PROCEDURE FOR HIGH VOLTAGE CABLE PULLING

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. 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.

 

STORAGE AND HANDLING HIGH VOLTAGE CABLES

  1. Store the cable drum in firm surface and dry location, to protect from mechanical damage or weather effects.
  2. Cable drum should always be stored in an upright position, resting it vertically on cable flange edge and not in horizontal position.
  3. Use wooden block support to avoid rolling over.
  4. Keep sufficient gap between stored cable drums. It is a good practice to use pesticides at regular intervals in storage area to avoid termite & rodent attack on wooden drums.
  5. During transportation the cable drum shall be fastened to the base through the center hole or across the flanges, to prevent movement of drums.
  6. When lifting the drum using crane, use a shaft through the center of the drum and a spreader beam.
  7. Lifting cable drum with fork lift is only allowed from the flange side. The fork may never touch the cable or its protective cover to avoid damage. The fork must support both flange while lifting.

 HIGH VOLTAGE CABLES INSTALLATION

  1. All cable drums and coils, upon receipt shall be inspected against the packing list for completeness and physical damage, and on reel inspection shall be required for all cables.
  2. Where physical damage or non-compliance with the specification is found or any problems associated with the supplied cables such as incorrect cable drum quantity, sizes, etc., Subcontractor shall record using Material Receiving Inspection Report and report immediately to company for disposition. Any damages and discrepancies found during receiving and/or installation shall be documented on a Non-Conformance Report (NCR) form or Observation Report form.
  3. The CMIC / Supervisor shall monitor the withdrawal of cables at the warehouse ensuring the cable type, number, size, length and drum number are correct and no visible damage on the cable drum packaging.
  4. Cable drums must be stored on their round side and must not lie on its flat side. It shall be stored in designated areas in such a manner that it can be easily identified and/or removed.
  5. Upon receiving of cable drum, check cable for continuity and insulation resistance for possible handling damages and factory defects.
  6. Refer to Cable Drum Schedule for drum selection and withdrawal.
  7. The CMIC/Supervisor is responsible in determining the necessary cable length allowances on both ends of the cable taking into consideration the location, route and elevation of the termination point.
  8. Use Mega phones, two way radio communication, signal flag (green – for Go and red – for Stop) for signaling and communication during cable pulling progress.
  9. For the maximum pulling tension of the cable, refer to cable manufacturer’s technical data sheet – attachment 3 & 4.

ABOVEGROUND  HIGH VOLTAGE CABLES INSTALLATION

  1. Cable tray/conduit route length shall be verified. The required length as per the cable route shall be measured physically and leaving sufficient length for final connection before cutting the
  2. Cable tray/conduit shall be free from any sharp edges, foreign       objects and unnecessary bends. Before installation of cables, remove debris and moisture from conduit and equipment For all conduits, low point drain and breather shall be installed as per requirement.
  3. Where instrument signal and power cables run in parallel,    segregation distance shall be followed and maintained in accordance with SAES-J-902 para. 14.2.
  4. Position cable drums at an appropriate point for installation and    ensure that cable drum number matches the number in the Cable Drum Schedule.
  5. Ensure that the individual cable lengths are taken from the properly designated drum.
  6. Wires and cables pulled into a conduit shall use an acceptable lubricant or pulling compound as per approved MAR.
  7. Communication and other low current cables shall be installed on separate cable trays or cable trunk with fire alarm cables separated by mechanical separators from other cables
  8. CMIC / Supervisor must ensure that proper cable tag is installed at the lead end of the cable before the start of the pulling and at the back end of the cable after the pulling.
  9. CMIC / Supervisor must monitor and record each completed cables everyday and report to subcontractor Electrical Manager and responsible engineer the daily accomplishment.
  10. All cables shall be dressed in a proper manner on cable trays and to Junction Box or Panel.
  11. After complete installation and dress-up, individual lengths shall be Continuity and Insulation Resistance tested.
  12. QC inspection and testing for completed cable installation shall be requested and recorded using applicable forms based on SATIP.
  13. If the cable is not going to be terminated immediately after its installation and testing, seal or cap its end to avoid moisture and water ingress.

UNDERGROUND HIGH VOLTAGE CABLES INSTALLATION

  1. Trenches are of proper route, width, depth and sand bedding dimensions as shown on approved for construction drawings.       Compaction requirements shall be as per QC Inspection and testing shall be requested and recorded (to be handed   over by Civil Subcontractor).
  2. Sand bedding and sand filling materials to be used shall be as per Project Specifications of the approved type for the cable used and free from any sharp stones, debris and contaminant materials.
  3. Duct banks shall be inspected and shall be free from any foreign materials and/or sharp edges.
  4. Duct banks shall be cleaned using mandrel. Wrap clean cloth       around the mandrel and with the aid of pulling wire/rope placed at both ends of the mandrel, clean the interior of the duct bank by       pulling the mandrel back and forth from both ends of the duct bank.
  5. All road crossings and duct banks to building entries shall be identified according to construction drawings. Temporary trench  sectional marking shall be installed near the trench for ease of
  6. CMIC/Supervisor shall insure that the individual cable lengths are taken from the properly designated drum.
  7. Where instrument signal and power cables run in parallel, above or below ground, segregation distance shall be followed.
  8. Position cable drums at appropriate points for installation and ensure that cable drum number matches the number in the Cable  Drum Schedule.
  9. CMIC/Supervisor must ensure that proper cable tag is installed at the lead end of the cable before the start of the pulling and at the       back end of the cable after the pulling.
  10. Set cable drum jacks on leveled ground, use wood planks or plywood if necessary.
  11. If necessary, ensure that sufficient cable routes are set out and positioned at suitable intervals for ease of installation and to avoid       excessive tension and damage to cable.
  12. Cable shall be pulled according to the Cable Drum Schedule and according to the direction of arrow shown on the cable drum side.
  13. Cable pulling shall be done carefully to avoid kinks, damage or stress on the cable.
  14. Where cables need to be pulled inside underground conduit, the conduit shall be cleaned and pulling wire/rope must be set inside       the conduit prior to cabling.
  15. Make sure, while pulling cable, that the bending radius specified by the cable manufacturer is not exceeded and that sufficient length is   allowed for ease of termination.
  16. Cable rollers, such as corner rollers and straight rollers shall be used properly.
  17. Once cable laying/pulling is completed, cable rollers shall be removed, cables shall be laid in its final location and visually       inspected for any physical damage, stress and/or kinks.
  18. Before cutting the cable, both ends must be inspected to ensure sufficient length is left for slack and for ease of termination.
  19. CMIC/Supervisor must monitor and record each completed cables everyday and report to company responsible engineer the daily       He shall also update the cable pulling guide       board by putting distinctive mark on completed cables.
  20. CMIC/Supervisor shall record the estimated length of excess cables on every cable drum and provide visible marker on the drum       itself for future use.
  21. The operation shall continue until all cables in trench, duct bank entries and exits are permanently/securely identified.
  22. Prior to sand filling and/or backfilling of cables or layer of cables, the CMIC/Supervisor, QC and Foreman including the cable pulling       crew shall check and double check the completeness of the cables       based on the latest issued cable schedule, layout drawings, duct       bank/trenches cross-sections, monitoring sheet and cable pulling       guide board.
  23. Where installed in trenches prior to backfilling, individual cable lengths shall be Continuity and Insulation Resistance tested.
  24. If the cable is not going to be terminated immediately after its installation, seal or cap its end to avoid moisture and water ingress.
  25. Route markers for underground cable shall be installed as per standard drawings.

HIGH VOLTAGE CABLES CABLE TERMINATION

  • Manufacturer’s drawings and instructions for termination kits shall be studied prior to cable terminations.
  • Electrical cables shall be terminated in accordance with SAES-P-104.
  • Prior to fit-up of cable glands, check the Cable Gland Schedule to conform to its correct size, type and area classification. Where glands are to be installed in hazardous areas, the certification of the gland shall be verified.
  • Particular attention shall be paid to glands intended for steel wire armored and lead-sheathed cables to ensure that correct sealing and clamping components are supplied and properly fitted.
  • Before tightening and sealing the gland, the whole assembly shall be inspected of the following:
    • The cable tails are correct length and undamaged during stripping.
    • The steel wire armor shall be stripped to the correct length such that it mates with, but does not protrude into the enclosure.
    • Earth is terminated and tagged as required.
    • The outer sheath of the cable is contained within the gland.
    • The gland shroud is fitted (if required).
  • Cable glands should not be over tightened and for instrument cables, special attention shall be paid to cable screens in such a way that the screening is earthed only at the intended location and that multiple earthing does not occur.
  • After assembly and tightening, the gland shall be checked to ensure that:
    • The body is securely fitted to the enclosure.
    • The gland is mechanically sound and complete.
    • The clamping and the steel wire armor are secure.
    • The outer sheath is sealed.
    • Gland shroud is properly fixed (if required).
  • When cable glanding is completed and core markers are installed, point-to-point checking shall be performed to prove identification and color codes of cables are correct and cable connections are in accordance with reference drawings.
  • Screen/drain wires shall be electrically insulated and terminated as shown on construction drawings.
  • For the termination of the electrical cables, the following points shall be followed:
    • For bolted connections, the specified torque values shall be followed and calibrated torque wrench shall be used.
    • Crimp cable lugs shall only be used with the proper crimping tool and dies.
    • The cable shall be terminated in accordance with equipment manufacturer’s instructions, including torquing of bolted connections.
  • Phase location and marking of cables: left-to-right, top-to-bottom or front-to-rear shall be in accordance with specification requirements and drawing details.
  • Visual inspection shall be conducted on the completed termination work to be witnessed by ARCC and DEC/JGC.
  • QC inspection for completed cable termination shall be requested and recorded using appropriate inspection form on SATIP.

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