manufacturing (if any) and country of origin.

9.1.5 Verify the Test certificate of cable is available for reference.

9.1.6 Proper protection will be provided against wind, dust, rain corrosion etc as per
material preservation procedure

9.2 INSPECTION PRIOR TO INSTALLATION:

9.2.1 Check and verify the installation Procedure and make sure the proper method
of installation is being used as per the approved Method Statement

9.2.2 Verify the cable type, size, colour and route of the cables are as per the
approved drawing & cable schedule.

9.2.3 Continuity & Insulation resistance test on drum. Insulation resistance shall not
be less than as per DEP 63.10.08.11-Gen, A12.2 (10 x kV / km) in MΩ

9.2.4 Verify cable trench & sand bedding as per project specification.
ie, 132 kV 100 mm & all other cable 75 mm

9.2.5 Ensure trained, well experienced and skilled persons do the cable pulling.

9.3 QUALITY CONTROL CHECKS DURING INSTALLATION

9.3.1 Under Ground cables

9.3.1.1 Verify the laying sequence of the cables to avoid crossing and over lapping.
9.3.1.2 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

9.3.1.3 Verify actual cable length against the cable schedule.

9.3.1.4 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.

9.3.1.4 Follow the direction shown in the cable drum for the rotation of cable drum.

9.3.1.5 Make sure the cable coming from the top of the drum and cable shall not drag
on the floor.

9.3.1.6 Follow and adhere to the manufacturer’s permissible pulling force for cable pulling.

9.3.1.7 Maintain the minimum bending radius as

Single Core Unarmoured – 20 D, Single Core Armoured – 15 D, Three Core Unarmoured – 15 D,
Three Core Armoured – 12 D. (D – Diameter of Cable).

9.3.1.8 Each set of single core cables comprising a three phase circuit shall be run
close together in trefoil formation.

9.3.1.9 Cable crossing under road shall be through reinforced concrete duct bank.

9.3.2 Above Ground Cables

9.3.2.1 Cable shall be laid on trays in accordance with laying pattern indicated on
AFC layout drawings.

9.3.2.2 The cut end of the cable shall be protected from moisture entry.

9.3.2.3 Cable identification shall be for underground and above ground application, engraved
stainless steel cable tags, at each end, at both ends of sleeves, all entry point to JB and along the
route shall not exceed 10 M for under ground cabling. For above ground cabling the spacing
between cable number shall be at every 25 meters. Cable shall also be numbered where they
branch off from main route.

9.3.2.4 Witness & verify continuity & insulation resistance test are carried out as acceptable
critical DEP 63.10.08.11-Gen, A 12.2 before and after installation of every length of cable.

9.3.2.5 Witness & verify the Hi-pot test for HV & MV Cables. The test voltage & timing
of Hi-pot test shall be as per DEP 63.10.08.11 Appendix A 11.1.1
9.4 QUALITY CONTROL CHECK DURING CABLE JOINTING & TERMINATION

9.4.1 All cable joints / termination shall be strictly in accordance with cable manufacturer’s
recommendation

9.4.2 All cable joints / termination kits shall be compatible to the cable and shall be
Confirmed by the cable manufacturer.

9.4.3 At most care shall be taken while preparing the cable for jointing / termination

9.4.4 Qualified and well experienced person shall be engaged for cable jointing /
termination

9.4.5 Check continuity & insulation resistance with calibrated instrument before cable jointing /
termination.

9.4.6 Check and ensure the cable jointing / termination kit is complete with all
materials as per the packing list.

9.4.7 All cable conductor shall be fitted with company approved make & correct size ferrule / leg.
The ferrule / leg shall be crimped compression type as specified by the manufacturer.

9.4.8 Cable glands shall be double sealed compression type with earth clamping features to IP55.

9.4.9 All EE xd, EE xe cable glanding and termination shall be done by trained technician

10.0 TESTING

Following electrical test shall be conducted for HV, 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 REQUEST FOR INSPECTION

RFI shall be raised 24 hours before the actual schedule for inspection as per
approved ITP
12.0 HEALTH AND SAFETY REQUIREMENTS
12.1 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.
 Electric shock during megger testing / Hi-pot testing.
 Pollution due to excess & waste materials.

12.2 control measures:

 Strictly ensure that the entire activities of cable laying, termination & joininting shall be carried
out under consolidated Permit to Work system.
 Toolbox talk shall be carried out to keep the team-mates aware of job activities before starting
any work, identification of all hazards including hidden one and control measures of it.
 Emergency evacuation contingency plan shall be known to work performing crew members.
 Safety equipments, warning devices and signboards shall be in position at work site.
 All work performing personal’s shall be provided with PPE and ensure proper use of it.

12.3 Safety Precautions:

 Prior to commencement of any activity, all personnel involved on the job shall attend the
project HSE Induction training.
 The site management, supervisors and safety officers will closely supervise and monitor all
phases of activities in connection with the compliance of safe working models.
 All equipment like Cranes, Fork lifts, Chain pulley blocks, lifting belts, slings and other
necessary tools and tackles for rigging & material handling operation, electrical equipment etc.
shall be inspected by competent personnel prior to use at site. Equipment will be regularly
checked and inspected by the safety officer.
 Any accident / Injury / near miss shall be reported immediately to appropriate authorities.
Work shall stop and area secured until approved
 The Construction Engineer / Supervisor shall immediately correct any hazards observed or
reported to him. In the case of major hazards, work shall be stopped and appropriate and
satisfactory permanent action to remove the hazards shall be taken.
 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 –

13.0 DOCUMENTATION & RECORDS

Mateerial Receipt Inspection Checklist –

Material Receipt & Inspection Repor (MRIR) –
Excess, 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.
– Insulation Resistance & Continuity test record-Electrical cable on trench,
Before backfilling.
– Inspection of cables in trench before final backfilling..
– Cable jointing certificate for LV/MV/HV cables.
– Inspection of electrical cables after installation, glanding and termination.
– Insulation resistance & continuity test record-Low voltage cables after
Glanding and termination
– Hi-Pot test of MV / HV cables.

NOTE: Sample copies of above are as attachments of this procedure.