TABLE
OF CONTENTS
1. PURPOSE
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3
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2. SCOPE
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3
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3. REFERENCES
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3
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4. DEFINITIONS
AND ABBREVIATIONS
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3
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5. GENERAL
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4
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5.1.
PERSONNEL DUTIES AND RESPONSIBILITIES
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4
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5.2.
QUALIFICATIONS AND
TRAININGS
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4
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5.3.
EQUIPMENT AND TOOLS
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4
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5.4.
MATERIAL RECEIVING,
STORAGE & INSPECTION
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5
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6. SAFETY
REQUIREMENTS
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5 -6
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7. GENERAL
INSTALLATION
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6
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7.1.
CABLE PULLING
CONSIDERATIONS
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6
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7.2.
DIRECT BURIED/TRENCH CABLE
PULLING CONSIDERATIONS
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6 - 7
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7.3.
CABLE PULLING IN CABLE
TRAY CONSIDERATIONS
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7
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7.4.
CABLE PULLING IN CONDUITS
CONSIDERATIONS
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7
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7.5.
PROTECTION OF EQUIPMENT
AND MATERIALS
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7
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7.6.
EXPLOSION PROTECTION
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7
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8. PROCEDURE
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8
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8.1.
CABLE PULLING INSTALLATION
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8 - 9
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8.2.
STORAGE AND HANDLING
FIGURES
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9 - 13
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9. QUALITY
ASSURANCE AND TESTING
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13
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10. ATTACHMENTS
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13
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1. PURPOSE
The purpose of this method statement is to
provide guideline for laying and pulling of cables shall carry out in a neat,
efficient and skillful manner, assuring satisfactory results. The work shall be
in accordance with the requirements of the project specifications, standards,
and shall fulfill their true intent and meaning.
This method statement covers the methodology
for laying and pulling of cables in Luberef Yanbu Expansion project.
These guidelines and information describes
laying and pulling techniques and different requirements to be adhered during
the course of execution for laying and pulling of cables, to get a satisfactory
result and in accordance with established safety practices. It does not intend
to cover all details and variations in laying and pulling of cables nor provide
for every possible installation contingency.
3. REFERENCES
a)
Project Scope of Works
b)
Project Technical Specification
c)
Applicable Saudi ARAMCO standards.
d)
Issued for Construction drawings
e)
Cable Schedule
4. DEFINITIONS AND ABBREVIATION
a)
SAES
b)
SATIP
c)
SAIC
d)
NEC
e)
IEC
f)
RFI
g)
MRR
h)
ITP
i)
COMPANY
j)
CONTRACTOR
k)
SUBCONTRACTOR
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Saudi
Aramco Engineering Standard
Saudi
Aramco Technical Inspection Procedure
Saudi
Aramco Inspection Checklist
National
Electrical Code
International
Electro-Technical Commission
Request
for Inspection
Material
Receiving Report
Inspection
and Test Plan
Luberef
or its designated Representative
Samsung
Engineering Const. Ltd.
Any
Individual or Corporation under contract to the CONTRACTOR who perform the
entire and/or some portion of the work or services
on a project which the CONTRACTOR has agreed
upon.
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5.1.
PERSONNEL, DUTIES AND RESPONSIBILITIES
a)
Instrumentation
Manager
i) Manager will
be coordinating with concerned personnel at site, plan the daily work schedule,
allocate the job to concerned supervisors, and controlling the installation
works in all the areas.
b)
Instrument Supervisor
i)
Supervisor is responsible and ensuring that
the works are carried out according to the Contract Specifications and approved
Method Statement.
ii)
Provide all necessary information and
distribute responsibilities to his construction team.
iii)
Monitor the progress of work in relation with
the work program and to report to the Manager.
iv)
Coordinate with Safety Officer and to ensure
that the works are carried out in safe practicing methods.
c)
Quality
Control Manager
i)
Responsible for the implementation of all
required quality control activities such as test and inspection for this
particular job and keeps record of its necessary documentation.
d)
Quality
Control Inspector
i)
Inspect the work to comply according to
contract drawings and Company standards.
e)
Safety
Supervisor
i)
Make sure that all safety measures are
complied before starting the work.
ii)
Provide safety instructions to the workers.
iii)
Ensure
the implementation of all the safety measures in accordance with the HSE plan
and everybody aware of it for its proper implementation.
iv)
Ensure
all the implemented safety measures are adequate to maintain the safe working
on the site.
v)
Inspect
all the site activities and train the persons to prevent accidents and its
proper reporting to the project manager and the client.
5.2.
QUALIFICATIONS
AND TRAININGS
a)
Supervisors & Inspectors must be eligible
and competent for the job.
b)
Workers must able to understand his work and
require trade certificates if necessary.
c)
Conduct trainings regularly to maintained
safety and good workmanship.
5.3.
EQUIPMENTS AND TOOLS
a)
Cable hand shear, Hydraulic shear, Cable
hauling winch
b)
Cable roller (straight and bend)
c)
Cable drum support stand
d)
Hand Tools, Tape (Masking and Clear type) and
Marker pen
e)
Mobile Crane, Boom truck, Forklift
f)
Fish tape, cable basket, wire basket, rope
g)
Appropriate safety equipment
5.4.
MATERIAL RECEIVING, STORAGE & INSPECTION
a)
Upon receipt of the material, it shall be inspected
with respect to project specification, approved construction drawings, data
sheets and delivery note. Be sure to note and report any damage on the MRR
documents.
b)
Do not allow the drums to drop from the
delivery truck during the unloading process. When a forklift is used, the forks
must support both drum flanges. Drums can be hoisted by lifting on a metal
shaft of sufficient size and strength placed through the center hole of the drum.
Handling equipment must not come in contact with the cable.
c)
Cable drums shall only be rolled in the
direction shown, or in the direction opposite to the direction that the cable
is wrapped on the drum. Rolling drums in the wrong direction can cause the cable
to loosen on the drum, which may cause problems during cable dedruming or
installation.
d)
Do not allow drums to roll uncontrolled as
they may roll into objects, damaging the cable or causing personal injury. When
rolling drums down inclines, the incline shall be as gradual as possible, and
control of the drum must be maintained.
e)
Use care when choosing a location for cable
storage. The temperature of the storage location shall be -10°C or higher.
Cable drums shall be stored indoors on a dry surface or, if stored outdoors,
placed on suitable dunnage of sufficient size to support the drum weight
without sinking or allowing the drums to come in contact with moisture. Drums
stored outside (prior to and after installation) shall be covered with
weatherproof material to protect drums and cable from sunlight and moisture,
and cable ends must be kept sealed and shall remain fastened to the drum flange
to prevent them from laying on the ground.
f)
Store drums on their flanges, properly
chocked to prevent rolling. Be sure to allow enough room between drums to allow
access to the drums for removal. Note: Perform
Insulation Resistance and Continuity Test prior to transfer of cable drum in
Construction site.
g)
Refer to ‘8.2. Storage and Handling Figures’
for proper handling of cable and cable drums.
a) Conformity
and execution in accordance with field Safety Management Plan.
b) Safety
management during work (Worker Personnel Protective Equipment and temporary
safety structure establishment / operation).
c) Regarding to
safety all relevant JHA (Job Hazard Analysis) will be submitted separately.
d) Toolbox talk
shall be conducted daily prior to work start Permit to Work (PTW) must be
obtained and available at the work location.
e) Safety Supervisor
/ Officer to ensure that all working flat forms shall be safe and in good
condition.
f) Safety Supervisor
/ Officer shall carry out the safety site inspections to ensure that safety
requirements laid in the safe work plan are being followed during and after the
work.
g) CONTRACTOR/SUBCONTRACTOR
shall provide safety equipments as necessary according to an evaluation of
expected needs during construction. This applies to temporary fire
extinguishers first aid equipments, stretcher, etc.
h) Authorized
personnel shall inspect all equipments and electrical tools prior to commence
any Work and shall be inspected & tag by safety personnel to ensure their
safe worthiness at work. The inspection reports shall be kept for record.
i) Workers
shall ensure that before leaving their working places, it must be clean, tidy
and free from rubbish.
j) Working at
heights (if necessary)
i.
Full body harness with two lanyards must be
issued for all workers working on 1.8 meters and above and 100% tied off shall
be strictly implemented.
ii.
CONTRACTOR/SUBCONTRACTOR Work at Height
training must be completed by the involve workers prior to mobilization to the
site.
iii.
Install / erect proper scaffolds / ladders
wherever required for safe installation practices.
iv.
The Scaffolding inspector shall inspect, certify
and tag the erected scaffolding platform before use.
v.
Tools and materials must be secured and tied
properly when using and lifting on height respectively.
vi.
When using mobile elevated working platform,
ensure it is in good working condition, free of defect and with valid third party
inspection certificate. Working area shall be barricaded and warning signs must
be posted.
7. GENERAL INSTALLATION
Typical
installation of power and wiring systems for instrumentation shall be in
accordance with SAES-J-902, approved construction drawing, and site condition unless
otherwise supplemented by this procedure.
7.1.
CABLE PULLING CONSIDERATIONS
a) Ensure that
a worksite location has been released and ready for safe work execution.
b) Check
availability of all approved Issued for Construction (IFC) drawings, cable list
and schedules.
c) Before
starting cable-laying work, cable route/size/depth of the cable trench shall be
checked, cable rollers and cable drum stand/jack shall be available as well.
Ensure that the cable drum stands/jacks can sustain the load/cable drum.
d) Cable drum shall
be placed at suitable place so that its placement shall not disturb the other
activities.
e) Cable
rollers to be installed as required. Maintain the minimum cable-bending radius
during pulling is as per the standards or manufacturer's recommendation.
f) Cables
emerging from below ground shall be protected by nonmetallic protective sleeve.
g) All cable
ties used in the field shall be 'nylon coated SUS material.
h) All cable
ties used inside of enclosures and buildings (i.e., field junction boxes,
marshaling cabinets, control rooms, and PIBs) shall be weather resistant nylon
cable ties.
7.2.
DIRECT
BURIED/TRENCH CABLE PULLING CONSIDERATIONS
a)
Complete installation of cable trench
(coordination to Civil contractor)
b)
Voltage level of cables were identified,
cable schedule as per Project Specification.
c)
Verify that the cable pulling rollers are
placed at appropriate intervals and at offsets.
d)
Cables are not being pulled over sharp or
abrasive edges / put protection.
e)
Do not pull cable with excessive tension /
force.
7.3.
CABLE PULLING
IN CABLE TRAY CONSIDERATIONS
a)
Cable trays are inspected free from sharp
edges and burrs that could damage the cable.
b)
Cable trays were properly and completely
supported.
c)
Identification of cable tray was cables are
to be placed in reference to voltage level.
d)
Place the cable pulling rollers at three (3)
meter interval and secure them on the tray.
e)
Larger cables will usually require a basket
grip and/or pulling eye attach to the leading end of the cables metallic
conductor(s).
f)
Avoid excessive pulling.
g)
Cables shall be fastened every Five hundred
(500) millimeter on vertical trays and One thousand (1000) millimeter on
horizontal trays using cable ties.
7.4.
CABLE
PULLING IN CONDUITS CONSIDERATIONS
a)
Complete installation of cable duct/conduit.
b)
Verify that sharp edges on cut lengths are
smoothened.
c)
Voltage level of cables were identified,
cable schedule as per specification.
d)
Cables are not being pulled over sharp or
abrasive edges.
e)
Do not pull cable with excessive
tension/force.
f)
Protection of cable insulation at pulling
location (sleeve, pull box, stub-up, bends, etc.)
7.5 CABLE
PULLING PROCEDURE IN CONCRETE SLAB REMOVEL
CONSIDERATION.
a)Ensure that a worksite location has
been released and ready for safe
Work
execution.
b)
7.5.
PROTECTION
OF EQUIPMENT AND MATERIALS
a)
During the installation, equipments shall be
protected from water, moisture, dust, falling objects and other adverse
effects.
7.6.
EXPLOSION
PROTECTION
a)
Within explosion-hazardous areas, only
equipment approved for such application shall be used.
b)
A hazardous area classification shown in the
drawing, apart from the hazardous areas, the safety distances required shall
serve as a basis.
c)
The area classification, and thus selection
of the equipment, depends on the gases and vapors occurring in the hazardous
areas.
8.
PROCEDURE
8.1.
CABLE PULLING INSTALLATION
a)
Field supervisor shall organize the cable-pulling
plan, lifting method to be used (by boom truck, crane or forklift), number of
required persons and location of cable drum.
b)
Larger cables will usually require a basket
grip and/or pulling eye to be attached to the leading end of the cables
metallic conductor(s). Where pulling attachments are used on the conductors,
cover them with rubber-like or plastic tapes to prevent scoring of the cable
trays and installation sheaves during a conductor pull.
c)
Cable drum will generally be placed on drum
jacks with an axle of sufficient size and strength to allow the drum to turn freely
with a minimum of friction.
d)
Communications shall be established between
the pulling end of the run and the drum end of the run.
e)
Be sure to have adequate personnel available
at the drum end to aid in feeding the cable, watching to prevent cables from being
crossed and for drum braking if necessary.
f)
Cables may be pulled by hand with operatives
placed at frequent intervals to support the cables and avoid excessive tension.
Where cables are not supported at frequent intervals by operatives, then they
must be supported by cable rollers and placed at suitable intervals to avoid
contact of cable sheath with abrasive surfaces.
g)
The cable shall be pulled by hand at a
constant speed during the pull.
h)
At smaller conduit size, “Pull by fish tape”
is common method in pulling cables. Fish tapes breaks free of the wire during
pull because of improper method. Fish tapes shall not be jammed through the
wire way, this put kinks in the tape and make difficult for wire to be pulled.
i)
Cable pulling lubricant (pulling compound)
shall be applied during cable pulling inside conduits. In duct banks care shall
be taken to protect the cables already pulled by means of temporarily inserted
half cut PVC pipes or by means of rubber sheets placed above cables already
pulled.
j)
Ensure that the cables are installed on the
correct level of ladder rack in accordance with the cable pull-sheet. Where
cables are routed through ducts, an approved commercial lubricant or
appropriate cable protection to be provide compatible with the cable sheath. Pulling ropes are provide in each PVC duct.
k)
Cable shall not be pulled bends excessively;
Care shall be taken to avoid any scratches on the cable sheath while pulling
cables.
l)
Do not allow the cables to drop in the cable
tray as this may damage the cable and/or the cable tray.
m)
Extra care shall be taken when pulling cables
to avoid loops. If a loop shall occur under no circumstances, attempt be made
to remove the loop by tensioning the cable, the loop shall be removed by
carefully coiling to the nearest end.
n)
Unwind the cable from the drum to secure the
required extra length to reach the panel and coil it on the tarpaulin.
o)
When the cable reaches end of trench at the
equipment location, allow two (2) meters of extra length of cable fro dressing
and termination requirements.
p)
Cutting cables must be done with appropriate
tools such as hydraulic shears, hand shears, cable cutter or hacksaw (measure the
required length before cutting).
q)
Immediately after a cable has been laid and
cut temporary protection cover shall be made on the ends to avoid moisture
absorption to the cable strands and temporary identification label shall be
made at each end, the identification shall be as on the cable pull schedule.
Final label or identification will have to be installed after termination is
completed.
Note: For
underground cable, Insulation Resistance and Continuity test is recommended
prior to backfilling.
r)
Each cable shall be dresses to provide at
right installation along its entire length. Once, all cables have been laid on
a route level; dress the cables, removing all temporary tie wraps and securing
with permanent tie wraps/clamps on all vertical cable risers.
s)
Mark-up / as-Built drawings for any changes
made. Clean the area after completing cable pulling, cable tagging were
installed.
8.2.
STORAGE AND HANDLING FIGURES:
a)
Figure A. Transportation
i.
Do Not Drop
Cables from Vehicle
ii)
Secure Drums
Adequately Before Transportation
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b)
Figure B. Handling and Storage
i.
Correct Drum
Storage
Incorrect Drum Storage
The drum shall be
stood upright, using wedges in the heels of the flanges.
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This type of
storage is not recommended.
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ii.
Drum storage
view from the top
The drums shall be
aligned as shown.
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iii.
Manual Handling Of Drums
Cable
drums shall be rolled for short distances over flat, solid ground in the
direction indicated by the arrow on the flange (see figure below), having
regard to:
ü The mass of the
drum
ü The method and direction of rolling
ü The condition of floor/ground including
slopes
ü The risk
assessment
ü Particular care shall be taken when drums are
full of cable
NOTE: Wooden drums
frequently have an arrow marked on their flanges to indicate that cable is to
be wound on to them and the direction in which the drum is to be rolled.
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iv.
Lifting By Crane
v.
Lifting by Fork lift
It is important that drums are correctly position on
the forks.
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vi.
Unwinding cable
Cable shall be
unwound as shown.
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Cable shall be
unwound in this way.
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NOTE: The arrow on
the drum flange does not indicate direction of unwinding.
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c)
Figure C. Coiling at Ground
i.
Do Not
Attempt “Coiling” Of Cable on the Ground
ii.
On the
Ground Cable Can Be Flaked In A Figure Of Eight Formation
A
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B
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C
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D
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NOTE: “R” minimum permissible bending radius
of cable.
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9. QUALITY ASSURANCE AND TESTING
a) A Quality
Assurance System shall be operated conforming to related Standards,
Specifications and Procedures.
b) Controls and
checks shall be established and documented Manufacturer’s recommendation for
products and materials that used needs special attention.
c) Inspections
and tests shall be carried out in accordance with the approved ITP and
procedures and in accordance with the project specification.
d) Request for
Inspection (RFI) and material testing to be raised as per procedures.
e) The
inspection result shall be documented on the related reports/checklist.
10. ATTACHMENTS
Job
Safety Analysis (JSA)
Activity
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Potential
Hazards
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Preventive
Measures
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Apply
for permit to work
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1)
Permit inadequate
2)
Non compliance to permit
3)
Lack of understanding of Permit
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1)
Strict compliance to the PTW procedure and
requirements will visible in the work area.
2)
The permit issuer and receiver prior to the
issuance and acceptance of the PTW should conduct work area inspection.
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Offloading
of cable drums at site
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1)
Sub standard working practice
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1)
Wear correct PPE at all times.
2)
Ensure that there are enough personnel to
unloading & ensure correct lifting technique.
3)
Chock cable drums.
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Preparing
to Pull cables
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1)
Unauthorized personnel
2)
Abrasive / sharp edges
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1)
Barricade the working area
2)
When pulling the cable ensure the route to be
taken is free from sharp edges and abrasive surfaces.
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Lift
cable drums using jacks
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1)
Uncontrolled movement of cable drum
2)
Sub standard jacks
3)
Un even surface
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1)
Chock cable drum or even surface
2)
Inspect cable jack prior to use and ensure
they are in good order.
3)
Ensure the cable drum and cable jacks are
position in even surface.
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Positioning
of personnel
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1)
Excessive drum speed during manual transfer.
2)
Incorrect positioned of personnel.
3)
Personnel not secured
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1)
Position one person to control the drum speed.
2)
Only one person seated per length of cable
racks.
3)
No person is allowed to walk in cable racks.
4)
All personnel to wear double land yard safety
harness and both land yards are securely fasten.
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Cable
Pulling
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1)
Twist and Kinks
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1)
When unrolling cable from drum take care to
prevent cable from developing twists and kinks.
2)
Do not pull cable which has twists or kinks in
it.
3)
First remove any twists or kinks.
4)
Ensure the cable end is properly controlled to
prevent “whip lash” as the drum draws empty.
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Hoisting
cable end to cable
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1)
Sub standard sock and rope
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1)
Rope and sock must be inspected for flaws
prior to use.
2)
Damaged rope and sock must be marked as such
and removed from site.
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Personnel
handling cable
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1)
Hand / Finger injuries.
2)
Injury to back
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1)
All personnel to wear gloves.
2)
Pick up and hold cable correctly, bent knees
and hold cable close to body.
3)
Foreman to ensure enough personnel are
available for the task.
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Secure
cable to cable rack
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1)
Cable not properly secured to cable rack
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2)
Use prescribed securing method and material to
secure from cable to cable rack.
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Housekeeping
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1)
Tripping Hazard
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1)
Access shall be free of equipment materials
that would create a tripping hazard for personnel using the access.
2)
Receptacles for waste shall be provide at site
and regular clean-ups shall be conducted
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