Zs, pcoeon rh Yb sciv mace roceoune (> Technical submittal Review Tcimcoor ented s Comments Form-JCPDI- intomsicomy Toren Wo” Oa comers OA [Joven big mrt ACTRANSMITIAL NO: 2004-502 [7]? tewieanértmt —[~]4 Roiratrequed erry ocd sine Steet teargratonct Wek od sta tation of med anger anéconmen ‘hildd Joho, Uearmore, 19K, 2988" ee Note: Permission 10 proceed does not constitute SeSpence o design day easton antes, ast tmatnods ar materias developed or elected te Supplier does not rleve the contactor tort Nis Siesta Brite, Facmova la” a are: 06-65 uharm Usmen Gal ote: Erato Creche bent ca eri ‘anmrtoopens a rt U er aah agrctooven i crc th Mde ‘Ses Sa reat anno ste gosap) ome em Pree ‘Siler atte cms omTR UREA | a 12 HRI squaUWUOD moIRoY [EHIUIANS JeOIUYDSL ususyedsg uonansisu09‘Sau ao 2m es uesu09 osvoyd‘somumdaom ker so] cass | © ‘SUIS! AUP ays op wd se s.uuoy uonoodsu an geeny | __corsu | & z go way aie) ‘Sop Jo Bug THIN] “Sued ages Buunp von i9ppE Uosiod 9 puns joquow jo mod Sana slog sz sjouusyy "wont Supung 2189 "10: ‘xivo uowsua ed PaHESSp POUT Uo 05S poem ayy povonau rou sepansseuday| _cos-su| © aueupeny sr-o0am 31 sunazoous aniaDeNH ATARIIDW AODEVNONO | seouea pmanerraaa | voney2.6s enue Toe | sau eewens YA 1st poousean pewoer seme Ge sen tums jo wna uate Poa, eons aot Ea (pny aad Bo OD A = OE HOae sa enve9 siuawog many jepuians eEKLPL ‘usuaiedeq uoranastoo IGdpf-w0g squaWIWOD ra oupeay rea0avsat mawnay feniuans eowyoo,osteo Uys Ast OF (0 Se tm See = tt a 2S ‘echnical/Non-Technical/TO/FCD Submittal Centract No: 1CPDI12008, Ba Pri Name: taste Developm ning Rote les Resa! re Dist N23 “Transmittal No: (502) pseudo — (ben arte ot ene Cae a ewer — O-—= oO oo a= ny ——— Hi tne =e oe Bene oO ome Oa eee mtr ae Ol nmin en lwo i mnt Sie os = iserie pinto | Nth Statement METHOD STATEMENT Biiatoue Gals A552 gd C))\C or tia 3th mt Ic a8 oes BA 2X 22525 GeO ENGINEERING CORFORATION(A0D) RANCH JAZAN CITY FOR PRIMARY AND DOWNSTREAM INDUSTRIES (JCPDI) CONTRACT NO.JCPDI |-2004 Installation of Medium voltage cables, shielded, jacketed, un-armored, 15kV, 25KA. Method Statement No: MS-E-003 1 “Apo By tere | Doeserton | Prepared By ‘choxked owas PROJECT Instataton ot | QCENGIVEER | MANAGERS | MANAGER Mediu vot SAFETY ‘atten, sed, ENGINEER jacketed, un- + | aeons | mores, 18 eK aUNAID wast Cvistopher AanaTAT Maiayo & Wajid | Mustafa _ Petnan‘TABLE OF CONTENTS LOTTE 2.0 SCOPE OF WORK 2.1 General Description 2.2 Plant and Equipment 2.3 Materials 2 Site Planning and Preparation 2.5 Work Methodology 2.6 Organization, Responsibility & Supervision 2.7 Work Force 3.0 HEALTH AND SAFETY 3.4 Risk Assessments 3.265 & H Contactor Requirements 3.3 Protective & Safety Equipment 3.4 Contractual Requirements 2.5 information to Personn 3.6 Emergency rocedures 3.7 Permitting Requirements 4.0 ENVIRONMENTAL ISSUE 41 Environmental Impact Assessment 4.265 & H Contactor Requirements 4.3 Contractual Requirements ‘44 Emergency Procedures S.0QUALITY ASSURANCE 5.1 Contractual Requirements 5.2 Gtical Works Activity 5.3 Inspection & Testing 5.4 Follow up # Evaluation6.0 APPENDICES/ REFERENCES 6.10rganization chart {6.2 Drawing for the Location project site 6.3Traffic management plan 6.4 PTB CARD ( PRE TASK BRIEFING )1, TM ‘Method statement for MV Cable Pulling and Termination 2, SCOPE OF WORK 2.1 GENERAL DESCKIPTION This procedure provides Medium voltage cable pulling and termination methods usually encountered inindusrial and commercial applications and should be used in conjunction with the Royal Commissions installation specifications and standards. This, ‘method is recommended forall types of medium voltage cable pulling and termination. This procedure aims toprovide guidelines on good practices for Medium voltage able pulling and termination. 2.2 PLANT AND EQUIPMENT ‘+ Dynamo-meter(i necessary) + Wire mesh pulling grip 1s ope + Fishtape + electrical tape + Spleing knife + Wire rope sings of various lngths + Rubber tape + imping toot ing lubricant + Hipot Test + Megger Test + Cable puting mehit + Cable roller Cable drum stand + Forklit Boom truck/erane + Trailer2.3 MATERIALS ‘+ Medium Voltage cable + Terminal lugs + Termination kits and accessories + Splicing hts + Concrete warning tiles Warning mesh wire + Waring post/marker + Cable accessories 2.4 SITE PLANNING & PREPARATION ‘+The entire route shall be inspected to ensure that the routing fs complete, proper bends are used and free fom any sharp edges. Ensure that last revision &-awings are used, ‘+ Termination pont inside the panels/equipment’s shall be considered for sultable spare length tobe left available during pulling of cable termination. The maximum length shall be equal to depth height and width of panels. ‘Before start of pulling eabe, the actual route length shal checked for adequate length of cable. ‘+ Confiem that al tools and tackles required for installation area avaiable. + Ensuce sufficient quantity of cable tags is readily available, + check adequate place for unloading the eable drums. ye measured and [MATERIAL WITHDRAWN FROM WAREHOUSE/LAYDOWN AREA, + Material Inspection willbe carsied out to ascertain that no damaged has occurred tothe cables + QCEngineer Cable shall be tested onthe cable drums prio to removal at worksite with 5000 V insulation tester, The values wll be noted for core to core and ground. * After the tes, the ond ofthe cable shal be sealed with end cap or PVC tape to prevent the ingress of moisture. + Store material requisition shall be made, The cable drums shale cl-loaded at the site location. lt shall be ensured that there fsno obstruction to novement of vehicles or any hindrance to works of ‘other companies.+ For lifting of eable drum’s. Depending on the weight and size ofthe drum shall use ‘rane and Boom truck. For smal cable drum lift with Boom truck big eable deur lie with crane see the atached Lifting Caleulation of eran. 2.5 Work Methodology. INSTALLATION OF CABLES A, General: 1. Cables will te installed outdoors in underground duets or direct buried. 2, Provide andinstal al raceway materials, cable supports and cable fasteners as required. 13. Repair any existing duct bank and! manhole damage or deterioration to provide raceways suitable for cable Installations. B. Installation of Cables in Ducts: 4, Ducts shal he thoroughly cleaned and mandels followed witha swab shall be pulled ‘through concrete-encased duct runs before cable pulling ‘operations begin. Attachments fr pulling purposes shall be patented cable grips or other devices approved by the Royal Commission. Inset ‘able lubricant approved by the Royal Commission may be used as an aid to pulling oleable. Grease or other material harmful to cable Insulation of jacket material wil not be allowed. 2. Exiting manholes are generally equipped with cable hangers, racks and ‘alls, Cables shall ret on porcelain or PVC sales at least 70mm long, [Any adltional support required for the cables and splices in manholes shall be furnished by the Contractor. The Contractor shall ground the able support system. 3. Cable length required for pulling cables shall be determined based on contract and design drawings. Contractor shall be responsible for the ‘material take-off an for determining actual cutting length of cable he Install4. Alleable ends shall romain sealed til such time they are ready for terminating. At the end of each workday Contractor shal eal (watertight) atmanholes. unprotected cable ends, Make no splices o joints except 5, The Contractor shall sel all used ducts in manholes, after cables have ‘been installed, with duct sealing materials ofthe non-hardening type. Ducts penetrating the substation basement wall shal be sealed with either prefabricated seals made of rubber not foam to prevent hotspots, with stainless steel metal parts, designed fr sealing water of atleast 20 {eet of head, or with watertight rsh SCOTCHCAST 92-5112, 92-5113 ‘or approved equa 6. Where cables require bending, the minimum bending radi ofthe cables shall be strictly observed. The cables shall be bent a litle as possible and shall be kept preferably inthe same plane to avoid twisting. As faras possible there should be no “figure eighting” of cables. 7. inmanholes rack cables with sack to allow for expansion and future splice, 8. After palling the cables through the duct bank, the cables shall be rung ‘ut and property phase Identified a: both ends. 03, allsafety requirements for working in manholes, dewatering and ventilation, shall be the contractor Responsibly.MEDIUM VOLTAGE CABLE TERMINATION PRE-TERMINATION CHECKLIST ‘+ check the tenmioation/splicing kt to ensure that the kits gong to use fits the cable. Refer tothe kit abel and the ttle of the installation Instruction. Carefully read and follow the steps nthe installation Instruction. ‘+ Use a propane (p:efered) or butane gas torch or heat gun. + Adjust the torch to obtain a soft blue flame with a yellow tp; pencil ke blue flames should be avoided. + Keep the torch aimed inthe shrink direction to preheat the mater + Keep the flames moving continuously to avd scorching the materia + Glean and decreae all parts that wl come into contract with adhesive “Tubing should be cut smoothly with a sharp knife leaving no jagged edges. ‘Start shrinking the rubbing at the position recommended in the instruction, “Ensure that the tubing i shrunk smoothly all ound before continuing along the cable. ‘+ Tubing should besmooth and wane tee with inner components clearly defined. PREPARATION OF CABLES FOR SPLICING AND TERMINATION ‘+ Remove the over sheath tothe dimension required ‘+ Gleanand degeesse the end ofthe over sheath for about 100mm + Wrap one layer ofthe red sealant tape with a small ovelap and sight tension around the end ofthe over sheath, ‘+ Thoroughly remeve the core screen to the dimension given so that the insulation surface is free from ll traces of conductive material Smooth out any irregularities con the intulationsurtac.Cable Ties and Accessories: 4.Cable es used shallbe capable of withstanding electromagnetic forces produced by short cirult currents specified, 2.cable ies used outdoors or expose to sunlight shal be suitable for ‘outdoor use ‘3.Cable ie accessories (e.g. anchor mounts, standoffs and te plates) may be used indoors or outdoors within equipment enclosures. Adhesive type mounts are not acceptable. Terminations 4.the cables shall be terminated in he switchgear and transformers. After permanent connections have been made to substation switchgear, they ‘shall be insulated with materials to cover exposed bus conductors and ‘exposed portions of cable terminates 2:The Contractor shal provide all the necessary cable termination its to ‘complete the cable terminations Inthe suitchgear/transformers 2:Where cables enter the equipmen: from below the termination point, ‘they shall be supported in their conduit by approved grips. Where all conductors emerge from the condui they shal be neatly formed and, trained tothe point of termination. ll conductors shall be securely supported within a maximum of 91¢ mm from the point of termination to avoid stressing the bus to which the able fs connected and the bus support insulators. Where cable supports are not supplied with the ‘equipment, they shall be provided ty the Contractor and shall be ofthe porcelain cable clamp type with aluminum straps, or as otherwise approved by the Royal Commission.Splices 1. Salices shall be located in manholes 2. The numberof splices shall be kept ata minimum. 3, Inmanholes, supports shllbe provided within 150mm from each end of the cable splice. COMPLETION OF TERMINATION 1+ Wap the void filing strip round the end of the coe screen. Start 20mm from the ‘over sheath cut. Cover 20mm ofthe core screen and 10mm of the insulation. Stretch the strip to half fits orginal width to achieve afine, edge onto the insulation (For 1 core termination, cable with tape shield remove the wire binder ‘rom the end ofthe metal tape shield. Wrap the veld filing strip onto the metal ‘tape shield, continuing over the core sereen and ont the insulation, + lace the stress control tubag over the cable core and the position it evel with ‘the over sheath et shrink the tubing starting atthe bottom and working towards the core end 1 (For core termination, remove the release paper , pass the break out over the cores and pullita fr downinto the crutch as possible. Shrink the breakout into the place starting at the center. Work frst towards the lower end then shrinks laurels into the cores.) + cutback the core insulation o dimension required. Install the cable ug Clean and degrease the lug and the cor Insulation, ‘+ Wrap the sealant tape around the barrel ofthe cable lug, Stretch the tape to half ofits width and apply with half overap. 1+ Use the remaining sealant te fillin the space between the core insulation andthe cable lug to leave a smooth transition. 1+ Remove the release paper from non-racking tubing. Place the tubing with the sealant coated end downwards over the core, level withthe wire binder. “+ Shik the tubing starting atthe over sheath end working towards the cable ug + Gutthe tubing back onto the cable lug barrel i necessary. ‘+ Post heat the pal ofthe cable ig untia bed of mastic is seen around the top of the tubing.2.6 Organization, Responsibility & supervision PROJECT MANAGER ‘The Project manager is responsible fr assuring that adequate tots, equipment and ‘qualified manpower, Forman and superisors ae provided to implement the work ‘without delays and performing the work right the frst time ‘CONSTRUCTION MANAGER “The Construction manager i texponsibe for overall Implomentation of this Method statement and shall be responsible fr execution and contol of cable pulling procedure ‘The Construction manager shall be responsible for coordinating te activities ofthe site survey team , Ensuring all setting out and inspection functlonare performed accurately and reported effiiently to avoid delay on site QUALITY CONTROL MANAGER ‘The Quality Control Managers responsible to review the method statement and overseeing all the actives are in conformance with Projet Quality Plan, approved technical submittal, Project contract specification and IFC drawing. ELECTRICAL FIELD ENGINEER/SUPERINTENDENT “The assigned Field engineer/Superintendent shall be responsible for specific works, to control and supervise operations and workmanships and efficent use of resources to progress work in accordance with the approved drawings, specifications, material submittals and schedules to achieve the required quality, wll roport ll all matters concerning the work with the survey and quality control department to ensure that the planned tested and inspection activites as detaled inthe quality controlQUALITY CONTROL ENGINEER ‘The QC Engineer is responsible for ensuring test compliance from an applicable Specifations, conducting surveillance and inspection duties at various stages of Works as detailed Inthe QC program anc efficient recording and reporting of results as required, SURVEYOR ‘The survey department i responsible forthe setting out the works, dimensional Control and the preparation of as-built records as required. ES &H Manager The ES & H Manager shell be responsible for the implementation ofall safety measures at site provide risk assessments glve special concerns to housekeeping and to ensure site Isat tidy and lean contin, Foreman/ Field Supervisor The Foreman Feld Supervisor shal b ‘making sue that works are ercod ou approved drawings sponsible forthe fulltime supervision of works- accordance tothe specifications, quality and 2.7 Work force + Project Manager + Construction manager + electrical superintendent + Electrical field engineer + acelectrical engineer + conduit puting cea Equipment operators/Orivers + Sklled/ Unsklled labors -leetrian3. HEALTH AND SAFETY 2A. Risk Assessment see attachmet 901 3.2. ES& H CONTRACTOR REQUIREMENTS + Site safety control wl be conducted in accordance with the guidlines stipulated Ais Assessment© The folowing ES8H Standard Operating Procedure from Contractor ES8H Construction Phase Pian shalbe applied in ths Method Statement; Personal Protective Equipment Warehouse & Storreem Hand Tools Electrical Safety Safety Signage & baricades 3.3, PROTECTIVE & SAFETY EQUIPMENT “+ Mandatory PPEs (Hardhat. Urifor, Safety Shoes, and Safety Glasses) must be wom at all imes. Additonal PPE for specifi types of work shall be based on Personal Protective Equipment of ES&H Construction Phase Plan 3.4, CONTRACTUAL REQUIREMENTS = Contractor shall execute the works in accordance to RC Construction ESBH Manual and ES&H Construction Phase Plan, Whichoverhas the highest and stingent rules and ‘standard shall be applied to tis work «= Inabsence of aocepted standard, best accepted industy practice shal be engaged in the implementation of activities which includes the folowing but not ited t; ‘+ Provision of protection toutes “+ Provision of fagman for every equipment + Related totaling to all workers ‘+ Provaion of eafeaccoss and agroas to al personne! + RC Construction ESSH Manual shal be followed and discussed to all workers prior to execution of work ‘2.5. INFORMATION TO PERSONNEL, «Pir to start of any activity, a re-task biting shallbe conducted by foreman to ensure clear understanding ofthe stivity and the risk involved136. EMERGENCY PROCEDURES. + Inthe event of any accident or emergency, workers should immediately inform their ‘mnmedto supervisor and safely ofcers at sit «+ Worksite shal be evacuated 2s needed and all personnel shal proceed tothe nearest ‘Aswembly Point «+ Shou there be any patient that needs to be transfer, ambulance and site nurse shall be deployed immediatly to accent area. ‘Emergency Phone numbers sal be posted in all area for immesiate reporting of any emergency. 3.7, PERMITTING REQUIREMENTS + Allnecessary shall be secure prior to any activity st site 2s pr required by RC. 4, ENVIRONMENTAL ISSUES 44. Environmental impact Assessment “+ Afer all work activites in the electrical have been completed, all equipment and vali al Le eee Ge es + Alrubbish and Smal piece of cable and drum shal be cleared and shall be Disposed to designated disposal area. {2 6 & H CONLRACION HEQUIREMENTS ‘Sito safety contol willbe conducted in accordance withthe guidelines stipuate in Rsk ‘Assessment 1+ The folowing ES&H Standard Operating Procedure from Contractor ES&H CConetruetion Phase Plan shal be applied in his Method Statomont,Personal Protective Equipmant Warehouse & Storeroom Hand Toots Electrical Safety Salety Signage & baricades 43, CONTRACTUAL REQUIREMENTS. + Contractor shall execute the works In accordance to RC Construction ESBH Nana ‘and ES&H Construction Phase Plan. Whichever has the highest and stiingentrues and standard hall be applied to this work + Inabsence of accepted standards, best accepted industy practice shal be engaged in the implementation of activites which nudes te folowing bu nt inte to; + Provision ef protection to uiltes + Provision cf agman for every equipment + Related to airing to all workers + Provision cf safe access and egress to all personnel ‘+ RC Construction ESH Manual shal be folowed and discussed to a workers prior to execution of work 4.4, EMERGENCY PROCEDURES, “+ In te event of any ecodent or emergency, workers shoud Immediately inform Ut Immediate supervisor and safety officers at site “+ Work ste shal be evacuated as needed and all personnel shal proceed fo the rearest ‘Assembly Point. + Shouid thers be any patient that needs to be transfer, ambulance and site nurse shall lw doplayed inmediatly to accent aren ‘= Emergency Phone numbers shall bs posted In all aren for wanda voporny of ay ‘emergency5. QUALITY ASSURANCE. 5.41, CONTRACTUAL REQUIREMENTS, Contractor shall malstain the Qualty requirements ofthe works forthe whole course of Implementation of instalation of MV ‘cable pulling and Termination for the Project Conatuction Standard raquiroments areas flows For the assigned QC Engineer! Inspector to corr and monitor al quality requirements befor, ding and ater activites. Prepare and keep record of all gc related site aves including testing & inspection ‘material dliveries, Coordinate and witness electrical testing actives and anather elated test. 5.2, CRITICAL WORK ACTIVITY Ensure that the area is surrounded by safety caution tape during pling Low voltage ane contro! cable testing and termination should be performed by quaiied personel with Cable Slicer Certticaton trom authorizes agency. 5.2. INSPECTION & TESTING (ITP) Visual inspection for material reeaving and storage as well as Jurys end ator Iinctlation fs compulsory + Insuiaton Resistance Testng should be done pir Lo cable pli5.4, FOLLOW UP & EVALUATION © Review of dally/ meekly reports including test and inspections) shall be analyze with actions (including corecive and preventive ations, If required) to be recorded in accordance withthe procedure for review and aetlon purposes 1© Action items are tobe followed-up on subsequent reviews to ensure closure at time Specified © Complete review minutes and other written reports are to be kept and maintained for references 6.0 APPENDICES/ REFERENCES © Section 16407 Conductors and cables © Organization chart ‘© Drawing for the Location project site ° ° Teaffic management plan PTB CARD ( PRE TASK BRIEFING )CONFIRMATION OF INSTRUCTIONS TO OPERATIVES [Tie person Rate aio ont reap af Wetied lalemant apd ave hd he conn pained to them understand iad ae sare of testo ESB requremonts. 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