SAF-EL-01 R1

Method Statement UG Cable Installation

Underground LV up to 33KV Cable Installation

Document Ref. : SAF-EL-001

Revision : 01

Date : 20/10/2013

Summary : This is an Engineering instruction manual detailing the adopted standards and specifications used in the Emirate of Abu Dhabi and are accepted as the absolute minimum requirement to properly install LV, MV and fiber optic cables to a satisfactory, safe and efficient manor.

Prepared by : Eng. Mohamed Ibrahim Abdel-Fattah Technical Manager Eng. Abdel-Fattah Ibrahim Abdel-Fattah Planning & Safety Manager

1 Of 17All Rights Reserved Safari General Contracting Company LLC 2013


Table of Contents1 Scope.................................................................................................................................................32 References.........................................................................................................................................33 Document Goals................................................................................................................................34 On Site requirements.........................................................................................................................44.1 Direct buried cables........................................................................................................................4

4.1.1 LV Cables...........................................................................................................................44.1.2 11KV Cables......................................................................................................................54.1.3 22KV Cables......................................................................................................................54.1.4 33KV Cables......................................................................................................................54.1.5 FOC Cables........................................................................................................................5

4.2 Cables in Ducts & PVC Conduits..............................................................................................64.2.1 Ducts..................................................................................................................................64.2.2 PVC Conduits.....................................................................................................................6

5 Trench Details....................................................................................................................................75.1 LV Cables...................................................................................................................................75.2 11kV Cables...............................................................................................................................85.3 22kV Cables...............................................................................................................................95.4 33kV Cables.............................................................................................................................10

6 Cable Installation.............................................................................................................................116.1 Trench Bedding........................................................................................................................116.2 Cable Covering Tiles................................................................................................................116.3 Warning Tape...........................................................................................................................116.4 Cable Route markers................................................................................................................11

7 Installation Procedure......................................................................................................................127.1 Excavation & Cable laying......................................................................................................127.2 Jointing works to existing cables.............................................................................................13

8 Annexures........................................................................................................................................148.1 Cable Covering Tiles...............................................................................................................148.2 Cable Route Markers...............................................................................................................158.3 Typical Cross Section of 4C XLPE LV Cable-grip.................................................................168.4 Risk Assessment......................................................................................................................17



1 Scope

This is an Engineering instruction manual detailing the adopted specification and standards used in the Emirate of Abu Dhabi and are accepted as the absolute minimum requirement to properly install LV, MVand fiber optic cables to a satisfactory, safe and efficient manor.

2 References

The following resources are referenced and sited for the preparation of this instruction:

Reference Description

S-AAA-CAB-INST-LV (Rev.0-2011) Installation Requirements for LV Cables & Wires in SS Buildings

S-AAA-CAB-INST-MV (Rev.0-2011) Installation Requirements for MV UndergroundCables

S-AAA-CAB-INST-CONT-FOC (REV.0-2011) Installation Requirements for Control & Fibre Optic Cables

DWG AAA CAB 01 00 07 (LV CAB Trench) Typical LV Cable Trench Section

DWG AAA CAB 01 00 08 (11kV CAB Trench) Typical Section Of 11kv Cable Trench

DWG AAA CAB 01 00 09 (22kV CAB trench) Typical Section Of 22kv Cable Trench

DWG AAA CAB 01 00 10 (33kV CAB Trench) Typical Section Of 33kv Cable Trench

DWG AAA CAB 01 00 11 (11-22-33 CAB Trench) Trench Details of 11kV, 22kV & 33kV, & FOC

DWG AAA CAB 01 00 12 (Manhole Details) 11kV, 22kV & 33kV, & FOC Manhole Details

S-AAA-CAB-GEN (Rev.0-2011) General Requirements

31.12.97 ADM Standard Specifications for Road and Bridge construction

3 Document Goals

The goal of the document is to provide a complete and up to date instruction for the installation of different types of cables directly & indirectly buried in ground this can be achieved by showing the following:

Types & Sizes of the cables to be used and installed directly & indirectly in the ground

Trench details including its depth, layout, material to be used, etc...

Proper procedure for the pulling of the cables

Site tests & inspections to insure the health of the installed cables



4 On Site requirements

4.1 Direct buried cables

Direct burial of new cables is the preferred installation state in the Emirate of Abu Dhabi except where on site condition dictate otherwise.

All Cables to be PVC sheathed to give it protection against the harsh conditions of underground installation whether that be salts, insects, etc.. to give it a long service life.

4.1.1 LV Cables

The following table shows the most widely used LV Cables for power distribution:

No. of Cores + Core Size Core Material + Armoring + Insulation

ADWEA/ADDC/AADC Data sheet

4Cx4mm Cu/XLPE/SWA/PVC D-AAA-CAB-LV-DB-4C-4upto300 (Rev.1-2011)
















4.1.2 11KV Cables

The following table shows the most widely used 11KV Cables for power distribution:



3Cx95mm Cu/XLPE/STA/PVC D-AAA-CAB-11-3C (Rev.0-2011)





4.1.3 22KV Cables









4.1.4 33KV Cables






4.1.5 FOC Cables

The following table shows the most widely used FOC Cables for power distribution:

No. of Cores ADWEA/ADDC/AADC Data sheet

32 Fiber D-AAA-CAB-FOC-DB-32 (Rev 0-2011)

64 Fiber D-AAA-CAB-FOC-DB-64 (Rev.0-2011)

144 Fiber D-AAA-CAB-FOC-DB-144 (Rev 0-2011)



4.2 Cables in Ducts & PVC Conduits

4.2.1 Ducts

Generally cables pass through ducts when the cable run is needed to pass under a Road or Street to feed a point on the other side of the road or under pavements & side walks where excavation works are not desired. These ducts shall be concrete encased to provide safety against load pressure applied on the conduits due to the passing of cars, trucks, buses, etc.. on the roads above the installation.

4.2.2 PVC Conduits

The main types of cables that pass in PVC Conduits are FOC cables used for control purposes & LV power cables used in street lighting systems, this type of arrangement is beneficial for the ease and quickness of maintenance of such networks where the need to repair any faults in the systems are critical. The outside diameter and minimum wall thickness of PVC electrical conduit shall be as follows:

Nominal Size (cm) Minimum Wall Thickness (mm)

2.0 1.8

2.5 1.9

3.2 2.5

3.8 2.5

5.0 3.2

6.0 4.7

10.0 6.0

15.0 7.1

20.0 8.2



5 Trench Details

5.1 LV Cables



5.2 11kV Cables



5.3 22kV Cables



5.4 33kV Cables



6 Cable Installation

6.1 Trench Bedding

All Cables shall only be laid directly onto the bottom of the trench at a depth as shown in the trench details above or as directed by the Engineer.

A sand bedding shall be constructed as shown in the trench details or as directed by the Engineer to insure that the cables will not be damaged due to any protruding elements from the ground such as stones, rocks, etc..

6.2 Cable Covering Tiles

Cable Covering Tiles shall be installed over all newly directly buried cables as a means of protection of the cables as shown in the drawings or as directed by the Engineer. There is no requirement to install such tiles above approved ducts but it may be installed if it is deemed that additional protection is required.

6.3 Warning Tape

Warning Tape shall be installed over all newly directly buried cables as a means of protection of the cables asshown in the drawings or as directed by the Engineer. There is no requirement to install such tapes above approved ducts but it may be installed if it is deemed that additional protection is required.

6.4 Cable Route markers

In installations of 11kV, 22kV, 33kV it is necessary to show the route of the cable run for future purposes of quick identification in case the necessity of excavating the cables is required.



7 Installation Procedure

7.1 Excavation & Cable laying

1. Cable Route approval to be acquired from Town Planning department

2. NOC to be obtained from different authorities such as TRANSCO, PRFD, ADM, etc..

3. Cable sizing and routes to be approved by the Engineer/DOT/ADDC

4. Trench route to be indicated by the use of steel rods directly installed in the ground

5. A survey has to be carried out on the proposed cable route to finalize the cable length and the cableroute itself and to confirm no obstacles will be meet during the work

6. If any obstacles are found, they will be promptly relayed to the Client/Consultant for their review and recommendation

7. Excavation to commence adhering to the route detailed by the steel rods and to a depth as shown on the drawings or as detailed by the Engineer

8. Excavate to Locate will be done at site at intervals of 50m from pit to pit to identify any and all services in the excavation area

9. If services are found manual excavation will be used otherwise the use of machinery will be utilized such as Backhoes, Excavators, etc..

10. Warning fences, Warning ropes, danger notices, etc.. will be used to insure public safety around the working area

11. When Excavation is to be done in sidewalk area, the removal of existing tiles will be done with care not to damage the tiles. The same will be reinstalled after back filling has been completed.

12. Making sure the trench bottom is clean from any sharp objects that would other wise damage the cable outer sheath

13. Constructing Sand bedding at the bottom of the cables as detailed in the drawings

14. Trench inspection to be conducted and approval to be acquired from the Engineer

15. Termination point inside the panels / equipment shall be considered for suitable spare length to be left available during pulling of cable termination. The maximum length shall be equal to depth + height + width of panels.

16. Cable rollers to be installed at a distance of 2m center to center to allow unhindered movement of the cable above the roller to insure cables are not damaged

17. Check adequate place for Unloading the cable drums.

18. Check suitable position for placing the Cable pulling winch depending on the length of the cable and the site condition.

19. Cable winch to be firmly fixed as to not move/slide from its position due to the tension exerted to pull the cable

20. The cable drum intended for cable pulling shall be identified as per that indicated in the drum schedule

21. The cable shall be fixed to the winch, if used, by means of a cable sock or gripper

22. Special care will be taken when pulling the cable through cable ducts as to not damage the cable ends or outer sheath

23. Cable Ducts/Pipes shall be cleaned using proper equipment to insure the smooth and safe passage of the cables with out damage or obstruction.

24. Lubricant to be applied around the cables to facilitate the easy movement of the cable in the duct



25. Cable laying will generally start from one end of the route length or at any suitable point if required

26. In case of cable lengths which are more than one drum length, all cables which can be laid from original position will be completed. And then the cable pulling set-up will be re-positioned to the nextlocation, from where the next length will be pulled

27. Cables will be laid / pulled by hand and / or winch.

28. During pulling with winch, if required, the tension on the cable will not exceed that given by the manufacturer and this will be monitored by means of Dynamo-meter.

29. Unless the lengths exceed the maximum drum lengths joints shall be avoided

30. Before cutting the cable, both ends must be inspected to ensure sufficient length is for proper dressing and end termination

31. Soon after completion of every cable the cables will be tested for insulation resistance and witnessedby the Engineer

32. Daily progress report will be submitted for the activity as well as summary of used cable for each drum

33. Approval of laid cables to be acquired from the Engineer

34. Final Sand bedding level to be constructed and inspected by the Engineer

35. Cable Covering tiles to be installed as detailed and or required, to be inspected by the Engineer, Tilesorientation to be as show in Annexure 8.1

36. Layer of natural back fill material in the area of work to be used as detailed in the drawings

37. Warning Tape to be installed as detailed to be inspected by the Engineer

38. Warning Tape to have the following arrangement, notice to be made that depending on Voltage of cable warning tape will be modified

- DANGER - BURIED ELECTRICAL L.V. CABLE BELOW ADDC

39. Back filling to final ground level with natural material at the area of work

40. Cable route markers to be installed in case it is required

7.2 Jointing works to existing cables

1. Location of Joint connection to be agreed upon with AADC

2. After approval is acquired Excavate to Locate the cables to be jointed

3. Permit to work to be issued by AADC

4. Lock Out Tag Out system of Electrical Switch gear to be put into effect during the shut down period to allow us to perform our works

5. Before work to proceed on any cables, AADC to perform spike test on cabling to insure the correct cables have been de-energized

6. Work to proceed with jointing works by approved Cable Jointer

7. SAT to be performed on the joint in presence of AADC before energization

8. Clearance from our side that all works have been completed and it is safe to energize the cables



8 Annexures

8.1 Cable Covering Tiles



8.2 Cable Route Markers


8.3 Typical Cross Section of 4C XLPE LV Cable-grip


DWG AAA CAB 01 13 03-D

Abu Dhabi Water & Electricity Authority

123

567

4

Typical Cross Section of Low VoltageXLPE-Insulated Four-Core

Underground Cable (Conductor Shaped)

8.4 Risk Assessment

Hazard Who Mightbe Harmed

Controls in Place Risk Rating

Risk of Slips, Trips and falls:

Waste around the site

Changes in level

Workers inthe area

All workers trained in good housekeeping techniques.

Good housekeeping to be maintained at all times.

Work are to be cleaned before leaving.

Moderate.

Manual Handling: Injury from poor

manual handling procedure.

Workersconducting

manualhandling

Pulling the cable as a team. Good communications within the team must

be maintained when cable is pulled over a long distance.

A brakeman is required on the drum to ensure that the drum doesnt over run

Close supervision is required to ensure no over stressing of cable occurs.

Cable pulls must be smooth and maintainedat a reasonable rate to ensure control and tension requirements are met.

Moderate.

Falling objects: Cables slipping

when manual handling.

Loose cable gripperon winch.

Workerspulling thecables or

supervisingwinch

pulling.

Training on good handling and steady rate pulling

Checking cable gripper periodically for looseconnection.

Providing high grip gloves and safety boots to reduce risk of slipping.

Low.

Falling from height: People. Vehicles. Equipment/Material Workers in

the area.Generalpublic.

Barrier off the area to reduce risk of public accidental approach.

Display suitable signage to indicate excavation is present.

Provide access points into excavation wherenecessary.

Banks-man available to guide vehicles dropping off material nearby.

Providing chocks to nearby parked vehicles/equipment.

Moderate.

Electricity: Working near live

services.Workers inthe area.

All services must be made dead before work if possible.

Barricading of the live services to keep workers away.

Moderate.


1 Scope2 References3 Document Goals4 On Site requirements4.1 Direct buried cables4.1.1 LV Cables4.1.2 11KV Cables4.1.3 22KV Cables4.1.4 33KV Cables4.1.5 FOC Cables4.2 Cables in Ducts & PVC Conduits4.2.1 Ducts4.2.2 PVC Conduits

5 Trench Details5.1 LV Cables5.2 11kV Cables5.3 22kV Cables5.4 33kV Cables

6 Cable Installation6.1 Trench Bedding6.2 Cable Covering Tiles6.3 Warning Tape6.4 Cable Route markers

7 Installation Procedure7.1 Excavation & Cable laying7.2 Jointing works to existing cables

8 Annexures8.1 Cable Covering Tiles8.2 Cable Route Markers8.3 Typical Cross Section of 4C XLPE LV Cable-grip8.4 Risk Assessment

Documents

SAF-EL-01 R1