Doc. No.

ABE-PRJ-MS-114
Issue No. 01
Rev. No. 00 MV CABLE SPLICING, TERMINATION AND
Date 14-02-2021 TESTING PROCEDURE
Page 1 of 8

MEDIUM VOLTAGE CABLE SPLICING, TERMINATION AND

TESTING PROCEDURE
FOR BERRI & MARJAN PROJECT

Almas Syed Saneesh Hashid

00 07/06/2020 Issued for Quotation
E&I Engineer Project Manager General Manager

Rev. Date Description of Revision Prepared Reviewed Approved

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© 2014 Atlas Business Incorporated. All Rights Reserved.
Doc. No. ABE-PRJ-MS-114
Issue No. 01
Rev. No. 00 MV CABLE SPLICING, TERMINATION AND
Date 14-02-2021 TESTING PROCEDURE
Page 2 of 8

INDEX
1. COMPANY OVERVIEW.........................................................................................................3
2. SCOPE AND PURPOSE.......................................................................................................3
3. ABBREVATION..................................................................................................................... 3
4. OUR REFERENCE................................................................................................................ 4
5. REFERENCE SPECIFICATIONS AND CODES....................................................................4
5.1 QUALITY STANDARDS..................................................................................................4
5.2 INTERNATIONAL CODES, STANDARDS, SPECIFICATIONS AND REFERENCES......4
5.3 SAUDI ARAMCO ENGINEERING STANDARDS (SAES)...............................................4
5.4 OTHER APPLICABLE SAUDI ARAMCO STANDARDS.................................................4
6. RESPONSIBILITIES.............................................................................................................. 4
7. GENERAL REQUIREMENTS................................................................................................4
8. LIST OF EQUIPMENT / TOOLS............................................................................................5
9. TUBING INSTALLATION PROCEDURE...............................................................................5
10. TUBING LEAK TESTING PROCEDURE...............................................................................7

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 Doc. No. ABE-PRJ-MS-114
Issue No. 01
Rev. No. 00 MV CABLE SPLICING, TERMINATION AND
Date 14-02-2021 TESTING PROCEDURE
Page 3 of 8

1. COMPANY OVERVIEW
EoI
WoI
Atlas Business Est. (ABE) is a wholly owned Saudi Company, in the construction sector. The major
business of the Company is directed towards General Constructions of Civil, Mechanical, Electrical, IT
Sector and Manpower Support services to the major industries in the Kingdom of Saudi Arabia.

2. SCOPE AND PURPOSE

ABE has been awarded the contract of Medium Voltage cable splicing, Termination and Hi-Pot Testing
under RFQ NO: 11661037 & 11660559 for Marjan WHP Deck 11660561 &11660560 for Berri WHP Deck
These documents specify and elaborate the technical details and inclusions/Exclusion throughout the
project. This document will cover all the scope relevant to the following decks under BERRI project.
Work Location: STAR YARD, King Abdul Aziz Port, Dammam

3. ABBREVATION

COMPANY SAUDI ARAMCO

CONTRACTOR STAR
SUBCONTRACTOR ATLAS BUSINESS ESTABLISHMNET [ABE]
SAEP SAUDI ARAMCO ENGINEERING PROCEDURES
SAES SAUDI ARAMCO ENGINEERING STANDARDS
SAMSS SAUDI ARAMCO MATERIAL SYSTEM SPECIFICATION
IFC APPROVED/ISSUED FOR CONSTRUCTION
SOW SCOPE OF WORK
BOQ BILL OF QUANTITY
MTO MATERIAL TAKE OFF
DPR DRAWING PROGRESS REGISTER

4. OUR REFERENCE

 ABE‐CTR‐HSE‐01 – Health and Safety Manual

 ABE‐CTR‐QM‐01 – Quality Manual

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Doc. No. ABE-PRJ-MS-114
Issue No. 01
Rev. No. 00 MV CABLE SPLICING, TERMINATION AND
Date 14-02-2021 TESTING PROCEDURE
Page 4 of 8

5. REFERENCE SPECIFICATIONS AND CODES

5.1 QUALITY STANDARDS

 ISO 9001:2015  Quality Management System Requirements

5.2 INTERNATIONAL CODES, STANDARDS, SPECIFICATIONS AND REFERENCES

In general, installation and Testing activities shall be following the following specifications:
 NFPA 70 National Electrical Code (NEC)

5.3 SAUDI ARAMCO ENGINEERING STANDARDS (SAES)

 15-SAMSS-502 Medium voltage Power Cable 5kV through 35kV

 SAES-P-100 Basic Power System Design Criteria
 SAES-P-104 Wiring Methods and Materials
 SAES-P-111 Grounding

5.4 OTHER APPLICABLE SAUDI ARAMCO STANDARDS

 Saudi Aramco Inspection Procedure (SAIP),

 Saudi Aramco Inspection Checklist (SAIC), and Saudi Aramco Test Report (SATR),
 Saudi Aramco Typical Inspection Plan (SATIP),
 Saudi Aramco Checklist & Test Report

6. RESPONSIBILITIES

Splicing, Termination and Testing works will be carried out by ABE supplied Aramco certified Technicians,
STAR production Engineer and witnessed by STAR QC inspector and Saudi Aramco Company representative.

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Doc. No. ABE-PRJ-MS-114
Issue No. 01
Rev. No. 00 MV CABLE SPLICING, TERMINATION AND
Date 14-02-2021 TESTING PROCEDURE
Page 5 of 8

7. GENERAL REQUIREMENTS

7.1 Abe installation team shall ensure that all the splicing kit and associated materials shall inspected by
star qc and released for the splicing and termination activities.
7.2 All received materials are properly handled, stored and transported in accordance with applicable
Saudi Aramco and STAR quality procedures
7.3 All permanent materials, consumables, equipment to be installed and its accessories, construction area
and resources shall be prepared and checked prior to installation works.
7.4 Special tools shall bear a valid calibration certificates traceable to a national standard indicating
calibration validity and periodically (at least six months) checked by a company approved third party
laboratory testing facility.
7.5 The cable splicer/Terminator shall have valid Splicer certification issued by Saudi Aramco
7.6 Design and Installation of Wiring and Cable Systems shall be in accordance with the NEC as
supplemented by SAES-P-104 and/ or as approved Saudi Aramco Standards.
7.7 Cables shall be permanently identified prior to the Splicing / Termination process; Ref SA Std.  SAES-P-
104 6.10.
7.8 The Vendor Instruction Manual requirements shall be incorporated into the installation procedure. NEC
110.3B; Ref SA Std. SAES-P-104 4.1.
7.9 All Compression Dies / Connectors shall have a Manufacturer’s Reference compression die number and
conductor size normally printed or stamped on the connector as required as SAES-P-104 Para. 6.1.

8. LIST OF EQUIPMENT / TOOLS

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:

 Electrical Hand Tools

 5Kv Megger
 Multi meter
 Torque wrenches
 Semi-conductor peeling device
 Insulation remover
 Conical cutting tool with conical knife
 Gas Torch and Butane Gas
 Hydraulic Crimping tool with Die Set
 Diameter measuring tape
 Nylon Ropes
 Splicing Knife
 Other Relevant Tools
 All tools utilized in a classified area should be intrinsically safe and suitable for hazardous areas.

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Doc. No. ABE-PRJ-MS-114
Issue No. 01
Rev. No. 00 MV CABLE SPLICING, TERMINATION AND
Date 14-02-2021 TESTING PROCEDURE
Page 6 of 8

9. CABLE TERMINATION/ SPLICING PROCEDURE

9.1 Obtain work permit as per STAR and ARAMCO work permit system and requirements
9.2 Ensure the type and size of the splicing kit is ideal with cable to be spliced
9.3 Cable outer jacket should be cleaned and free from accumulation of dust, oil, and moisture using
required cable cleaning spray and materials.
9.4 Cable shall not be bent sharp to a small radius handling or installation, for cables the minimum bending
radius for PVC/XLPE cables shall be 12 times the overall diameter of Cable.
9.5 Cable gland must be installed over the cable before starting the Splicing and Termination process.

9.6 Remove the cable outer jacket and armouring as per the requirement. Length of the exposed
armour depends on the cable gland size.
9.7 Remove any fillers to the level of the bedding cut.
9.8 Secure the armour wire by a temporary binding wire.
9.9 Clean the exposed core and the remaining over sheath.
9.10 Fit the three earth braids to the copper tape using the roll springs around the braid and the copper
tape screen. Fill the braid with solder to form a 30mm moisture block 10mm from the over sheath end
Wrap the void filling strip around the core screen starting 20mm from the end of the screen and
continue unto the insulation for 10mm.Stretch the strip half of its original width to achieve a fine thin
edge onto the insulation.
9.11 Position the stress control tubing over each core and position them 70mm above the end of the over
sheath cut, shrink using a soft yellow flame, shrink from bottom, working upwards
9.12 Tightly wrap the red sealant tape, with a 50% overlap over each roll spring.
9.13 Lift the Earth braids from the inner sheath
9.14 Wrap one layer of sealant tape over the inner sheath.
9.15 Lay the Earth braids into the sealant and apply black sealant tape over the braids.
9.16 Position break boot over the cores. Ensure that the boot is seated well down.
9.17 Using a soft yellow flame shrink the breakout boot from the centre, working downwards, then and
work upwards towards fingers
9.18 Cut cores as per the required length, remove the insulation for the Lug depth +5mm

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Doc. No. ABE-PRJ-MS-114
Issue No. 01
Rev. No. 00 MV CABLE SPLICING, TERMINATION AND
Date 14-02-2021 TESTING PROCEDURE
Page 7 of 8

9.19 Fit the cable Lug as per the manufacturer’s instructions

9.20 Overlap the core insulation by 10mm.Stretch the tape to half of its width and apply with half overlap.
Use the remaining sealant (red) to fill in the space between the core insulation and cable lug to leave a
smooth transition.
9.21 Fit the outer red anti track tubes over the legs of the breakout. Place the tubing over the cores with the
sealant coated end downwards. Push the tubing over the breakout turrets far as possible and shrink it
down using a soft yellow flame in an upwards direction.
9.22 Cut the tubes so that it just fits into the palm of the Lug. Make sure that the tubes do not prevent
contacts with the terminals.
9.23 The gland plate assembly should be completed as per the requirement. The terminations should be
allowed to cool before moving or energizing.

Note: Guidelines for the cable termination shall follows as per manufactures instructions and
installation manuals.

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Doc. No. ABE-PRJ-MS-114
Issue No. 01
Rev. No. 00 MV CABLE SPLICING, TERMINATION AND
Date 14-02-2021 TESTING PROCEDURE
Page 8 of 8

10. HI-POT TESTING PROCEDURE

10.1 After the splicing has been done inform site team to submit the request for inspection (RFI) through
STAR QA/QC team to SAPMT for the schedule of inspection.
10.2 Attain work permit as per STAR and ARAMCO work permit system and requirements
10.3 Objective of Hi-pot test to verify the insulation of medium voltage cable is adequate to withstand
voltage after cable splicing/termination. The below steps will be executed for testing. (Duration of each
core is about to 30-40 minutes and extendable if any).
10.4 Ensured that before testing, where potentially dangerous condition exists, all safety precautions has
been taken. Personnel shall be informed barriers and caution signs shall be in place. Barricade &
standby/watch man to be provided at both end of the cable destination.
10.5 Test equipment should be kept in clean and uncluttered area, then connect with proper grounding and
are properly bonded and secured. Hot stick probe for static discharge keep always nearer to the test
equipment and for easily access.
10.6 One end of the hot stick should relate to safe ground connection.
10.7 Power supply for test kit feed from yard power supply as per kit input voltage specification 230V or
110V.
10.8 Approved cable splicer to make sure the connections between the test equipment and the cables.
10.9 Warning label indicating “Equipment Energized “must be labelled on the equipment to be energized.
10.10 Insulation resistance (megger) test to be done before Hi-pot by applying input voltage 5kV DC. Record
the value and ensure to proceed for next.
10.11 Ensure input voltage level is 230V/110V ±10% before energizing the testing equipment.
10.12 Switch ON power supply and assure equipment is stable to inject high voltage to the cable.
10.13 Inject DC voltage slowly and note any distortion occurs, if everything fine keeps injecting the voltage as
recommend in SA-P-041. Max. 64kV DC.
10.14 Once Voltage is completely applied hold the voltage for 15 minutes.
10.15 Record the voltage level, leakage current and cable resistance from zero second to 15 minutes
duration.
10.16 Switch off the power supply and touch the open lead connection with hot stick probe (static discharge
kit) to discharge static CHARGE ON THE GROUND.
10.17 Disconnect cable supply and continue the 5kV insulation resistance test once again and record the
readings.

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