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REV
DATE
ORIGINAL
BY
CHECKED
BY
APPROVED
BY
DESCRIPTION
Page 1 of 13
REV
REMARKS
FIRST ISSUE
Page 2 of 13
CONTENTS
1.0
2.0
3.0
4.0
5.0
6.0
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
7.0
7.1
8.0
8.1
1.0
PURPOSE................................................................................................... 3
SCOPE....................................................................................................... 3
DEFINITIONS / ABBREVIATIONS.........................................................................3
REFERENCES............................................................................................... 4
RESPONSIBILITY & AUTHORITY.........................................................................4
DESCRIPTION OF ACTIVITIES............................................................................4
General Requirements.................................................................................4
Material Inspection Prior to Installation.............................................................4
Pre-Installation Test....................................................................................5
Cable Installation Inspection..........................................................................5
D.C Sheath Integrity Test of MV/HV Cables.........................................................6
Cable Glanding and Termination.....................................................................7
Cable Jointing........................................................................................... 8
Insulation Resistance and Continuity Test...........................................................9
High Voltage Test.......................................................................................9
Inspection & Test Status..............................................................................10
Testing & Measuring Equipment.....................................................................11
Safety................................................................................................... 11
RECORDS.................................................................................................. 11
List of Verifying Documents (ITRs)..................................................................11
APPENDICES.............................................................................................. 12
Guideline for Cable Repair at Site (Appendix-1).................................................12
PURPOSE
1.1 The purpose of this procedure is to define the inspection and testing method,
acceptance criteria for the installation of electrical power & control cables and
the responsibility of construction and Quality Control personnel with regard to
this procedure.
2.0
SCOPE
2.1
2.2
3.0
DEFINITIONS / ABBREVIATIONS
Company
ORPIC-OMAN
OEC or Contractor
Project
QCP
ITP
:
:
ITR
Page 3 of 13
4.0
QC
Quality Control
PPE
RFI
Volts
KV
Kilo Volts
DC
Direct Current
MV/HV
PA/GA
IP
Ingress Protection
U0
HSSE
REFERENCES
S-000-5380-001 REV 3 SPECIFICATION FOR ELECTRICAL FACILITIES
5.0
6.0
DESCRIPTION OF ACTIVITES
6.1
General Requirements
5.1
5.2
5.3
6.1.1
All material received at site shall be inspected upon receipt in accordance with
Construction Management Procedure for Material Receiving.
6.1.2
The Site Electrician under the supervision of Electrical Supervisor shall
conduct all tests and the test shall be witnessed and results recorded by Electrical
QC Inspector.
Page 4 of 13
6.1.3
Where damage to cable drum and/or cable is observed during material
checking, Subcontractor shall generate a Damage Report describing the
deficiencies according to Material Receiving procedure.
6.1.4
The test shall be recorded as defined herein and witnessed by
Subcontractor, Petrofac and Company as indicated in the ITP. Prior to issuing the
report forms, the inspection items shall be signed by the Electrical QC Inspector.
6.2
damage.
6.2.2
Where damage to cable drum is observed, the cable drum shall be opened
and the cable inspected.
6.2.3
Should the cable be damaged, this will be recorded and reported on a
Damage Report.
6.3
Pre-Installation Test
6.3.1
Cables shall be inspected and tested on the cable drums prior to removal to
the work site. Test voltage shall be as follows:
Cables rated up to 600V
MV/HV Cables
6.3.2
The continuity of each core, screen and armour shall be checked.
6.3.3
The insulation resistance of power and control cables shall be conducted
before installation, between cores and between individual cores and earth or
armouring/screen as applicable. Conductors, metallic sheath, armour and screens
which are not under test shall be grounded during the test.
6.3.4
Where cables fitted with a pulling eye, above tests (6.3.2 & 6.3.3) shall be
conducted if any damages observed only.
6.3.5
After completion of the tests, cable ends shall be sealed to prevent the
ingress of moisture.
6.3.6 The cable drums shall be marked as tested and inspected.
6.3.7 Inspection and test results shall be recorded on SHR-FRM-QUA-E-0101X.
6.4
Page 5 of 13
to avoid risk of damage to outer sheath of the cable in low or high ambient
temperature depending on cable type.
6.4.5
Where cable drum schedule is available, the site supervisor shall ensure
that the individual cable lengths are taken from the designated drum.
6.4.6
Throughout the cable pulling process the Site Electrical Supervisor shall ensure that
undue stress is not applied to the cable. Where a cable winch is used, the
manufacturers permissible pulling tension values shall be adhered to.
6.4.7
A sufficient number of workmen and rollers shall be used to prevent the
damage of the cable being pulled at the corners and cross-sections where the
cable changes its direction.
6.4.8
For all cables, the direction of pulling shall be as indicated by the arrow
on the cable drum.
6.4.9
Where cables of different voltage levels and/or service are run in parallel,
segregation shall be in accordance with the specification and typical electrical
installation drawings.
6.4.10
Ensure that single core cables feeding three phase loads are installed in
trefoil formation.
Any other formation shall be approved by Petrofac
engineering.
6.4.11
Cables shall be identified
Documents/Project specification.
6.4.12
properly
according
to
Engineering
following:
a) Cable segregation between different voltage levels, instrument/ PA/GA/ Telecomm
cables etc.
b) Cable arrangement, satisfactory bending radius, dressing and routing as per applicable
drawing and no physical damage.
c) Identification markers provided at specified intervals, route changes, at duct banks
and each bends etc.
d) Single core cable supplying three phase loads are in trefoil formation or as specified by
engineering.
e) All cable entries are sealed off with an approved sealant.
f)
Where cables are to be installed in a multi-layer cable trench, each layer shall be
inspected by Electrical QC inspector to ensure cable arrangement and thickness of
sand between/over the cables.
6.4.13
Prior to release the trench for final backfilling by civil, trench shall be
inspected to ensure thickness of soft sand filling over the cable, proper
installation of warning tape and protection tiles etc.
6.4.14
In addition to 6.4.12- a to d, aboveground cables shall be inspected to ensure
following:
a) Spare space is available in each tray and trays are not over filled.
b) Protected from sharp edges of cable trays.
Page 6 of 13
6.5
The minimum average thickness shall be used to calculate the test voltage .
6.5.3
For the test to be effective, it is necessary that the ground makes good
contact with all of the outer surface of the over sheath. A conductive layer on the
over sheath or moist backfill can assist in this.
6.6
6.5.4
6.5.5
Cable Glanding
The entire body of a cable shall enter a gland and the outer sheath of the cable shall
not be removed before entering the waterproof seal.
g) If specified, at outdoor locations the cable glands shall be provided by shroud and
shall be fitted with the close fitting shroud completely enclosing the gland.
h) Cable glands on equipment in the plant shall be mounted at the bottom to prevent
ingress of water. Where cable glands are installed in the side wall of equipment, the
cable shall enter from below the cable entry level. Cable coming from top shall first
drop to below the gland level. Top entry shall be strictly avoided.
i)
Page 7 of 13
j)
k) Verify proper dressing of cables at both ends and supports provided as required.
l)
m) Where cables are terminated by glands into non-metallic enclosures having threaded
entries and internal earth continuity plates, or metallic enclosures having clearance
holes, a locknut and serrated washer shall be used to guarantee the earth continuity
between the gland body/cable armour and the enclosure. Where applicable, verify
tightness of lock nut.
n) Ensure that gland components are properly assembled as instructed by manufacturer,
tightened and seals are not damaged.
o) Ensure that correct thread type is used and thread engagement is satisfactory. e.g. in
an Ex d enclosure, minimum five full thread engagement required for parallel threads
and wrench tight for taper threads.
p) Inspection results shall be recorded on SHR-FRM-QUA-E-0106A or SHR-FRM-QUA-E0108A as applicable.
6.6.2
Cable Termination
a) Within equipment terminal boxes an adequate cable core tail shall be provided to
enable each cable core to be connected to any terminal of the enclosure.
b) For multi-core terminal in boxes a sufficient length of cable tail shall be left to allow
for re-making and termination of each core.
c) Cable tails of conductors and wires shall be fitted with compression type terminal
connecting lugs. Wire/terminal lugs or thimbles shall be of the correct type and size
for each conductor. Crimping of the over/undersized lug is not permitted.
d) All connections at the cable termination shall be mechanically and electrically firm
and shall be protected against mechanical damage or any vibration liable to occur.
e) Cable conductor shall be identified according to the terminal block drawings. The
method of identification is as specified in the job specification and installation
drawings. Project cable colour code shall be strictly followed.
f)
Ensure conductors are insulated, not touching with the cable entry component.
j)
Bolted connections above 10mm size shall be torqued with calibrated torque wrench.
Torque value shall be as per manufacturers published data.
k) Inspection results shall be recorded on SHR-FRM-QUA-E-0106A or SHR-FRM-QUA-E0108A as applicable; in addition SHR-FRM-QUA-E-0105A shall be filled for medium
voltage cables.
6.7
Cable Jointing
6.7.1
Page 8 of 13
6.7.2
6.7.6
6.7.7
requirement.
Cable joint location shall be marked on As-built drawing.
Inspection and test results shall be recorded on SHR-FRM-QUA-E0105A.
6.8
6.9
After completion of jointing, glanding and end terminations the cables shall be IR
and continuity tested as mentioned in 6.8.
6.9.2
Prior to commencing the high voltage test, the area should be effectively roped
Page 9 of 13
6.9.4
6.9.5
The test voltage shall be applied to each conductor with all other conductors
shorted to armour shields and earth.
6.9.6
The initial test voltage (10% of final test voltage) shall be applied to the cable
and the voltage allowed to stabilize.
6.9.7
The applied voltage shall be increased gradually in 10% steps until final test
voltage is reached and the voltage and leakage current recorded at each
step after stabilization.
6.9.8
The final test voltage shall be applied for 15 minutes and the leakage current
values recorded at 5 minute intervals, including ambient temperature
and relative humidity. No breakdown of the insulation resistance should
occur.
6.9.9
When each test is complete the cable potential shall be discharged using a hot
stick and rubber insulated gloves rated for the test values. After
discharge, the cable shall be checked again for residual voltage potential
and left grounded for a time interval at least equal to the amount of
time, test voltage was applied to assure complete discharge.
6.9.10
Insulation Resistance test shall be repeated as in 6.8 after high voltage test.
6.9.11
After completion of the tests the cable ends shall be sealed to prevent the
ingress of moisture.
6.9.12
6.10.1
6.10.2
6.10.3
6.10.4
Page 10 of 13
6.12 Safety
6.12.1
Installation, inspection and testing shall be carried out in accordance with
Project HSSE Plan.
6.12.2
Site personnel shall adhere to the site safety policies at all times with
emphasis on wearing the correct PPE and equipment appropriate to the type of
the operation being performed.
6.12.3
All personnel including third parties shall be safety inducted prior to entry
on site.
6.12.4
Safety risks involved shall be constantly monitored for changes in site
conditions.
6.12.5
Prior to commencements of work every day, the supervisor shall check all
equipment and tools are in good condition.
6.12.6
Page 11 of 13
7.0
RECORDS
7.1
No.
ITR No.
Description
SHR-FRM-QUA-E-0101X
SHR-FRM-QUA-E-0102X
SHR-FRM-QUA-E-0103X
SHR-FRM-QUA-E-0104X
SHR-FRM-QUA-E-0105A
SHR-FRM-QUA-E-0106A
SHR-FRM-QUA-E-0107X
SHR-FRM-QUA-E-0108A
8.0
APPENDICES
8.1
8.1.2
8.1.3
Page 12 of 13
8.1.4
a)All the required materials and necessary tools to carry out the job shall be
arranged in advance.
b)
The heat shrinkable jacket or splicing kit (As required) shall be
verified for its expiry date before the unpacking of the kit. The cable types
and sizes will be verified to see the compatibility with the existing damaged
cable.
c)The cable trench in the area of work shall be well protected by warning
tapes/signs in the event the work is continued more than a day
d)
Ensure the Electrician / Cable jointer involved in the work will be
qualified to execute the work in a competent manner maintaining a high
quality cable repair works.
e)
Ensure that the weather conditions are suitable for the type of work
to be done.
f) Where applicable, ensure that the workmen are adequately briefed of the
working and safety procedures in the existing plant.
g)Where applicable, ensure that feeder for the cable is isolated and latched
to avoid electrocution by workmen.
8.1.6
Category 1: This type of damage shall be rectified by cutting that portion of the
damaged cable. Add a new piece of cable similar to the existing type
and rating and make a suitable splice joint by using approved slicing
kit.
Category 2: These cables shall be repaired by using a splice kit excluding the
straight ferrules to recreate the outer protection. However if the
cable does not satisfy the inspection/test, this cable shall follow the
category-1 procedure of repair.
Category 3: These cables will be repaired by self-amalgamating tape on the outer
sheath of cable or by heat shrinkable jacket.
8.1.7
Page 13 of 13
8.1.8
Page 14 of 13