AMA00E ----- ----- EI210 RA Erection Instruction for Laying of Power and Control Cables

Replaces

Customer Code

ALSTOM Document Code AMA/00/E/----------/EI/210

Responsible dept. TYCC-IN

Created by Samy A-L.

Checked by Gupta S.

Approved by Varshney S.

Format A4

Document Type Erection Instruction

Document Status Electronically released Identification number

1AHA608550

Originator

POWER GAS BUSINESS

Title, Subtitle Erection Instruction for Laying of Power & Control Cables

Rev. A

Date 21.05.2012

Lang. en

Sheet 1/18

Template No.: Att.1 to >XYZ/00/-/01-----001/PPI/001 A< (released with corresponding Project Procedure >XYZ/00/-/01-----001PPI/001<)

© ALSTOM 2012. All rights reserved. Please consider the environment before printing this document.

Erection Instruction for Laying of Power&Control Cables

Owner

Project

AL–MANSURYA GAS TURBINE POWER PLANT (PHASE I)

Space for Stamping (Review and Validation status)

Cross checked Department Name Date Signature

Revision History Rev. Revision Date Created by Checked by Approved by Brief Description

Description Current Revision

Qais.alhayali

Group

svarshne

Text Box

RFC

svarshne

Text Box

08.10.2012

svarshne

Text Box

SV

Electronically released

Originator

ALSTOM ‌ POWER Identification number 1AHA608550

Rev. A

Date 21.05.2012

Lang. en

Sheet 2/18

© ALSTOM 2012. All rights reserved.

Table of Contents:

1 PURPOSE ..............................................................................................................................................................3

2 SCOPE....................................................................................................................................................................3

3 SYSTEM DESCRIPTION......................................................................................................................................4

4 REFERENCE CODES AND REGULATIONS ....................................................................................................5

5 REFERENCE DOCUMENTS ...............................................................................................................................5

6 HEALTH AND SAFETY........................................................................................................................................6

7 TOOLS AND EQUIPMENT...................................................................................................................................7

8 MATERIAL RECEIPT AND STORAGE..............................................................................................................8

9 CABLE INSTALLATION.......................................................................................................................................9

9.1 GENERAL .........................................................................................................................................................9

9.2 PREPARATION................................................................................................................................................9

9.3 TRANSPORT OF DRUMS TO WORK SITE................................................................................................10

9.4 DRUM POSITIONING....................................................................................................................................11

9.5 PREPARATION FOR CABLE PULLING ......................................................................................................11

9.6 CABLE PULLING............................................................................................................................................12

9.7 CABLE DRESSING........................................................................................................................................13

9.8 PROTECTION OF CABLEs...........................................................................................................................14

9.9 CABLE CUTTING...........................................................................................................................................14

9.10 REPAIR OR CABLE DAMAGE .....................................................................................................................14

9.11 CABLE IDENTIFICATION..............................................................................................................................14

9.12 FINAL CABLE DRESSING ............................................................................................................................15

9.13 PROGRESS AND MATERIAL USAGE REPORTING.................................................................................16

9.14 PARTLY USED AND EMPTY DRUMS.........................................................................................................16

9.15 CABLE REMNANTS ......................................................................................................................................17

9.16 HIGH VOLTAGE CABLES.........................................................................................................................17

10 INSEPECTION AND TEST.................................................................................................................................18

11 RECORDS............................................................................................................................................................18


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 3/18


1 PURPOSE

The purpose of this document is to provide specific procedures and guidelines to ensure that correct installation, with good workmanship and proper documentation, is achieved for the cable laying operation for whole Project.

2 SCOPE

Power and C&I cables are to be installed covering the power station systems.

The cabling systems play a vital role in the overall control of the power plant processes and it is therefore essential that the highest quality of workmanship shall be applied to the installation of cables.


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 4/18


3 SYSTEM DESCRIPTION

Power cables provide interconnections between transformers and switchgears / switchboards and between switchgears / switchboards and electrical consumers.

C & I cables provide interconnections between points of control, measurement, indication, protection, etc…

Cables are installed on the following types of routes:

- Support steelwork

- PVC circular ducts (road crossings, building foundations)

- Conduits

Requirements for segregation, sizing, routing, etc… are generally incorporated in the design and installation is simply a matter of following these instructions and the documents and drawings referred to herein. In case of doubt refer to design principle document.

The cabling design is based upon a Computerised Cabling System and is issued on a system basis. The site cabling system:

- Site Quality Plan

- Project Quality Assurance Programme

- Consortium Site Health, Safety & Environmental Plan

- Consortium Project Management Dossier

- Consortium Construction Management Dossier

- Site Works Sub-Contractor Surveillance

The Computerised Cabling System is used to generate cable installation information (pull-sheets) and to record installation progress and material usage.


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 5/18


4 REFERENCE CODES AND REGULATIONS

The following Codes and Regulations are applicable to the full scope of cable installation and the Sub-Contractor shall ensure that he is familiar with their contents.

- Consortium Site Safety Plan

- Local Health and Safety Statutory Regulation

- Local Health and Safety Policy Statement

- Local Electrical Regulations / Codes of Practice

5 REFERENCE DOCUMENTS

All necessary documents provided by ALSTOM shall be used in conjunction with these instructions for cable installation.

Before the commencement of work, Sub-Contractor should verify that all documents are available and at the latest revision.

In case of any apparent conflict between the documents, it shall be brought to the attention of the site Engineer for resolution.


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 6/18


6 HEALTH AND SAFETY

Great importance is attached to site discipline regarding Health and Safety matters. The Sub-Contractor shall therefore ensure that:

- The cable installation is carried out by technically qualified and competent personnel

- Safe working practices are adhered to at all times

- He is fully conversant with all the information provided to carry out the work particularly on measures relating to safety

- He complies with all the conditions of the Site Permit to work Procedures or his requirement

- All personnel are provided with, and wear in the appropriate areas, the following Personal Protective Equipment as a minimum:

. Safety helmet

. Safety footwear

. Harness

. Gloves

. Eye and ear protection

Fire extinguishers should be available for emergency use. Warning types and danger notices should be provided.


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 7/18


7 TOOLS AND EQUIPMENT

Tools and handling equipment necessary for the work should be available and include, but not be limited to:

- General tool kit

- Cable drum transporting equipment (crane, forklift)

- Cable pulling machine

- Cable drum jacks

- Tension meter

- Drum support axles

- Flying pump

- Drum rollers

- Drum unwinding trolley

- Levelling equipment (sleepers, timber battens, steel plates, etc…)

- Cable rollers (straight and bend)

- Cable pulling sheaths

- Cable cutting equipment

- Temporary cable ties (string or other disposable method)

- Temporary cable number marking equipment

Handling equipment must be supplied by the Sub-Contractor and be certified to be capable of lifting in excess of the maximum tonnage of the equipment.


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 8/18


8 MATERIAL RECEIPT AND STORAGE

Cables are delivered to site on wooden cable drums. The wooden or metallic battens should be left intact until it is required to remove cable.

Upon receipt at site each drum shall be checked for:

- Damage

- Correct and complete accompanying documentation

Non-conformance shall be immediately reported in accordance with the appropriate procedure Site Functional Procedures.

Drums shall be stored in designated areas away from traffic and other possible causes of accidental damage, where they will not be disturbed until required. They should also be stores on hard shoulder & out of standing water and shall be spaced so that labels are easily visible.

Each drum will have additional marking written clearly on the side of the drum.

Each type of cable should have their diameter size checked and compared with diameter given in the cable data sheet; any discrepancy should be recorded and highlighted to AP Construction Manager.


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 9/18


9 CABLE INSTALLATION

9.1 GENERAL

The cable installation will be organised by the cabling supervisor into work packages, based on systems, system groups or work areas, dependant upon site strategy.

The following procedure shall apply to each work package.

9.2 PREPARATION

Familiarise workforce with all the requirements of the Health and Safety Directives.

Ensure that the following documents / reports are available:

- Cable pulling programme

- Cable routing network drawings for the area(s) to be cabled

- List of cables to be pulled

Ensure that the required cable make-ups, temporary cable ties, cleats and cable markers are all available.

Check that pull-sheets for the work package are available. The cabling supervisor issues pull-sheets.

Review the routes as detailed on the pull-sheets and network drawings. Check routes for:

- Support steelwork enough complete (including minor routes if required)

- Trenches complete / cable ducts

- Nodes marked

- No debris or obstructions

- No protrusions


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 10/18


- Access available (scaffold retained from steelwork installation)

9.3 TRANSPORT OF DRUMS TO WORK SITE

All cable drums will be marked on arrival in accordance with the list that AP supervisor will do on site. All drums will be recorded in the Computerised Cabling System just after marking.

All cable drums shall be tested before erection. This shall be applied for all MV, LV & C&I cable drums particularly in the case of drums that are found to have been damaged (slats or sides broken). Sufficient slats shall be removed to expose the outer cable end. Insulation shall be removed from the outer and central cable ends to expose the conductors and screens.

Continuity test have to be performed and insulation tests shall be applied for one minute at 1000V for LV & C&I drums and 5000V for MV drums. Results shall be recorded.

After testing the ends shall be wrapped in PVC tape.

Select the required drums and remove from storage; recording the removal (and subsequent return) of drums in accordance with the Site Storage & Material Control.

Note:

Some cables may be assigned to particular drums. In this instance it is imperative that only the drum specified on the pull-sheet is withdrawn from storage. If the pull-sheet does not specify a drum number then any drum of the correct make-up can be withdrawn, after checking that the cable drum has not already been allocated.

For short distances and for small drums, the drums may be rolled, in the direction of the arrow, on level surfaces only, which are free of obstacles. For longer distances and larger drums, a crane, forklift truck or drum carrier should be used.

Drums should be located in areas close to major equipment to be cabled. Drums must not be placed where they would impede personnel or emergency exit.


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 11/18


In order to avoid accumulation of drums on site, only those drums required for immediate cable pulling should be transported to the work area.

If there is any doubt regarding short-term drum placements, the cabling supervisor should be consulted.

9.4 DRUM POSITIONING

Drums should be positioned for cable unwinding using one of the following methods:

- Small drum: use a cable drum unwinding trolley

- Medium drum: use drum rollers

- Large drum: use drum jacks and suitable axle. Grease the steel drum flanges and jack supports to facilitate turning

Drum should never be placed on its side and cable removed by uncoiling

Cable should preferably be unwound from underneath the drum. Therefore, care must be taken when supporting the drum to ensure correct unwinding.

9.5 PREPARATION FOR CABLE PULLING

The Sub-Contractor will, at times, be required to remove (and subsequently replace) such items as trench covers, floor slabs, grid irons, false floor tiles and gland plates.

Such items may require removal and replacement more than once. These activities are within the Sub-Contractor scope.

All items removed for cable installation shall be safely stored and temporary Safety barriers and sign positioned for the duration of cable pulling.

All removed items shall be replaced as soon as the cable installation is complete.


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 12/18


Prior cable pulling, measure the route length along the route as shown on the pull-sheet. In the case of power cables, if the measured length is significantly greater than the designed length, refer to the Site Cabling Supervisor for possible re-calculation of the cable size.

Before pulling cable off drum check that the make-up corresponds to that stated on the pull-sheet. In the case of a specified drum number check that the correct drum is being used.

9.6 CABLE PULLING

Cables shall not be cut to the design length stated on the pull-sheet.

Cables shall be pulled, along the designated route, with the drum located as close as possible to the equipment. Pull the cable as far as the final destination. Due allowance shall be made at the destination for termination. This allowance shall not be excessive. If equipment is not located, an agreed allowance shall be made.

The cable should then be dressed back to source equipment.

Allowing for termination at the source equipment the cable may then be cut.

If it is not possible to use this method, e.g. cable drum cannot be located close to the equipment, then the total route length shall be measured (including termination allowances). This measured length shall be cut from the correct drum and transported to the work area for installation.

Prior cable pulling, measure the route length along the route as shown on the pull-sheet. In the case of power cables, if the measured length is significantly greater than the designed length, refer to AP Site Cabling engineer for possible re-calculation of the cable size.

In general rule any cable pulled with a length greater than 10 % of the design length should be immediately signed to AP site cabling engineer.

Particular attention should be taken before and during HV / MV cable pulling.

Cables may be pulled by hand with operatives placed at frequent intervals to support the cable and avoid excessive tension.


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 13/18


Alternatively, power assistance may be used. In this instance refer to the instructions applicable to the particular machine employed. Very high pulling rates are required during peak activities and it recommended that cable pulling machines are used to facilitate multiple cable pulling.

Where cables are not supported at frequent intervals by operatives then they must be supported by cable rollers, again placed at suitable intervals to avoid contact of cable sheath with abrasive surfaces.

Ensure that the cable is installed on the correct level of ladder rack in accordance with the pull-sheet.

Where cables are routed through ducts an approved commercial lubricant may be used, compatible with the cable sheath. Pulling ropes are provided in each PVC duct.

Cables must not be pulled over sharp or abrasive edges.

Cables shall not be pulled around bends to a radius less than that stated in cable data sheets.

Great care shall be taken when pulling cables to avoid loops. If a loop should occur under no circumstances shall attempts be made to remove the loop by tensioning the cable. The loop shall be removed by carefully coiling to the nearest end.

9.7 CABLE DRESSING

Each cable shall be dressed to provide a straight installation, along its entire length, using temporary tie-wraps. Steel or copper wire shall not be used for this purpose.

For single core cables in trefoil formation ABC phase install cleat bases at specified intervals. Dress three single cores together and cleat to bases, installing intermediate special tape as specified.

It is recommended when the cables are going to their final terminal point and / or at the ‘T’ and ‘X’ route crossing to exit cable ladders by under the ladder taking always in account the minimum cable bending radius. This will allow a tidier and cleaner cable arrangement avoiding unnecessary cable tangling.


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 14/18


The contractor shall have at all times a team for cable dressing.

9.8 PROTECTION OF CABLES

The Sub-Contractor is responsible for ensuring that cables are protected during installation.

Where cables are subject to damage from welding or flame cutting, they must be reported immediately to the cabling supervisor to take the necessary action.

9.9 CABLE CUTTING

Cutting cables must be done with appropriate tools such as hydraulic shears, hand shears or hacksaw.

9.10 REPAIR OR CABLE DAMAGE

Any damage to cables during installation shall be reported to the Cabling Supervisor, who will advise on corrective action. If damage is superficial, a repair may be done by use of an approved sheath repair kit. More extensive damage may be repaired by using a proprietary cable joint or, as a last resort, by replacement of the cable. Instructions are included with the repair kits and joints.

9.11 CABLE IDENTIFICATION

Immediately after a cable has been laid and cut, a temporary identification label shall be made at each end. The identification shall be as on the pull-sheet – ‘Cable No’. It is anticipated that indelible marker pens will be used for this purpose, or other appropriate method agreed by the Cabling Supervisor.

Final label will have to be installed after termination is completed.

Cable ends should also be protected against infiltration of humidity.


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 15/18


9.12 FINAL CABLE DRESSING

Dressing should be done every day for cables pulled during the day and when 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.


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 16/18


9.13 PROGRESS AND MATERIAL USAGE REPORTING

The Sub-Contractor is responsible for reporting to the Cabling Supervisor, on a daily basis, his progress and usage of materials.

Reports shall contain, but not be limited to, the following:

- List of cable laid (by cable number), with length, make-up, drum number and comments

- List of accessories installed if required (cleats, tie-wraps, etc…)

- Damage to the cable installation and cause of damage must be reported to the Cabling Supervisor immediately

If for any reason, a cable make-up has been installed, or a drum used, different to that stated on the pull-sheet, this should be reported immediately to the Cabling Supervisor.

9.14 PARTLY USED AND EMPTY DRUMS

As soon as a drum becomes empty it shall be returned to the stores or disposal area and noted on the stores records.

Partly used drums, on completion of cabling in a particular area, shall also be returned to the stores and the return recorded.

Unused accessories shall be returned to the stores and recorded. Only those accessories required for one day's work shall be taken to the work area.

Accessories shall, at no time, be left unattended on site.


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 17/18


9.15 CABLE REMNANTS

All cable remnants, whether loose or on drums, shall be returned to the stores. Disposal of remnants is the responsibility of the cabling Supervisor.

The Sub-Contractor shall not remove any remnants from site or attempt to burn the PVC from cables. Such actions are illegal.

Subcontractor should follow the document: Management of Cable Wastage.

9.16 HIGH VOLTAGE CABLES

All chapters above are applicable for HV / MV cables but particular attention should respected prior, during and after pulling these cables.

Civil work including duct banks and / or troughs, termination structures and scaffolding should be completed and in accordance with drawings prior pulling. All cable laying equipment should be checked; routes should be cleaned to avoid any scratch on the outer sheath of the cable. The location of drums should be carefully been defined and planned.

All laying tools and equipment such as jacks, rollers, winches, wires, ropes, shackles, swivels, communication devices, lifting devices should be checked.

During the pulling, the pulling force should be monitored. When cables are installed on the floor of the cable tunnels or basements they shall be cleated firmly to the floor at regular intervals not exceeding 1.5 m.

Bending radius should be respected during pulling.

Method statement and risk analysis should be done by the Sub-Contractor at least two months prior starting pulling cables.


Originator


Rev. A

Date 21.05.2012

Lang. en

Sheet 18/18


10 INSEPECTION AND TEST

Inspection of the cable installation shall be carried out in accordance with the Erection Check be filed in accordance with the Field Quality Plan.

Testing of cables is the subject of a separate document but as a general guide the following steps should be respected:

Before starting any testing, make sure that the area around both ends of the cable to be tested is safe and secure. Cables should be disconnected at both end and operators have to be at both ends of the cable and test carefully the continuity before starting any insulation resistance test.

For high voltage dielectric test a security area should cleared and marked around both sides of cables before starting the test.

11 RECORDS

In order to control materials the installation Sub-Contractor shall complete Test Sheets and Reports on a daily basis. The information will then be used by the ALSTOM Supervising Engineer to monitor material usage and predict possible shortages.

If, for any reason, materials are installed differently to the design then this shall be notified immediately rather than on completion.

Documents

AMA00E ----- ----- EI210 RA Erection Instruction for Laying of Power and Control Cables