Method Statement

Power and Control Cable Installation

Title of Works Method Statement Ref: MS 01
Contractor NEGEMCO For ENGINEERING &CONTRACTING Date: 05/12/2020
Client ARAB POTASH CO.
Project Tender No. IFB201901029/DH-Supply and Construction of Aqaba Screening

Structure Project. Job NO. J17082

1. Scope and Objective of Work

Supply, Installation, and testing of Power and Control cable

2-Risk Identification
Manual Handling
Electrical fire/shock
Slip/ and Falls – use of stepladder-Scaffolding- Man Lifting Wench when necessary.
Use of appropriate tools and electrical equipment
All risks involved with the works shall be suitably assessed and controlled prior to works commencing.
Work permits procedure to be followed supported by Isolation of power supply whenever is necessary.
Risk assessment is attached.
3. Safety Equipment and Personal Protective Equipment
Personal use Type
Head protection Hardhat (Helmet)
Eye protection Goggles
Breathing protection Dust mask & Ammonia Gas Mask
Safety footwear Standard
Working at Normal /High Level Stepladder/Scaffolding &Harness
High visibility clothing Yellow
Hand Protection Gloves

4. Responsible Manpower Requirement on Site

Electrical Engineer
Safety Officer
Electrical Supervisor

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 Method Statement

5. Pre-Start Requirements for Site

1. Client site rules and procedures to be followed.

2. Preparation of all required tools for the execution of the intended works.
3. Assuring of Provision of safety equipment and personal protective equipment.
4. Ensuring working area is clear of obstruction and hazard.
5. Visual Inspection of the Tools required for the intended works.

6-Preinstallation

1. Ensure all drawings are approved and available to the installation team.
2. Material used such as power cables, control, signal cables and cable glands will be as approved by the
Engineer.
3. The sizes and cable routing will be as per the approved shop drawing and cable schedule list. Only required
cables and its accessories to be shifted on the site for pulling.
4. Prior to cable installation in any location, Excavation route, cable ladder and its route must be inspected for
completion.
5. Check that cable ladder or conduits free from sharp edges and have sufficient space for Installing the cables.
6. Ensure that the cable ladders are provided with purpose made (supplied by manufacturer) bends to
Accommodate the minimum bending radius of the large cables.

7-Delivery, Storage, and Handling

1. Deliver wires and cables properly packaged in factory packed or fabricated containers, wound on
factory reels.

2. Store wires and cables in dry areas, and protect from hot and humid weather, fumes, water,
debris, etc.

3. Handle wire and cable carefully to avoid abrasing, puncturing and tearing wire and cable insulation
and sheathing. Ensure that dielectric resistance integrity of wires/cables are maintained.

4. The cable shall be tightly wrapped on the cable drum and no turn shall be left loose. Both ends of
the cable shall be adequately secured to the cable drum. Inner end of the cable shall be suitably
fixed / gripped to the cable drum so that it will not come out during cable laying operation. The
cable shall be wrapped on drums of suitable diameter such that the radius of bend of the
innermost layers is not less than the minimum radius of bend stipulated in relevant BS/IEC
standards for installation of the cable.

5. Central lifting hole of the cable drum shall be provided with a steel pipe. The pipe shall be welded
with steel plates at both ends and these plates shall be duly secured to the flanges of the cable
drum with suitable size bolts. The pipe and the welded end plates shall be of robust design to
withstand the weight of the cable drum during unrolling.

6. Each drum shall bear a distinguishing number on the outside of the flanges and particulars of the
cable, i.e. voltage, length, conductor size, cable type and gross weight shall also be clearly visible.
The direction for rolling shall be indicated by an arrow.

7. Immediately after the Works tests both ends of every length of metal sheathed cable shall be
sealed by means of a metal cap fitted over the end and plumbed to the sheath. All cables shall be
sealed by enclosing the ends in approved caps, which shall be tight fitting and adequately secured
to prevent ingress of moisture.

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 Method Statement

8. The cable end, which is left projecting from the drum, shall be adequately protected against
damage.

9. Cable shall be wrapped with black polyethylene sheet inside the wood covering of the drum.

10. The ends of factory lengths of cable shall be marked "A" and "Z", "A" being the end at which the
sequence of core numbers is clockwise and "Z" the end at which the sequence is anti-clockwise.
The words "Running End "A"" or "Running End "Z"" shall be marked on the flange and the
direction for rolling shall be indicated by an arrow. The method of drum marking shall be to the
Purchaser's approval.

11. All cables and accessories shall be carefully packed for transport and storage on Site in such a
manner that they are fully protected against all climatic conditions, particular attention being paid
to the possibility of deterioration during transport to the Site by sea or overland and to the
conditions prevailing on the Site.

8-Installation

1. Before pulling ensure that both ends of power cable are to be installed between the right equipment
and main distribution board or to starter cabinet in the motor control center.

2. Similarly instrument and control cable must be pulled and installed according to control and
instrument cable schedule and when the location of instrument is known.

3. Transport and place cable drums at location where space is available for working. The cable drum shall
be placed on a jack and spindle arrangement to assure free rotation of the drum.

4. Cable drum shall be placed near the pulling start end near substation C about 15m away from the
cable entrance to substation C.

5. Pulling shall be started from substation end as in 7.5, then pulled along excavation up to tower T9.

6. Cable shall be pulled with enough length near Tower T9 and then start pulling cable step by step with
care
7. from ground level to first floor, and then to second floor and so on and distributed on cable ladder and
to location of the various equipment.

8. Cable roller shall be place under the cable during pulling.

9. For avoiding any damaged for the conductors, insulation or jacket of the wire or cable during the
pulling stage, and lubricants will be used properly to prevent any stresses on conductors
(Manufacturer approved pulling Compound and not to deteriorate conductor or insulation), also do
not exceed manufacturer’s recommended maximum pulling tension and sidewall pressure value.

10. The cable shall be pulled by using pulling means such as fish tape in case of conduit and suitable
pulling rope in case of cable pulling inside duct or on cable ladder and care must be taken to ensure
the maximum pulling tension of cable.
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 Method Statement
11. Cable should be free of any static load i.e. to be placed side by side parallel on cable ladder.

12. At all times the cable schedule for power and I&C cables for all relevant area will be referred to ensure
13. proper location in the required cable ladder and to ensure the right cables for equipment or
instrument.

14. Power and instrument cable shall be installed on cable ladder then drop out to equipments, motors
15. Instrument either in smaller cable ladder covered or in a suitable size HDG g.steel conduit well
supported on channels .

16. All cables to be fixed on cable ladder by stainless steel ties for power cable and stainless-steel PVC
coated in case for instrument and control cables, cable ties to be applied every 3 m spacing.

17. Install direct-buried cables on leveled and tamped 75 mm bed of clean sand at bottom of trench.
Separate cables crossing other cables or piping from those items by a minimum of 100 mm of tamped
earth. Install permanent markers at ends of cable runs, changes in direction, and buried splices.

18. Install warning tapes for direct buried cables as per approved shop drawing.

19. stainless steel cable identification labelling/tags shall be placed every 15 meters straight
run, 8 meters maximum interval in congested areas, at changed in direction and
penetration of wall and floors.

20. Non-corrodible identification markers shall be placed at both sides of the road to indicate
utilities duct crossing. Identification shall be done in regular intervals.

21. Seal around cable passing through fire-rated elements using approved fire stopping
material.

22. Cables run on ladders shall be neatly dressed and where not provided with cleats shall be
secured by heavy gauge, type approved metal reinforced, clips or saddles. Not more than
6 cables shall be embraced by one clip and not more than 2 layers of cables run on 1
ladder. Care shall be exercised to ensure a "Reduced Fire Propagation" installation.

23. Instrument and control cables shall be installed on their own cable ladder and not in power cable.

24. Before termination of cable all pulled cables shall be tested for insulation resistance with 500-volt D.C
Megger for 400-volt cable and 2.5KV/5KV for 6/10KV cable and with continuity tester. All test reading
shall be recorded in test form sheets.
i. .
25. Termination shall be done by using the approved termination which include Brass E1W glands, lugs
26. Shroud all as approved by the Engineer, and use stainless steel gland on stainless steel instrument
enclosures.

27. Terminations are to be carried out strictly in accordance with cable manufacturer's
recommendations, and made with correct specified materials, boxes, tapes, compounds or
mixtures, cold shrinkable insulation, stress cones, glands and bonds as applicable,
termination material are to be inspected on site by the Engineer just before usage.

28. Cutting tools for jointing and terminating cables are to be purpose made, to prevent
damage to insulation in general, and to cable shielding of MV Cable.

29. The termination shall be performed by certified technician and special tools.

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30. Cleaning of lacquer on conductors is to be by use of “Scotch Brite” sponge and white spirit
or equal approved.

31. MV cable testing agency to be approved by the Engineer and to be witnessed by the
Engineer, results to be certified by manufacturer or authorized representative.

32. MV Cable testing shall be as per project specification.

33. Cable Termination shall be carried out under low humidity and dry ambient condition.

34. Splices are to be protected from the dust, dirt etc., using a tent/cover, being
35. present during the whole splicing process.

36. Proper supervision during the course of MV cable termination and Proper & functional tools
to be on the site.

37. Termination for small cables shall be performed using hand operated crimping tool and for large cable
manual Hydraulic crimping tool.

38. Install tags /labels as per project specification and as approved material submittals.

39. Tagging: Tag main and feeder cables in pull-boxes, wireways and wiring gutters of
panelboards or distribution cabinets. Tags are to identify cable or circuit number and
conductor size as per Employer requirements and in accordance with the Schedules.

40. Tag cables just before glands such that identification is clearly visible from the front of the
panel

41. Tags to be provided at both ends of cable and at interval of 15mts on cable ladders.

9-Inspection and Testing

1. Visual Inspection: The installation of the cable to be checked to ensure the correct laying, proper glanding,
corrects termination, adequate supports, labeling, identification etc.

2. Use 500 V megger on installations with nominal voltage up to 500 V, and 1000 V megger on
installations with nominal voltage over 500 V up to 1000 V. All test equipment shall have
calibration certificate not older than 6 months on date of test.

3. Insulation resistance for LV power and lighting installations is to be carried out in accordance
with BS 7671requirements.

4. Site test after installation shall include AC voltage test at power frequency as per clause 20 A
of IEC 60502.

5. Insulation resistance for control and signal cables is to be minimum 10000 Megohm-km for PE
insulated cables and 100 Megohm-km for PVC insulated cables, all measured core-core and
core-earth, in accordance with the Regulations.

6. Insulation resistance for all cables on drums and after pulling length to be recorded in Testing Form.
a. For low voltage cable testing voltage- 500 VDC
b. For Medium voltage cable Testing between 1000 VDC and 5000 VDC
c. For control cable voltage testing between 125 VDC to 250 VDC
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 Method Statement
7. Prior to energization of circuitry, check installed wires and cables with megohmmeter to
determine insulation resistance levels to ensure requirements are fulfilled.

8. Prior to energization, test wires and cables for electrical continuity and for short-circuits.

9. Works tests shall include all routine electronic, electrical and mechanical tests when relevant in
accordance with the appropriate IEC Standard and the Specifications to ensure that the
individual plant or equipment being supplied meets the requirements of the Specification.
10. Cable tests are to be carried out in accordance with the requirements of the Regulations and
Standards.
11. MV cable testing agency to be approved by the Engineer.
12. MV Cable Testing: to be witnessed by the Engineer and results are to be certified by
manufacturer and authorized representative.
13. Test Equipment: Provide megger testers of various ranges as applicable, and HV test equipment
as necessary for testing MV installations.

14. On installation of medium-voltage cables and before electrical circuitry has been energized,
demonstrate product capability and compliance with requirements.

15. MV Cable testing: Provide cable test set with D.C. output voltage and ampere range sufficient
to test MV cables. Cables are to be laid in position with ends free of equipment and clear of
ground.

16. MV Cable Testing: D.C. test voltage is to be applied between core under test and the screen in
steps, pausing 1 minute or more each step (first step being the A.C rms rated voltage of the
cable, followed by 2 equal steps) up to maximum test voltage. At each step, and for the last 5-
15 minutes duration at maximum test voltage, the ammeter (normally a micro-ammeter) is to
be monitored closely and recorded. If, except as voltage is increased, the current starts to
increase, test is to be stopped and the installation inspected and tested for the fault.

17. MV Cable testing: Each cable is to be tested independently. Maximum D.C. test voltage for
grounded neutral system is to be 3 times rated A.C. rms voltage of cable.

18. MV Cable testing: alternative test is to apply A.C. rms voltage up to 1.5 times A.C. rms rating
of cable applied for 15 minutes, by an approved A.C. test set. Readings are to be within same
range and in accordance with IEC 60502-1.

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 Method Statement

10.Equipments & Tools

8.1- Cable drum jack.

8.2-Cable rollers

8.3-Pulling rope suitable size

8.4- Step Ladder /Scaffolding for taller height.

8.4-Cable core cutter

8.5-Cable cutter

8.6-Measuring Tape

8.7- Set of Ratchet Spanners.

8.8-Cable Crimping tool (Manual and Hydraulic)

8.9-Multimeter

8.10 -500-1000-2500-5000 VDC insulation tester.

8.11 Wench on flat Bed Truck or Crane

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