PROJECT : RASGAS ONSHORE EXPANSION PROJECT, PHASE 2 (RGX2)

COMPANY : RASGAS COMPANY LIMITED

CONTRACTOR : CTJV (JV OF Chiyoda – Technip)

SUBCONTRACTOR : Dodsal Engineering and Construction Pte Ltd

JOB NUMBER : RG6-CS-004

METHOD STATEMENT
FOR
INSTRUMENT CABLES
INSTALLATION, TERMINATION AND TESTING

DOCUMENT NUMBER : DOD-MST-INS-003

REVISION NUMBER :0

Rev. Issue Reviewed Approved

Reason for Issue Prepared Dodsal
No Date Dodsal Dodsal
Contractor’s comments
incorporated and Issued for Avaneesh Bikas
B 23-04-07 Ravi shivdasan
Approval.MST number changed as Chaudhary Sinha
per CTJV,From DOD-MST-EI-021
Contractor’s comments
Avaneesh
C 19-07-07 incorporated and Issued for Nitin.N.Baviskar A. Sinha
Chaudhary
Approval
Company’s Comments
Pankaj Shukla Avaneesh Antonio
0 16. 09.07 incorporated Issued for
Chaudhary Marchese
Construction.

Document No. DOD-MST-INS-003, Rev. 0

Instrument Cables Installation, Termination and Testing Page 1 of 11
 REVISION CONTROL SHEET
Sr. Rev. Issue Issue
Description
No. No. No. Date
Contractor’s comments incorporated and Issued for
1 B 0 23.04.2007 Approval.MST number Changed as per CTJV, From-
DOD-MST-EI-021
Contractor’s comments incorporated and Issued for
2 C 0 19.07.2007 Approval
Company’s Comments incorporated and Issued for
3 0 0 16. 09.2007
Construction.

Document No. DOD-MST-INS-003, Rev. 0

Instrument Cables Installation, Termination and Testing Page 2 of 11
 INDEX

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 DEFINITIONS

5.0 RESPONSIBILITIES

6.0 PROCEDURE

7.0 DOCUMENTATION

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Instrument Cables Installation, Termination and Testing Page 3 of 11
1.0 PURPOSE

The purpose of this Method Statement is to accomplish the Instrument cables Installation,
Termination and testing in accordance with Project Specifications, Codes and
Standards.

2.0 SCOPE

This scope covers Installation of Instrument cables installation, termination and testing
which is covered within subcontractor’s scope of work for RasGas Onshore Expansion
Project, Phase-2.

3.0 REFERENCES

3.1 Contractor’s Documents

RG6-S-00-1370-002 : Project Specifications General

Requirements for Instrumentation.
RG6-S-00-1370-011 : Instrumentation – Wiring for
instruments and Computers.
RG6-S-00-1370-026 : Instrumentation – Installation of Field
Mounted Instruments.
RG6-S-00-1370-081 : Instrumentation – Fiber Optic Cables
RG6-S-00-1378-001 : Instrument Installation Drawings Design
Procedure.
RG6-D-00-1370-009 : Standard Drawings
RG6-S-00-1378-001-01 : General Notes / Symbols / Legend
for Instrumentation

3.1 Subcontractor’s Documents

DOD-QMS-M001 : Quality Assurance System Manual

DOD-QA/QC-PQP-M130 : Project Quality Plan
DOD-HSE-RG-HSEP-H001 : Health, Safety, Environment Plan
DOD-QCP-QC-001 : Material Control & Storage
DOD-QCP-QC-002 : Material Receiving Inspection
DOD-ITP-INS-003 : ITP for Instrument Cables Installation,
Termination and Testing
DOD-QCP-INS-003 : QCP for Instrument Cables Installation,
Termination and Testing
4.0 DEFINITIONS

Company : RasGas Company Limited

Contractor : CTJV (Chiyoda – Technip Joint Venture)

Subcontractor : Dodsal Engg. and Construction Pte Limited

Supplier : Sub-Contractor to Dodsal Engg and

Construction Pte Ltd.

IS : Intrinsically Safe

Non-IS : Non-Intrinsically Safe

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5.0 RESPONSIBILITIES

5.1 CHIEF CONSTRUCTION MANAGER : Shall be responsible for the implementation

of this Method Statement and shall pass on instructions down the line to ensure the
required HSE and Quality standards, practices and procedures are maintained at each
stage of the Work.

5.2 E&I MANAGER / DEPUTY E&I MANAGER: Shall be responsible for the
implementation of this Method Statement and ensure the required HSE and Quality
standard, practices & procedures are maintained for Instrument cables installation,
testing and termination works.

5.3 SENIOR INST ENGINEER: Shall be responsible for implementation of this Method
Statement and correct working techniques and shall ensure that the instrumentation works
are carried out as per approved IFC drawings, Project Specifications & Standards. He
shall be responsible for overall site supervision and work execution with strict adherence
to this method statement and required HSE & Quality standards, practices and
procedures at site. He shall arrange for necessary inspection & documentation.

5.4 SITE- ENGINEER’S / SUPERINTENDENT: Shall be responsible for the execution of

instrumentation works as per approved IFC drawings, Project Specification & Standard. He
shall be responsible for supervision of execution works with strict adherence to this method
statement and required HSE & Quality standards, practices and procedures at site. He
shall be responsible to raise RFI for the works to be inspected and attend punch- points
as required .

5.5 INSTRUMENT FOREMAN: Shall be responsible for the execution of the

instrumentation work as per approved IFC Drawings, Specifications & Standards, method
statement and responsible for required HSE and Quality standards, practice and
procedures at site.

5.6 QC INSPECTOR :The Instrument QC Engineer/Inspector shall be responsible to forward

the RFI (Request for Inspection) Form No: DOD-RGX-F056 to CTJV after carrying out
internal inspection of the work. He will perform daily pre-inspection for instrument cable
laying & associated installation works and confirm readiness for the inspection of the
instrumentation works, compilation and retention of reports and records as per QCP’S and
ITP’S requirements as well as the loop release. He will also be responsible for issuing non –
Conformance Reports (NCR) and punch list for the discrepancies of the work. All Instrument
cables will be inspected upon receipt at site and checked for any damage during transit
and
shall be verified against manufacturer’s relevant test certificates & inspection reports duly
signed. OSDR (Overage, Short, Damage Report) to be prepared as applicable, shall be
duly signed by concerned personnel / Deptt. / Client representative and to be immediately
Submitted to the client with all the documentation & procedural requirements.

5.7 SAFETY OFFICER shall ensure that all the Equipment, Tools and Tackles are certified in
accordance with the site HSE requirement. All manpower, directly or indirectly involved in
this activity shall be informed of the hazards and risk factor. All regular Safety Equipments
(PPE) shall be used like helmet, goggles, work gloves, safety harness etc.

6.0 ERECTION PROCEDURE

6.1 Safety

6.1.1 All equipment and accessories shall be verified for adequate capacity according to HSE
requirements. Refer JSA No.: DOD-MST-INS-003

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6.1.2 All personnel involved in Instrumentation cable installation and testing shall be informed of
hazards and will adopt preventive measures while undertaking subject instrumentation
works.

6.1.3 All personnel must use their Safety Equipments and Personnel Protective Equipments
(PPE).

6.1.4 Tool Box meeting shall be held daily, prior to start of the work

6.2 MATERIALS

All Materials shall be supplied by M/s CTJV based on the M/s RasGas Standard,
and Project purchase documents & approved manufacturer’s specification.
All materials purchased by Dodsal will be approved before usage by
CTJV vía “MAR” (Material Approval Request) form no: DOD-RGX-F037

6.3 Equipments & Tools / Tackles

 250 V Megger
 Cable Drum- Jack
 Cable Rollers
 Multimeter - Digital Multimeter
 Crimping Tool spring loaded ratchet type
 Cable Cutter
 Knife for removing of cable insulation.
 Pliers, Screw driver set
 Hammer - Steel / Plastic Lead Hammer
 Hand tools Kits
Note: All testing equipment shall have valid calibration certificate and calibration stickers shall
be affixed to them.

6.4 INSTRUMENTATION CABLE INSTALLATION

General Requirements:

6.4.1 All material received at site shall be inspected, handled and stored upon receipt in
accordance with Subcontractor’s Procedure: DOD-QCP-QC-002.

6.4.2 The installation activities shall be carried out in accordance to Contractor’s IFC
Drawings. (Specification, Schedules ), Standards & Procedures.

6.4.3 Cable tray / ladder, angle and channel shall be installed in accordance with IFC
drawings and project specifications. Main runs shall follow the routes of plot plans
and branch routes shall be decided as per field condition to avoid mechanical
obstruction and hot or other detrimental areas as much as feasible. Covers shall
be provided over main cable tray / ladder up to field junction boxes from stub-up
conduits.

6.4.4 Cable tray / ladder Angle & Channel’s shall be aligned in vertical and horizontal
planes and shall be internally smooth. Bolts shall be installed with head inside
and Nut / washers outside.

6.4.5 Cable shall be run in continuous lengths between termination locations, such as
junction boxes, panels, instrument casings, etc., and intermediate Junction Box
connections are not permitted, except for Fiber Optic Cable.

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Instrument Cables Installation, Termination and Testing Page 6 of 11
6.4.6 The entry of cables into field mounted Junction boxes, enclosures and local
panels shall be via suitable gland assembly. Ensure that the glands used are the
correct type and size for the cable and are as per correct safety code as
applicable. Barrier glands shall be used on home run armoured and unarmoured
cable connected to all explosion-proof or flame-proof equipments and cable from
classified areas to non-classified areas as per specifications.

6.4.7 Cable routes passing through outside walls of buildings via MCT transits shall
be sealed on completion of the cable installation to prevent the ingress of water
and dust into the building. Whereever fire-proof seals or hazardous area
boundaries are involved, the method of installation will be carried out as per IFC
drawings.

6.4.8 The earthing, continuity and insulation of metal screens in cables shall be as per
Project Specification and IFC Drawings.

6.4.9 Field instruments shall be considered grounded by means of the cable gland via
the field cable steel wire armor. This applies in all cases where adequate earth
continuity cannot be provided by mechanical supporting connections or via the
instrument connected to the process piping by impulse tubing.

6.4.10 Cable shall not be bent to radius less then the manufacturer’s recommendation
as defined in their catalogue or on the relevant data sheet. Typical 6 to 8 times
OD diameter of the cable shall be implemented.

6.4.11 The minimum spacing between instrument and power cables shall be followed
as per cable project specification: RG6-00-1370-011.

6.4.12 Special signal cables such as co-axial and fibre optic cable shall be installed in
accordance with manufacturer’s guidelines and recommendations.

6.4.13 Any deviation / exceptions to the requirements of the project specifications and
drawings require prior written approval by Contractor / Company.

6.5 Cable Installation and Drum Handling at Site:

6.5.1 On receipt, cables shall be tested and witness by Dodsal and CTJV/CPY
QC. Inspectors on the cable drums, within the lay down yard and all
measurements will be recorded on Form No. : DOD-RGX-F-359

6.5.2 Where damage to cable drum is observed, the cable drum shall be opened and
the cable inspected with CTJV & CPY representatives for any damages.
Necessary inspection report to be prepared.

6.5.3 Transportation of cable drums from receiving storage area to the designated lay
down area at site. The cable drums Nos & cable specifications will be verified
as per cable schedule. Cable Drums to be inspected for any mechanical
damage.

6.5.4 Any Damage to drum or Cable shall be recorded on the OSD report form No:
DOD-RGX-F049 with due signatures from all concerned.

6.5.5 The cables will be tested and witnessed by Dodsal and CTJV/CPY
QC.Inspectors, using a 250 Volts Digital Insulation Tester having valid
calibration certificate.

6.5.6 The Resistance of each core shall be checked using Multi Meter.
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Instrument Cables Installation, Termination and Testing Page 7 of 11
6.5.7 The insulation resistance shall be checked and recorded with the Megger
between individual core to core, core to shield, core to armor, shield to armor
and shield to shield as applicable.

6.5.8 The results of test shall be recorded on Form No. DOD-RGX-F-359-Rev-0

6.5.9 After completion of the tests, the ends of the cable shall be sealed with suitable
Cap / PVC Tape to prevent the ingress of moisture and dust.

6.5.10 The cable and drum schedule will be checked before starting the installation
activities.

6.5.11 For optimum cable usage and to prevent wastage and shortfalls, careful
measurement of the predetermined cable route shall be made and verified
against the cable lengths mentioned on the cable drum and cable schedules. All
measurements shall be recorded and the relevant schedule to be as built
accordingly.

6.5.12 Any pulled cables that can not be immediately glanded must be carefully coiled
in figure 8 configurations and to be provided with cover to protect from damage.

6.6 Underground Stub-up/Conduits

6.6.1 Conduit orientation, routing and sizing shall be in accordance to Contractor’s IFC
Drawings, Standard & Specifications.

Conduit stub-up shall be inspected to ensure the following:

6.6.2 Conduits are debarred and clear of blockage.

6.6.3 Bushings and grounding are installed as per standard drawings.

6.6.4 The inspection results shall be recorded in Form No : DOD-RGX-F364

6.6.5 After cable is pulled through stub-up, the stub-up is to be sealed with foam and
putties in-accordance with the standard drawings.

6.7 Installation of Instrument Cables

6.7.1 The site instrument supervisor shall ensure that the individual cable length is
taken from the designated drum as per drum cutting schedule provided to the
sub contractor and all cut length shall be recorded.

6.7.2 Where instrument signal cables are run in parallel with I/S (Intrinsically) cables,
above or below ground, segregation shall be maintained in accordance with
Contractor’s IFC Drawings and/or Standard Drawings.

6.7.3 Cables shall be tagged in as per the to cable schedule.

6.8 Aboveground Instrument Cable Installation

6.8.1 For above grade installation such as cable route on cable tray/ladders or cable
protector, ensure no sharp edge are present and inspection shall be performed
to ensure complete installation prior to pulling instrument cables.

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6.8.2 Aboveground cable installation shall be mechanically protected with 100% cable
tray / ladder cover for non armored cables.

6.8.3 Routing and supporting of armoured cable shall be by dedicated tray and/or
protector.

6.8.4 Cables installed on tray / ladder shall be fixed by PVC coated stainless steel tie-
wraps.

6.8.5 Critical cable circuit shall use cable constructions that have a confirmed electrical
performance under fire conditions or they shall be fireproofed in accordance to
Project Specification and cable schedule.

6.8.6 When aboveground intrinsic (IS) and non-intrinsic (Non-IS) cables are run on the
same ladders / trays. The cables are to be separated & clipped into two
appropriate bundles and shall be separated by a physical partition for the
complete run of cable.

6.8.7 Cables on cable tray / ladder and protector shall be installed according to
Project Specification and Standard drawings.

6.9 Below ground Instrument Cable Installation

6.9.1 Prior to start cable pulling in trench, inspection shall be done to ensure the
trench depth and width as per Contractor’s IFC drawings. Sand bedding to be
provided as per drawings, specifications and standards.

6.9.2 Throughout the cable pulling process, it is to be ensured that undue stress is not
applied to the cable. Cable winch to be used as per site conditions.

6.9.3 Where instrument cables cross power supply cables, ensure that they shall be
arranged at right angles, a vertical separation as per RG6-S-00-1370-011.

6.9.4 Where instrument and power supply cables are run in the same trench, the run
shall be inspected to ensure separation is as per typical installation of cables
RG6-S-00-1370-011.

6.9.5 Ensure that on completion of laying, individual cable lengths are re-tested for
resistance and insulation resistance.

6.10 Glanding and Termination

6.10.1 Prior to installation, the cable glands will be checked to ensure for the suitability
with respect to size, type and area classification .

6.10.2 Particular attention shall be paid to glands intended for steel-wire armored and
unarmored cables to ensure the correct sealing and clamping components are
supplied with the gland.

6.10.3 All glands shall have suitable area classification certification of material and shall
be sealed as per manufacturer specification .

Prior to sealing and tightening extended cap of the gland, the assembly will be
ensured for the following:

6.10.4 The cable tails are of the correct length and undamaged during stripping.

6.10.5 The steel wire armor is stripped to the correct length such that it mates suitably
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 but does not protrude through the clamping ring.

6.10.6 The shield and mylar is stripped to correct length with sleeve installed over
drain wire and made off with insulation tape as shown by standard drawings.

6.10.7 Earth tag is fitted as required.

6.10.8 Ensure that suitable sealing washer is fitted to all Junction boxes, equipments
and enclosures as per specifications .

6.10.9 The outer sheath of the cable is contained within the gland.

6.10.10 Shroud will be fitted to cable glands as per project specifications and standards..

6.10.11 Tightness of cable gland to be checked and ensured.

6.10.12 The body is securely fitted to the enclosure.

6.10.13 The gland is mechanically sound.

6.10.14 The clamping on the steel-wire armor is secure.

6.10.15 The outer sheath is sealed.

6.10.16 The inspection will be done to verify correct installation by Dodsal and CTJV/CPY
QC.Inspectors.

6.10.17 Cables termination shall be performed in an orderly manner. Field cable cores
shall be terminated with screw terminals, connections will be limited to one per
terminal. Common terminals shall be made using terminal manufacturer’s
bridging arrangements.

6.10.18 Termination materials shall be in accordance with Project Specifications and

termination details or Standard drawings.

6.11 Post – Installation Testing

6.11.1 On completion of lying and, where installed in trenches prior to backfilling,

individual cable lengths will be tested for resistance and insulation resistance will
be recorded in DOD-RGX-F360 . After installation of tiles and backfilling, cable
markers shall be installed according to the applicable IFC Drawings.

6.11.2 Cables, fittings supports, routing and terminations shall be checked to ensure
they comply with the specifications and general installation documentation.

6.11.3 Cables run in conduit or underground shall be fully tested before sealing or back
filling operations are commenced.

6.11.4 Earthling provisions shall be fully inspected and in particular the earth loop
Impedance for I.S. earth systems must be checked to ensure compliance with
associated safety certificates.

6.11.5 Testing shall be carried out before the commissioning period when no
hazardous areas exist on the site. It is sub-contractors responsibility to ensure
that any test done subsequent to this where hazards may exist are performed
with the appropriate IS earth test meters or similar. All such test arrangements
shall be agreed with Contractor / Company.

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6.11.6 Instrument cables shall be tested recorded in DOD-RGX-F361

6.11.7 After completion of glanding and termination inspection, the cables will be
checked for resistance and insulation resistance with instruments/panel circuits
isolated from cable loop Results will be recorded in the Form Nos. DOD-RGX-
F366.

6.12 JOB SAFETY ANALYSIS (JSA)

6.12.1 Job Safety Analysis (JSA), as per attachment. JSA NO: DOD-MST-INS-003

7. DOCUMENTATION

7.1 Overage, Short, Damage Report : DOD-RGX-F049

7.2 Insulation resistance and continuity test report : DOD-RGX-F359

Pre-Installation of Instrument Cables

7.3 Insulation resistance and continuity test report : DOD-RGX-F360

After laying on trench of Instrument Cables

7.4 Insulation resistance and continuity test report : DOD-RGX-F361

Post installation of Instrument Cables

7.5 Cable trench and Duct Bank : DOD-RGX-F362

Inspection before cable pulling

7.5 Cable trench and Duct Bank : DOD-RGX-F363

Inspection after cable pulling

7.6 Installation of Stub-up Conduits : DOD-RGX-F364

7.7 Installation of Instrument Trays / Ladders : DOD-RGX-F365

7.8 Instrument Secondary Cable, Glanding/ : DOD-RGX-F366

Termination Inspection Report

7.9 Cable trench and Duct Bank : DOD-RGX-F367

Inspection for Final Backfilling

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