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ONSHORE MAINT POTENTIAL PROG – NA1 ZONE

PROCEDURE FOR MV CABLE SPLICING AND TERMINATION

BI-10-01483

ISSUE FOR
0 14 Oct. 2018 IFA
APPROVAL

REV DATE STATUS ISSUE PURPOSE PREPARED BY CHECKED BY APPROVED BY

CONTRACT No.: 6600042362 DOCUMENT No.: CPP-NA1-PM-PLN-0029

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DOCUMENT REVISION HISTORY SHEET

REV STATUS TRANSMITTAL NO. DATE ISSUED UPDATE / AMENDMENT DETAILS

0 IFA T-CPP-ARAMCO-NA1-00001 14 OCT 2018 ALL

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INDEX

6 Scope

7 Purpose

8 Definitions

9 Reference

10 Responsibilities

11 Material Control

12 Quality Control

13 Work Execution

14 DC High Potential Testing of Medium Voltage Cables

15 Safety Precaution

16 Documentation

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1. Scope

 This procedure covers the inspection and testing activities to be followed in all
construction locations for the installation of MV Cable and Splicing under the
scope of SAOMPP Project.

 This procedure shall be applied to the Saudi Aramco Standards.

2. Purpose

The purpose of this procedure is to provide guidelines to performing Inspection for cable
testing, splicing and termination under the scope of SAOMPP Project.

3. Definitions

COMPANY SAUDI ARAMCO

CONTRACTOR CPP

SUPPLIER (Vendor) Any person, firm partnership, company, corporation

combination thereof with which the Buyer has sent to Quotation
Request of placed the Purchase Order.

SUPPLY All material, equipment and services to be provided expressly or

by implication under the Purchase Order.

ITP Inspection and Test Plan

RFI Request for Inspection

4. Reference

4.1 Saudi Aramco Standards and drawings

4.1.1 Saudi Aramco Standards

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SAES-B-068 Electrical Area Classification

SAES-P-100 Basic Power System Design Criteria

SAES-P-104 Wiring Methods and Materials

SAES-P-111 Grounding

SATIP-P-104-02 Medium Voltage Cable and Conductors (1.001kV to

35kV)

4.1.2 Saudi Aramco Standard Drawings

AB-036273 Surface Marker Underground Electric Cable

AB-036326 Standard Sign: Underground Electrical Cables

AD-036874 Installation of Direct Buried Electrical Cables and

Conduits

AB-036766 Standard Electrical Symbols - Plan Layout

AA-0366S9 Concrete Buried/Underground Cable Route Marker

AA-036373 Direct Buried/Encased PVC Conduit in concrete

4.2 Industrial Codes and Standards

IEC International Electro Technical Commission

IEC 60423 Conduit systems for cable management-Outside

diameters for Electrical installations and threads for
conduits and fittings

IEC 61537 Cable tray systems and cable ladder systems

IEC 60840 MV cable above 30 KV

IEC 60227 Polyvinyl chloride insulated cables of rate voltage and

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including 450n50 V general requirement

IEC 60502 Power Cables with extruded insulation and their

accessories for rated voltages from 3KV to 30KV

IEC 60228 Conductors of Insulated cables

NFPA 70 National Electrical Codes

G.I. 2.705 Certification of High Voltage Cable Splicer

5. Responsibilities

5.1.1 The Project manager / Construction Manager are responsible for the proper
implementation of this procedure.

5.2 The QA/QC Manager is responsible for the implementation of all required quality
control activities such as test and inspection for this particular job.

5.3 The QA/QC Engineer is responsible for the proper carrying out of the inspection
and testing details respective to this procedure.

5.4 The Electrical Manager will be coordinating with concerned personnel at site, plan
the daily work schedule, allocate the job to concerned supervisors, and controlling
grounding installation works in all the areas.

5.5 Electrical Supervisor is responsible to monitor all day to day field activities,
assuring that implementation is as per this procedure and relevant referenced
standards and as per HSE policy manual.

5.6 Safety Manager / Supervisor will make sure that all the safety requirements are
fulfilled prior to start of the job. Job Safety Analysis / Safety Task Assignments will
be strictly implemented.

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6. Materials Control

6.1 Check all the materials received are in conformance with Purchase Order and
specification requirements.

6.2 Check/inspect all the materials received are free from physical damages. Any damage
or discrepancies shall be recorded and reported immediately to Procurement
Department.

6.3 Ensure all materials are stored and protected against atmospheric action, dust and dirt.

6.4 Before installation MV cable and splicing materials, QC shall conform to all
applicable requirements and Specifications prior to release to be used as part of the
work.

6.5 Cable reels shall be bandied, transported and unloaded to job site on a safe and
most efficient manner. Ensure that these materials must be stored in accordance
with Manufacturer's Recommendations and Material Control System.

6.6 Cable ends shall be sealed (water and dust proof seals) during transportation and
storage. Cable ends shall be re-sealed after reel testing or sampling with proper end
caps.

6.7 Cable reels shall be stored in vertical position on the firm dry supports, away from
open flames, fire, arc welding, brazing, grinding and other sources of heat or ignition.

6.8 Cable shall be durable marked by manufacturer to indicate the following information:
Maximum rated voltage, cable type, manufacturer's name or trademark, cable size
and year of manufacture.

6.9 Termination and splicing Kit materials must be inspected before using it for cable
termination.

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6.10 Cable shall be prepared by a certified Cable Splicer as per attached manual and
testing as per project specification.

7. Quality control

7.1 The Electrical Quality control inspector shall raise request for inspection (RFI)
minimum 24 hours for site inspection, 48 hours for weekend inspection to PID.

7.2 The Medium Voltage cable termination and testing shall be witnessed by ID and
POD.

7.3 Prior to install at site, cables shall be checked if it complies with the design
requirements and applicable P.O. and Saudi Aramco Material System specifications
(SAMSS). Inspection of cable drums shall be performed, visual checks of damages
suitability of proposed application.

7.4 Insulation resistance and continuity test shall be performed prior to unreel cables and
delivered to site for installation. Cable shall be tested as per SAES-P-104. After the
test, cable ends shall be sealed to protect against moisture.

7.5 HV voltage cables shall be extruded insulation and rated voltage from 1 KV up
to 30 KV according to IEC 60502-1, SAES-P-104 shall have a minimum
operating temperature of 90 °C and final short circuit temperature of 250 °C.
HV cables shall be non-flammable/fire propagation according with IEC 60332.3.

7.6 Armored cable (unless specifically designed as type AC) shall be manufactured to
IEC 60502-1 or 60502-2 and shall have a galvanized steel wire armor or galvanized
double steel tape armor under the jacket. For installation and application purposes,
armored cable manufactured to IEC 60502-1 or 60502-2 shall be considered
equivalent to MC (Metal Clad) cable.

7.7 HV Power Cable should have core identification: Red, Black and White color for

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three core cables and Black for single core cable

8 Work Execution

8.1 The cable splicer/terminator shall hold a valid Job Skills Training Department (JSTD)
splicer certification card for Medium Voltage cable as per GI 2.705.

8.2 Cable splicers shall carry their certificates and JCC's while working on the cable GI
2.705.

8.3 Design and installation of wiring and cable systems shall be in accordance with
the NEC as supplemented by SAES-P-104.

8.4 The cable systems shall be in accordance with the regulated vendor list for
equipment.

8.5 The manufacturer's documentation for the Medium Voltage cable splicing /
termination kit shall be reviewed for compatibility with Saudi Aramco Standards and
the cable being spliced / terminated.

8.6 The Medium Voltage cable splicing / termination procedure shall include
requirements as indicated in manufacturer's recommendation for support and
fastening.

8.7 The manufacturer's recommended minimum bending radius of Medium Voltage cable
to suit the installation shall be included.

8.8 The Medium Voltage cable splicing / termination procedure shall include
requirements for environmental control including provisions for climate control, air
conditioning, totally enclosed splicing enclosures, be free from dust and wind, and
other requirements as indicated in manufacturer’s recommendation.

8.9 Cables shall be permanently identified prior to the splicing/terminating process

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8.10 The Vendor Installation Manual requirements shall be incorporated into the
installation procedure.

8.11 Compression (crimped) type connectors shall be used for splicing and terminating
stranded conductors.

8.12 Compression terminal connectors for 4/0 and larger conductors shall be two hole
NEMA design.

8.13 All compression connectors shall have a manufacturer's reference compression die
number and conductor size printed or stamped on the connector.

8.14 Medium Voltage Cables (5KV through 35KV) shall be 5kV megger tested before and
after backfilling and then DC high-potential tested after installation and prior to
placing in service (during commissioning) at voltage levels specified in 15-SAMMS-
502 or 15-SAMSS-503 and listed in table.

8.15 The high potential test on medium voltage cables shall be performed after mounting
or forming the terminations, provided:

 Terminations have creepage distances per Section 6.12;

 Terminations are not connected to equipment, unless the equipment can also be
tested at the same voltage

 There are sufficient clearances from enclosures and other adjacent objects.

8.16 The Medium Voltage cable manufacturers recommended field test voltage shall be
included in the procedure.

8.17 Medium voltage terminations (operating at 2.4 kV and above) installed outdoors shall

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have a minimum creepage distance to ground of 40mm per kV line-to-line nominal

system voltage.

8.18 Medium voltage terminations installed indoors shall have a minimum creepage
distance to ground of 25mm per kV line-to-line nominal system voltage.

8.19 For Splicing & Termination, follow the vendor instruction and the job to be
performed as per the same.

6 DC High Potential Testing of Medium Voltage Cables

6.5 Testing Equipment and Technical certification will be provided for Saudi Aramco
approval.

6.6 The ends of the cables shall be prepared for the test in accordance with the cable or
test set manufacturer's recommendations but shall not be connected or bolted to the
end-use or supply equipment.

6.7 Ensure that both ends of cables are properly barricaded with watchmen. All portions
of MV cables exposed to personnel such as cables in ladder tray or underneath the
substation shall be well barricaded also.

6.8 Test of medium voltage shielded cables shall be performed on each phase separately
with all other conductors, shields and metallic sheaths grounded. Before testing,
disconnect all equipment not to be included in the test, however, leave all ground
connection intact.

6.9 Test of medium voltage non-shielded cables shall be performed on each phase
separately with all other conductors grounded.

6.10 The cable shall be inspected and mega ohmmeter tested prior to DC high potential
test following SATIP & SAES-P-104 and cable vendor document.

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6.11 DC high potential test of new cables shall start at zero volts and be gradually
increased per the following table:
DC High-Potential Field Test Voltage
After Installation -
Cable Voltage Rating (Insulation before Cable is In Service - First 5
Thickness) Placed in Regular Years
Service

5 kV (115 mils) or 6/1O kV (3.4mm) 36 kV (a) ( c) 11 kV (a) ( c)

15 kV (220 mils) or 12/20 kV(5.5
64 kV (a) ( c) 20 kV (a) ( c)
mm)
35 kV (345 mils or 9 mm) 100 kV ( a ) ( c ) 31 kV (a) ( c)

69 kV (650 mils or 16.5 mm) 192 kV ( b ) ( c ) --

240 kV ( b ) ( c ) (
115 kV (800 mils or 20.3 mm) --
d)

The maximum test voltage is based on the recommended acceptance test voltage level
found in Table 1 of IEEE Std. 400.

6.12 Insulation resistance test shall be conducted on all power and control cables using a
calibrated insulation tester set at an appropriate test voltage. The wire shall be
disconnected from the terminals on both ends while performing the above testing

6.13 Testing equipment will be certified by approved third party certificates to be

submitted to Saudi Aramco

10. SAFETY PRECAUTION

10.1 Obtain approved work permit from the concerned Saudi Aramco operation
department before starting any work.

10.2 Check there is enough lighting provided in working areas and grounding inspected.

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10.3 Tools and equipment used shall be inspected and tagged with color code.

10.4 Continuous monitoring and inspection shall be implemented to detect and correct any
unsafe practices while performing work activities.

10.5 Precaution for working at heights shall be discussed to the working group during
preparation for the activities. 100% Tie off must be followed while working at height.

10.6 Scaffolding shall be inspected following safety standards before commencing the
work, it is not permitted to store cable tray in scaffolding.

10.7 Precaution shall be taken to avoid the usage of cable tray as an access of platform.

10.8 Close monitoring during installation shall be maintained to avoid clashing of trays
against lightings, valve, field devices, and related sensitive equipment installed in the
area. This should be discussed every toolbox meeting to remind the workers as well
as group leaders.

10.9 Good housekeeping shall be maintained in the duration of works. The site of all work
activities shall be kept in a clean and tidy manner.

10.10 Provide warning sign and sufficient barricade on working area and only assigned
personnel be allowed in the area.

10.11 Safety Officer shall monitor the work activities to help and protect all assigned
workers against exposure to safety hazard. He shall ensure that Personnel Protective
Equipment (PPE's) are supplied and worn at all times.

10.12 Tools I Equipment list/ Certificate to be submit before starting work.

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11 Documentation

SAIC-P-3210 Medium Voltage Cable - Termination and Splicing Special Work

Procedure - Document Review

SATR-P-3203 Low Voltage Power and Control Cable, Continuity and Megger
Insulation Resistance Testing.

SATR-P-3208 Medium Voltage Power Cable (Installed), Continuity and Megger

Insulation Resistance Testing

SATR-P-3209 Medium Voltage Power Cable, Termination Torque Testing

SATR-P-3210 Medium Voltage Power Cable, High-Potential Withstand Testing

P-040 Saudi Aramco Pre-Commissioning Form Low Voltage Cables

P-041 Saudi Aramco Pre-Commissioning Form High Voltage Cables (5KV-

15KV-35KV

END OF DOCUMENT

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