E&I CONSTRUCTION

TOOLS AND EQUIPMENT HIGH VOLTAGE CABLE PULLING

Tools and equipment needed should be in good condition and must be checked by Supervisor / Safety Engineer prior to use in the construction area.  These includes but not limited to:

1. Crane
2. Boom Truck
3. Multi-meter
4. Flat Bed Truck
5. Cable Pulling Machine
6. Cable Reel Stand
7. Cable Roller
8. Electrical Hand Tools
9. Cable Pulling Swivel
10. Hand Shovel
11. Cable Termination Tools (For 3kV~14.6kV and 35kV)
12. Cable Termination Kits (For 3kV~14.6kV and 35kV)
13. Splicing Kit (For 3kV~14.6kV and 35kV)
14. Set of Nylon Ropes
15. Wire Basket
16. Wheel Barrow

PROCEDURE FOR HIGH VOLTAGE (>1000V) CABLE PULLING

• All permanent and consumable materials shall be prepared prior to installation.
• Manpower, equipment, tools and other logistics shall be prepared and ready for installation.
• Suncontractor shall verify the trench and/or duct banks in correct routing, depth, and with readied sand bedding prior to cable installation.
• Ensure that all pertinent drawings and documents like the Cable Schedule for Plant Loads, Electrical Cable Schedule, Cable Drum Schedule, Layout of Main Cable Way, Duct Bank Layout (Cable Route), Cable Trench and Duct Bank Cross-Sections, Junction Box, Electrical Equipment Location/Plans, Substation/Control Room Layout, Conduit Stub-Up Drawings, Cable/Conduit Layout, Electrical Tie-Ins/Interface Drawings and One Line/Schematic Diagrams that will be used for construction and cross referencing in the cable pulling activity are of approved for construction and latest revisions.
• Insure the cable tray or conduit is inspected prior to cable pulling.
• Where cables are pulled in conduits or cable trays, cables should be free from foreign debris, cuts or damage.
• Ensure that work permit is prepared and secured. Safety concern and precautions are being complied and discuss with the crew.
• Prior to cable pulling, double check the following:

1. 1. Cable drum number
   2. Cable specification
   3. Cable size
   4. Cable type
   5. Cable Schedule
   6. Interconnection Diagram
   7. Cable Route
   8. Cable Drum Schedule

• Prior to start cable pulling, the following resources shall be prepared:

1. Fabricated special tools for cable pulling like cable roller for corners, intended for all cable size, in addition, for large size cable, cable rollers at straight part shall also be provided.
2. Cable stand for heavyweight cable, minimum of 20 tons capacity with solid shafting shall be available for deployment.
3. Lightweight cable stand shall also be available for deployment.
4. Cable roller shall be available for deployment. It shall be placed at a maximum distance of 2 meters.
5. Information board shall be available and placed.
6. Hand tools for uncrating of cables from cable drum like: bulk hammer, hack saw, cable cutter, claw bar, electrical flier and big screw driver.
7. Shovel, wheelbarrow, empty socks (sand bagging).
8. Masking tape, transparent tape, permanent marker pen, and ordinary electrical tape.
9. Nylon rope ¼” and ½” diameter, warning tape, signage stating (cable pulling on progress).
10. Physical barricade (scaffolding tube), stair ladder at trench for temporary access.
11. Mega phones, two way radio communication, signal flag (green and red).
12. Cable puller winch machine diesel driven (known as cable tagger) with operator.
13. Availability of manpower which is enough to accommodate the long trench or tray, cable arrangement, cable drum rolling driver, cable tag markings, taping cable ends, securing cable wire net basket and housekeeping.

 

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PROCEDURE FOR INSTRUMENT CABLE TERMINATION

Industry Codes and Standards for termination

NFPA 70                   National Electrical Code

NFPA 72                   National Fire Alarm Code

UL 44                         Thermoset-Insulated Wires and Cables

UL 83                         Thermoplastic-Insulated Wires and Cables

TOOLS AND EQUIPMENT FOR INSTRUMENT TERMINATION

Tools and equipment needed should be in good condition and must be checked by Instrument Supervisor prior to use. These includes but not limited to:

• Cable Drum Base
• Cable Cutter
• Man lift
• Cable Stripper
• Diagonal Cutting Pliers
• Electrical Pliers
• Fluke or Equal Multi Meter
• Measuring Tape
• Common Hand Tools
• Adjustable Wrenches
• Set of socket wrench
• Screw Drivers
• Cable Tie Fixing Gun
• Cable Numbering Tool
• Hack saw
• Crimping Tool
• Heat Gun
• Megger Tester
• Two way Communication Radio
• Test Lead with Test Probe, and Clips
• Terminal Lugs
• Insulation Electrical Tape
• Torque Wrench

CABLES CONNECTION AND TERMINATIONS

1. Compression (crimped) type connectors shall be used for splicing and terminating stranded conductors.
2. Compression in compression connectors is accomplished by means of a compression or crimping tool. Connectors in which compression is accomplished by means of bolts, set screws, etc., are mechanical, not compression connectors.
3. All compression connectors shall be tinned copper.
4. Check proper terminals and crimping die used on cable and proper crimping procedure is followed.
5. Inspect the proper connection in accordance with connection diagram or vendor connection.
6. Verify cable color coding or phasing.

TERMINATIONS/CONNECTIONS AT FIELD INSTRUMENTS & JUNCTION BOXES

1. Connections at Field Instruments: All connections at the field instrument shall be made on screw type terminal blocks. Wire nuts and spring type terminals shall not be used. Instruments with integral terminal blocks shall be connected directly to the field cable.
2. The outer jacket of shielded twisted single pair/triad cables shall be left intact up to the point of termination. Drain wires and mylar shields on shielded cables shall be cut and insulated with heat shrink sleeve at the field instrument unless otherwise specified by the instrument manufacturer.
3. All Cable entries to field Junction Boxes shall be through the bottom.
4. Conduit and Cable sealing shall be as per SAES-J-902 section 6. Cable gland being used shall be selected as per the “Cable Gland Selection Table”.
5. Twisted, multi-pair/triad cables shall be cut to the appropriate length to minimize looping and flexing of the cable within the junction box.
6. For twisted shielded single pair/triad cables the outer jacket shall be left intact up to the point-of-termination (approximately three to four inches from terminal blocks). The shield drain wire shall be insulated from jacket end to Approximately, one inch of heat shrink tubing shall be applied over the jacket end.
7. For individually shielded twisted multi-pair/triad cables each pair/triad shall be heat shrink sleeve insulated from the cable-jacket-end up to the point-of-termination to keep the foil shielding intact and free from accidental grounds.
8. The shield drain wire shall be insulated from foil end to terminal. Approximately, two inches of heat shrink tubing shall be applied over the jacket end.
9. All spare pairs/triads of a multi-pair/triad cable shall be terminated at both the field junction box and the marshaling cabinet. Drain wires for spare shielded pairs/triads shall also be individually terminated at these locations.
10. Each cable or group of cables carrying similar signals shall contain a minimum of 20% spare pairs or triads.
11. Cable shields must have a single, continuous path to ground. Special grounding terminals in intimate contact with the DIN Rail, jumper bars or preformed jumper combs designed for the selected terminal blocks shall be used to consolidate shield drain wires for connection to ground. Ground loops and floating shields shall be avoided. Shield drain wires shall not be daisy-chained to the ground connection.

 

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This article is explaining about instrument installation in industry, plants. Here we will see which international standards are used for instrument installation.

INSTALLATION PROCEDURE OF LOCAL INSTRUMENT

Process Industry Practices for Local Instrument

PIP PCCTE001        Temperature Measurement Criteria

PIP PCCLI001          Level Measurement Design Criteria

PIP PCCPA001        Process Analyzer System Design Criteria

PIP PCCPR001       Pressure Measurement Design Criteria

INSTALLATION OF LOCAL INSTRUMENT or INSTRUMENT INSTALLATION

1. Survey and study the designed location of local instruments to be    installed comparing the installation details and layout. Should    there be discrepancies or obstructions be found in the    construction drawings, site queries should be raised to EPC/COMPANY for further site instructions.
2. Check instrument locations and provide markings to which elevations, mounting height and orientations should conform in    the latest issued Approved for Construction drawings. 3D model provided by EPC/COMPANY shall be also referred to decide the most suitable location.
3. Verify the support against instrument to be installed if suited as per requirements of EPC/COMPANY technical scope of works and latest issued Approved for Construction Drawing.
4. Install necessary fabricated supports, brackets and pipe stanchions for local instruments, switches, local controllers,    indicators and other miscellaneous instruments. Ensure that the    orientation shall comply with the drawing layout considering    access point, service and tubing
5. Install the local instruments considering its visibility and the possible location of nameplate. Install identification tags to be attached to the case or mounted directly on an external surface as needed for Instrumentation System.
6. Install instrument in a safe manner that they are not subject to shock, excessive vibration or temperature extremes. All    instrument and connecting lines shall have allowance for    movement of equipment cause by seismic loading, vibration, or expansion and contraction cause by temperature change.
7. Installed instruments shall be confirmed the instrument type, instrument tag, correctly mounted, leveled, and aligned before    fastening to the support in accordance with hookup drawing and    project
8. All instruments shall be mounted as close to the process connection as possible. Impulse lines shall be as short as possible. The location of instruments shall be visible so that direct drainage of condensate, water or process fluids from adjacent equipment has no adverse effect. Instruments installation location shall be free from any vibration so that operation can read the meter reading clearly.
9. Instrument equipment location shall provide safe and easy access to operational and maintenance team. All field mounted instruments require access for maintenance and operational reasons. It shall not be installed on handrails nor supported by instrument tubing and shall be accessible from the grade or from permanently installed platforms.
10. All locally mounted off-line field mounted instrument, junction boxes and local panels shall be installed at 1.4m above the grade or access platform.
11. Instruments, panels, and associated wiring shall not obstruct walkways, platform and stairways.
12. Instrument vent ports shall be suitably protected with SS316 bug screen filters.
13. Installation of instrument, junction boxes and local panels in fire zones shall be avoided whenever possible,
14. Remote or off-line mounted instruments shall be installed on a dedicated mounting supports.
15. Instrument support for installation shall be hot dip galvanized otherwise specified. Support shall not fixed to gratings and not obstruct walkways.
16. Study the possible routes of instrument tubing together with the location of the tapping point and equipment or pipe to where the    instrument is intended. Install instrument tubing in a clean and safely manner to which the technical requirements shall be satisfied.
17. Local hand switches, terminal box, local panel for on/off valve, local panel for MOV, air volume tank shall be installed as per drawing. Also, accessibility and clearance shall be considered in its exact location.
18. Flow meters in liquid service shall be installed so that meters are always full of liquid and shall be installed to avoid trapping In gas service, liquid trapping shall be avoided. Refer to PIP PCCFL001 sec. 3.1.3.3.
19. Pressure switches shall be installed with connections for calibrations without removing the switch from its mounting. Pressure switches containing open contacts shall not be connected directly to flammable     or explosive process fluids. Refer to PIP PCCPR001 sec. 4.3.2.
20. Level transmitter shall be mounted at or below the centerline of the high pressure nozzle (lower nozzle of vessel). Refer to PIP PCCLI001 sec. 5.2.
21. Temperature transmitter shall be mounted remotely from the RTD/ thermowell assembly.
22. Put temporary identification tags for the instruments not completely installed and provide warning signs to remind   nearby    construction for the protection of instrument. Also,   protection cover shall be provided against damage during construction
23. Proper care shall be observed when removing and re-installing local instruments when replacement or repair shall be done.    Ensure that the flow direction after reinstallation has been followed.
24. After final installation, install sunshade to all field instruments as    required to its detail drawings.
25. No welding works shall be done to any process equipment and If damage or cut of galvanized surfaces of the support    will occur, repair shall be done using approved galvanizing    materials.
26. When local instrument will be installed on platform, kick plate should be installed as per standard.
27. When hole is necessary to penetrate the platform due to tray or tubing, kick plate should be installed as per standard.
28. When miscellaneous foundation is required for local instrument, finishing mortar for concrete foundation with sunlight  resistant coating shall be provided as per project specification.
29. QC inspector shall conduct inspection and acceptance for local instruments installed to be filed and recorded on appropriate approved forms.

 

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