BAKELEKTRO OJSC

EXECUTION PLAN

MV Power Cable and Accessories Installation

REVISION RECORD
 This cover page is a record of all revisions of the document identified above by number and title. All previous cover pages are
hereby superseded and are to be destroyed.

Rev. Date By Chkd. Approvals Description and Page Numbers of Revisions

No.
CONTENTS

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 DEFINITIONS

5.0 RESPONSIBILITIES

6.0 EQUIPMENT

7.0 EXECUTION PROCEDURE

8.0 ATTACHMENTS

1.0 PURPOSE
The purpose of generating this method statement is to define the procedure for MV power cable Installation
through the guidelines contained herein so as to ensure that the job execution complies with the
requirements where applicable in the building of the project.

2.0 SCOPE

- This method statement covers all processes related to MV power cable and installation as per
project specification, approved shop drawings and regulation.
- This procedure is to be read in conjunction with the relevant ITP, outlining the responsibility and
the quality verification to be performed by various parties.

3.0 REFERENCE

 Approved Shop drawings for External and Internal power distribution.

 Specifications
 Project Quality Plan
 Project HSE plan.
 Regulation of the local Electrical Authority

4.0 DEFINITIONS:

PQP : Project Quality Plan

PSP : Project Safety Plan
PPE : Personal Protective Equipments.
PTW : Permit to work.
QCP : Quality Control Procedure
HSE : Health, Safety and Environment
MS : Method Statement
ITP : Inspection Test Plan
QA/QC : Quality Assurance / Quality Control Engineer.
SK : Store Keeper.
WIR : Inspection and Test Request
MIR : Material Verification Record.
MV : Medium Voltage.

5.0 RESPONSIBILITIES:

Responsibilities for ensuring that the steps in this procedure shall be carried out are specified at relevant
steps in the procedure:
- Project Manager
- Construction manager
- QA/QC Engineer
- Site Engineer
- HSE officer
- SK
5.1 Project Manager

- Project Manager is the overall responsible for the project in terms of work execution, safety, planning
& quality. The Project Manager will maintain the planning progress and coordination of works with
the main contractor.
- The work progress shall be carried out as per planned program and all the equipment’s required to
execute the works shall be available and in good condition as per project planned.
- Specific attention is paid to all safety measures and quality control in coordination with Safety
Engineer and QA/QC Engineer and in line with PSP and PQP.
5.2 Construction Manager

- Construction Manager is responsible to supervise and control the work on site.

- Coordinating with QA/QC Engineer and site Team and foremen for all activities on site.
- Control and sign all WIR’s before issuing to Consultant approval.

5.3 Site Engineer

- The method of statement to the testing of the cables shall be implemented according to the Consultant
project specifications and approved shop drawings.
- Provision of all necessary information and distribution of responsibilities to his Construction team.
- The work progress shall be monitored in accordance with the planned work program and he will
provide reports to his superiors.
- The constant coordination with the Safety Engineer to ensure that the works are carried out in safe
working atmosphere.
- The constant coordination with the QA/QC Engineer for any works to be carried out and initiate for
the Inspection for the finished works.
- He will ensure the implementation of any request that might be raised by the Consultant.
- Efficient daily progress shall be obtained for all the equipment and manpower.
- He will engage in the work and check the same against the daily report received from the Foremen.
- The passage of all the revised information to the Foremen and ensure that it’s being carried out
properly.

5.4 QA/QC Engineer (MEP):

- The monitoring of executions of works at site and should be as per the approved shop drawings and
project specifications.
- Ensure WIRs are being raised for activities in timely manner and inspected by the Consultant.
- Check and insure that all activities / work done / completed prior to offer for consultant inspection.
- He will follow and carried out all the relevant tests as per project specifications.
- Obtain the required clearance prior to Consultant’s inspections.
- Should acquire any necessary civil works clearances and coordination.
- Coordinate with site construction team.
- One who will assist the Consultant Engineer / Inspector during inspection.

5.5 Site Foreman

- The carrying-out of work and the proper distribution of all the available resources in coordination
with the Site Engineer on a daily basis.
- Daily reports of the works are achieved and coordinated for the future planning with the Site
 Engineer.
- Incorporate all the QA/QC and Safety requirements as requested by the concerned Engineer.
- Meeting with any type of unforeseen incident or requirement and reporting the same to the Site
Engineer immediately.

5.6 Safety Officer

- The implementation of all safety measures in accordance with the HSE plan and that the whole work
force is aware of its proper implementation.
- The implementation of safety measures is adequate to maintain a safe working environment on the
work activity.
- Inspection of all the site activities and training personnel in accident prevention and its proper
reporting to the Construction Manager and the Project Manager.
- The site is maintained in a clean and tidy manner.
- Ensure only trained persons shall operate the power tools.
- Ensure all concerned personals shall use PPE and all other items as required.
- Ensure adequate lighting is provided in the working area at night time.
- Ensure high risk elevated areas are provided are barricade, tape, safety nets and provided with
ladders.
- Ensure safe access to site work at all times.

5.7 Store Keeper (SK)

- Responsible for overall Store operations in making sure to store the material delivery to the site and
keep it in suitable area that will keep the material in safe from rusty and damage.
- One who will acknowledge the receiving of materials at site in coordination with QA/QC and
concerned Engineer.

6.0 EQUIPMENTS

 Tool box
 Cable pull springs
 Cable drum
 Crimping tools.
 Measuring Tape
 Cable pulling compound.
 Ladder / Scaffolding.
 Safety requirements tools such as safety shoes, safety helmet, safety glasses, fluorescent vest,
and safety gloves to ensure maximum ability of safe work and dust mask when require.

7.0 EXECUTION PROCEDURE

7.1 Safety

- Ensure only trained/ Authorised & licensed persons only shall operate the power tools and do the
Installation and Testing job.
- Necessary PPE to be worn while working in energized to be worn while working in energized
circuits.
- Ensure adequate lighting is provided in the working area at night time and if inside the building area
to be well illuminated.
- Ensure service area/work area openings are provided with barricade, tape, safety nets and warning
signage to be provided (Danger: High voltage).
- Ensure LOTO procedure to be followed and implement comprehensive logout & tag out during
execution of work.
- Emergency evacuation plan and procedure to be developed prior to start of Installation.
- PTW to be applied and obtained to start work on the required area.
- Calibrated Instruments only to be used.
- Temporary power supply for T & C shall be taken through standard rated MCBs and RCBs.
- Power supply used to take temporary power supply shall not have any joints.

7.2 Work Sequence And Methodology

- Check all material delivered to site is inspected properly by QA/QC Engineer and check if it is stored
properly as per manufacturer’s recommendations.
- MIR shall be raised for the inspection of materials received at site to the Consultant Engineer.
- Work shall be carried out by the site staff under strict supervision and guidance of the concerned
Supervisors / Foremen / Engineers.
- The QA/QC Engineer shall check all the installations as per the Installation Check list.
- WIR shall be prepared by QA/QC Engineer and will be submitted to Consultant for their inspection
and approval.
- QA/QC Engineer shall coordinate with other contractors and arrange inspection for installation to the
Consultant Engineer.
- QA/QC Engineer is responsible for all installation activities for getting the work inspected and
approved by Consultant Engineer.

7.3 Handling and storage:

- All cables shall be handled and stores as per manufacturer recommendations.

- All cable ends shall be sealed with heat shrinkable end caps at all times to prevent the entrance of
moisture into insulation during storage and installation as per project specs.
- The drums should be stored in such a manner as to leave sufficient space between them. It is desirable
for the drums to stand on battens place directly under the flanges.
- For drums, overhead shade is not essential except in areas where the rainfall is heavy. The cables
should however be protected from direct rays of sun by leaving the battens on or by providing some
form of sun-shielding.
- Cable ends must be sealed against water ingress at all times.
- The drum should be rolled only in the direction of the arrow, indicated on them.
- No cable drums shall be slung except by a bar through the centre bore. Also the cable drums shall be
stored away from boilers or fumes.
- When unloading the drums from truck, crane should be used if available and drums carefully lifted
and deposited on the ground. If crane is not available then the drums should be carefully rolled down
a suitably arranged ramp or rail. Under no circumstances should the drums be dropped to the ground,
as the shock may cause serious damage to the inner layers of the cables.
- Transportation over long distance, from storage site to work spots- the drums should be mounted on
cable drum wheels strong enough to carry the weight of the drums, which are pulled by means of
rope, or alternatively they may be mounted on trailer or vehicle with low loading platform for
 transportation to the destination.

7.4 Installation Procedure:

7.4.1 Cable Pulling and laying :

- All materials to be used shall be in accordance with the approved material submittal.
- All installation shall be made with accordance to approved shop drawings.
- Check the location/route of MV power cables to be pulled as per approved shop drawing.
- Clean the puddle flanges, Pipes and ducts completely before starting pulling the MV power cables.
- Place the MV power cables in cable drum lifting jack, put cable rollers along the cable ladder, attach
cable grip at one end and pull it manually.
- The draw strain is applied to the armouring without exceeding the pull stress from the manufacturer's
recommended value and protected during drawing against damage.
- Provide cable supports, cable trays, cable ladders, etc. throughout the run of the power cables. Cable
supports shall be fabricated from fittings of hot-dipped galvanized C-channels in general; conductors
and cables shall be supported and terminated so that no strain is imposed on the terminals of the
equipment or the cables.
- Upon reaching the correct destination of the MV power cables, provide enough length for allowance
for dressing before cutting.
- Put temporary markings at both ends of the cable for easy identification; provide sealant with heat
shrink end caps at both ends to prevent the ingress of water after pulling.
- Keep a bending radius of not less than 12 times the diameter of MV power cables.
- Approved Crimping lugs shall be used on all power cables. The type and makes of all crimping lugs
and their associated hydraulic crimping tools are subjected to the approval of the CONSULTANT.
- Power cables and control cables shall be run in separate ladders/trays.
- All cables shall be laid in neat, one-layer parallel runs and shall be securely clamped by alloy cable
clamps. Cable clamp shall be subjected to the approval of the CONSULTANT. A minimum spacing
of one time of the cable diameter shall be maintained for the power cables.
- All cables shall be clearly labelled at both ends and at regular intervals if cables are run on cable
ladder/tray or in riser using appropriate cable labelling with 5mm high black lettering on yellow
background.
- Ground shields of shielded cable at terminations, splices, and separable insulated connectors. Ground
metal bodies of terminators, splices, cable and separable insulated-connector fittings, and hardware.
- Connectors and Splice Kits: Comply with IEEE 404, and AUTHORITY Electricity Wiring
Regulations; type as recommended by cable or splicing kit manufacturer for the application.
- Splicing Products: As recommended, in writing, by splicing kit manufacturer for specific sizes,
ratings, and configurations of cable conductors. Include all components required for complete splice,
with detailed instructions.
- Termination of cables shall be carried out by the AUTHORITY accredited and full experienced
jointers and evidence of this shall be produced to the satisfaction of the CONSULTANT before
termination of cables is being carried out.
- Raise the WIR for consultant approval.

7.4.2 Installation of Underground MV power cable:

- Mark the route of the cable as per approved shop drawings.

 - Check the size of the cables going from the MV panel to AUTHORITY manhole point as per
approved material submittal and AUTHORITY approval.
- Excavate the external route of the cable till the light pole point as per approved shop drawings and
AUTHORITY regulation 1000mm from the ground level.
- Apply Soft sand 100mm provided in the extreme bottom.
- Lay the cable into the route/trench/cable ladder or Tray and make sure that the cables not damaged in
pulling stage as per the method mentioned above in item 7.4.1 as per approved shop drawings and as
per AUTHORITY regulation and manufacturer recommendations.
- Raise WIR for Consultant approval before backfilling.
- Apply 100mm soft sand above the cable.
- Put the cable tiles above the soft sand along with the warning tape.
- Insure that marker for 11KV power cable provided as per AUTHORITY regulations.
- Then Complete backfilling in the witnessed of Main contractor & Consultant Engineer.

7.5 AUTHORITY Incoming Cables:

- The Contractor shall render all assistance to the AUTHORITY during the laying of AUTHORITY
cables.
- The Contractor shall provide all termination kits, coordinate with AUTHORITY and terminate the
incoming power and pilot cables at the incoming MV switchboard side.
- The Contractor shall provide cable supports for AUTHORITY’s cables.

8.0 ATTACHMENTS

- Quality Control Procedure

- Inspection and Testing Plan
- Check List
- Risk Assessment
 INSPECTION AND TEST PROCEDURES

Cables, Medium- and High-Voltage

1. Visual and Mechanical Inspection

1. Compare cable data with drawings and specifications.

2. Inspect exposed sections of cables for physical damage.

3. Inspect bolted electrical connections for high resistance using one of the following methods:

1. Use of low-resistance ohmmeter

2. Verify tightness of accessible bolted electrical connections by calibrated torque-wrench

method in accordance with manufacturer’s published data

3. Perform thermographic survey

4. Inspect compression-applied connectors for correct cable match and indentation.

5. Inspect shield grounding, cable support, and termination.

6. Verify that visible cable bends meet or exceed ICEA and/or manufacturer’s minimum
allowable bending radius.

*7. Inspect fireproofing in common cable areas.

8. If cables are terminated through window-type current transformers, inspect to verify that neutral
and ground conductors are correctly placed and that shields are correctly terminated for
operation of protective devices.

9. Inspect for correct identification and arrangements.

10. Inspect jacket and insulation condition.

* Optional
 INSPECTION AND TEST PROCEDURES

Cables, Medium- and High-Voltage (Cont.)

2. Electrical Tests

1. Perform resistance measurements through bolted connections with a

low-resistance ohmmeter, if applicable.

2. Perform an insulation-resistance test utilizing a megohmmeter with a voltage

output of at least 2500 volts. Individually test each conductor with all other
conductors and shields grounded. Test duration shall be one minute.

3. Perform a shield-continuity test on each power cable by ohmmeter method.

4. Perform an acceptance test on cables, including terminations and joints, after

cable system installation and before the cable system is placed into service.
In accordance with ANSI/IEEE 400, ICEA S-93-639/NEMA WC 74, ICEA
S-94-649 and ICEA S-97-682, testing can be performed by means of direct
voltage (dc), alternating voltage (ac), partial discharge (pd), or very low
frequency (VLF). The selection can be made only after an evaluation of the
alternative methods. Test procedure shall be as follows, and the results for
each cable test shall be recorded as specified herein. Test voltages shall not
exceed 80 percent of cable manufacturer’s factory test value or the maximum
test voltage.

1. Insure that the input voltage to the test set is regulated.

2. Current-sensing circuits in test equipment, when available, shall

measure only the leakage current associated with the cable under test
and shall not include internal leakage of the test equipment.

3. Record wet- and dry-bulb temperatures or relative humidity and

temperature.

4. Test each cable section individually.

5. Test each conductor individually with all other conductors grounded.

Ground all shields.

6. Terminations shall be adequately corona-suppressed by guard ring,

field reduction sphere, or other suitable method, as necessary.

7. Insure that the maximum test voltage does not exceed the limits for
terminators specified in ANSI/IEEE 48, IEEE 386, or manufacturer’s
specifications.
 INSPECTION AND TEST PROCEDURES
Cables, Medium- and High-Voltage (Cont.)

8. Raise the conductor to the specified maximum test voltage and hold
for 15 minutes.

9. If performed by means of direct voltage (dc), reduce the test set

potential to zero and measure residual voltage at discrete intervals.

10. Apply grounds for a time period adequate to drain all insulation
stored charge.

11. Spliced cables (new to existing)

1. When new cables are spliced into existing cables, the

acceptance test shall be performed on the new cable prior to
splicing.

2. After test results are approved for new cable and the splice
is completed, an insulation-resistance test and a shield-
continuity test shall be performed on the length of new and
existing cable including the splice.

*3. After a satisfactory insulation-resistance test, a test in

accordance with the types listed in section 7.3.3.2.4 may be
performed on the cable utilizing a test voltage acceptable to
owner and not exceeding 60 percent of factory test value.

* Optional
 INSPECTION AND TEST PROCEDURES
Cables, Medium- and High-Voltage (Cont.)

3. Test Values

1. The values associated with the testing methods shall be in accordance with
the applicable Table.

2. Compare bolted connection resistances to values of similar connections.

3. Bolt-torque levels should be in accordance with Table unless

otherwise specified by the manufacturer.

4. Microhm or millivolt drop values shall not exceed the high levels of the
normal range as indicated in the manufacturer’s published data. If
manufacturer’s data is not available, investigate any values which deviate
from similar connections by more than 50 percent of the lowest value.

5. Shielding shall exhibit continuity. Investigate resistance values in excess of

ten ohms per 1000 feet of cable.

6. If test is performed by means of direct voltage (dc), graphic plots may be

made of leakage current versus step voltage at each increment and leakage
current versus time at final test voltages.

7. Residual voltage at the end of each interval should be approximately the

same for each phase and/or parallel conductor.

* Optional