Method Statement For Power Cable Pulling

ZUBAIR OIL FIELD DEVELOPMENT PROJECT IRAQ METHOD STATEMENT FOR CONTROL, LV AND HV CABLE INSTALLATION

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ISSUED FOR APPROVAL

Validity Rev. Status number Date Revision Index Company logo and business name

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Prepared by

Description

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Checked by

Project name

ZUBAIR OIL FIELD DEVELOPMENT

eni iraq b.v. Contractor logo and business name

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Contract Approved or by Approval Company Identification

Company Approval

xxxxxxxxxxxxxxxxxx Job N. Contractor Identification

P12-1050 Weatherford Oil Tools Middle East Contract N. Vendor Identification

Vendor logo and business name

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Facility Name

Location

HAMMAR-RAFIDIYA-ZUBAIR IPF

ONSHORE

Document Title

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Supersedes N.

METHOD STATEMENT FOR INSTALLATION OF CONTROL, LV AND HV CABLE INSTALLATION Software: Microsoft Word 97-2003

Superseded by N. Plant Area

Plant Unit

File N° 00250621DEPC77013_EXDE00_14

This document is property of Eni Iraq BV It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent

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REVISION HISTORY

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CONTENTS

1.

PURPOSE

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2.

SCOPE

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3.

REFERENCE

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4.

DIFINITION /ABBREVIATION

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5.

RESPONSIBILITIES

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5.1 5.2 5.3 5.4 5.5 5.6 5.7 6.

PROEJCT MANGER PROJECT ENGINEER ELECTRICAL SITE ENGINEER ELECTRICAL SITE SUPERVISOR FOREMAN QAQC ENGINEER SAFETY OFFICER

PROCEEDURE 6.1 6.2 6.3 6.4 6.5 6.6

HSE REQUIREMENTS TOOLS & EQUIPMENT GENERAL REQUIREMENTS STORAGE HANDLING

INSTALLATION OF CABLES (UNDER GROUND, IN DUCT/CONDUIT, IN CABLE LADDER)

5 5 5 5 6 6 6 7 7 8 8 9 10 10

7.

PRECAUTIONS

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8.

ATTACHMENTS

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1. PURPOSE The purpose of this Method Statement is to ensure that all the works related to the installation of CABLES are carried out safely and in accordance with project specification. This Quality Control Procedure describes the activities and the inspections are performed for installation of Low Voltage /High Voltage cables so as to ensure the work is in conformance with the project/ contract requirements.

2. SCOPE This Method Statement covers the details of following activities:  HSE Requirements  Procedure  Inspection  Tools/Equipment

3. REFERENCE The following documents are considered as reference documents:   

Project specifications Project (Latest) approved drawings (and approved Procedures for all site works) Inspection and Test Plan (ITP)

4. DIFINITION /ABBREVIATION

The following abbreviations shall be relevant to this document;CLIENT

ENI

CONTRACTOR

Weatherford Oil Tools Middle East

SUB-CONTRACTOR

Calethon Group

ITP

Inspection & Test Plans

QCP

Quality Control Procedure

MS

Method Statement

ITR

Inspection / Test Request

MAR

Material Approval Request

NCR

Non-conformity Report

LV

Low Voltage

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HV

High Voltage

TRA

Task Risk Assessment

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RESPONSIBILITIES 5.1

PROEJCT MANGER

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Overall responsible for the implementation of this method statement.

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Ensure that all required submittal are made in timely manner

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Responsible for ensuring that the work is performed in accordance with the specification and within the time and cost constraints.

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Coordination with the CONTRACTOR, COMPANY, Other Subcontractors and Civil Personnel for the safety and quality during the execution of the project.

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Co-ordinate with the CONTRACTOR’S Coordinator for obtaining the necessary resources for the project and deployment as required.

5.2

PROJECT ENGINEER

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Ensure that the activities are carried out according to the Specifications, drawing and approved Method statement.

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Ensure that all required submittal are made in a timely manner.

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Arrange all materials and tools required for installation as per agreed project schedule.

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Provide all necessary information and distribute the responsibilities to his unit installation team.

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Monitoring that all in process test are carried out and obtained approval from Company’s Representative.

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Monitoring and ensuring that the work is performed in accordance within the time and cost constraints.

5.3 

5.4

ELECTRICAL SITE ENGINEER Electrical Site Engineer shall be responsible (along with the Site Supervisor locate the exact Drum, with a rope physically measure the run length and compare it to the length of cable in the cable schedule. Ensure that the approved cable cutting procedure is followed to cut the cables) for checking the cable drum length schedule before installation and testing of the cables before and after installation. ELECTRICAL SITE SUPERVISOR

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Electrical site supervisor shall be responsible for maintenance of all the cable drums and ensure that the individual cable length is taken from the designated drum as per cable schedule in addition to supervision of cable pulling, laying, dressing, glanding and termination.



He shall also be responsible for raising the inspection test request to QC at each stage as per QCP/ITP requirements.

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FOREMAN

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Carrying out the work and the proper distribution of all the available resources in coordination with the Site Engineer on a daily basis

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Continuous coordination and following Site Engineer/Supervisor’s instructions to meet quality requirement during the job execution

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Incorporate all the QC and Safety requirements as requested by the Company’s representative.

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Report to Site Engineer the accomplishments and problem encountered on daily basis.

5.6

QAQC ENGINEER

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Implement the QA/QC management system at site and coordinate with the customers representative on all quality matter.

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Distribute relevant QA/QC documentation to site personnel/subcontractors.

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Verify that the quality related site activities are in accordance with the applicable codes and standards.

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Participate in the site internal and external site audits and coordinate all the quality site inspections through the site QC inspectors.

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Control all nonconformance reports and provide remedial action and carry out site quality control instructions and action remedial responses.

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Review the customers specification and undertake relevant training to the site QC inspector.

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Monitor the implementation of the approved site QC Plan.

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Complete and coordinate the approval of the sites QC technical submittals to the Contractor.

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Coordinate with the Project manager on all quality issues Coordinate and chair the QA/QC site weekly meetings with the project team.

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Ensure the safety is adhered to at site and Assure all technical documents relative to site quality control are current status.

5.7

SAFETY OFFICER

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Ensure that the Provisions of the Project HSE Plan are applied on the project by regular monitoring and reporting.

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Monitoring and observing the permit to work

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Assist with the implementation of Job Safety Analysis and inspect job site activities during particularly difficult or hazardous work situations.

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Assist in developing and implementing field location emergency response procedures and evacuation plans

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Supervise on-site doctors and medical emergency response preparation and

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6. PROCEEDURE 6.1

HSE REQUIREMENTS

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All personnel shall have attended HSE induction / awareness training programs conducted inhouse.

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Work permits shall be obtained from the concerned authorities including revalidation at predetermined intervals. The personnel shall also be in possession of oil field pass / security pass suitable to the work locations. All permits and passes shall be issued before start of any related work.

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Necessary safety precautions shall be implemented for all activities associated with electrical and instrumentation such as excavation for cable trench, termination of cable and commissioning of electrical/instrument system.

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Equipment and instruments shall be complied with safety standards. (Provide Calibration and test reports for equipment as necessary)

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The entire tool must be insulated. They should comply with project risk assessment. Client site management system shall be implemented.

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All personnel involved shall use necessary PPE.

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Personal protection wears shall be used safety helmet, safety goggles, safety shoes, hand gloves, and gas mask.

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All equipment will be inspected by HSE prior to use. (The equipment approved and appropriately tagged by HSE for use on site.)

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Access and good housekeeping will be maintained.

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Tool Box Talk shall be carried out as per execution plan.

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All activities at heights will be provided with suitable working platform.

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Barrication, safety signs and site information banner shall be used.

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When working at height proper fall protection measures shall be taken.

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All access ladders and scaffolding shall be secured and safety tagged before use.

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Waste management should be strictly followed to keep the job site neat and clean.

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All scaffolding shall be used per safety “Tag” System.

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Scrap/garbage shall be removed on a daily basis from the working locations.

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Correct type and size of tool shall be used for each job.

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Fire extinguishers/fire blankets shall be provided at the places of hot work to comply with PTW system.

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First Aid kit shall be available at site and Escape plan in case of emergency alarm at the plant should be available at the work location, indicating the escape route, emergency assembly point, emergency call out numbers etc.

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The supervisor shall deliver toolbox talk daily to the workers.

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Ensure proper housekeeping at all times of the activities and avoid any tripping hazards.

6.2

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TOOLS & EQUIPMENT

The following are the equipment / instrument identified for execution of cable pulling activities:                                  6.3

Lifting equipment (Crain, Boom truck, fork lift, Man lift/Cherry Picker. Complying with load requirement) Hand Drill Machine Cable Jacks & shaft, Cable Drum Stands (Hydraulic up to 10 tons; see largest Drums being used) Cable Drum Spindle Cable Pulling Socks / Ropes Rollers Megger & Tester (Earth Tester) Multi meter Safety Harness Safety Goggles Crimping Tool, Hydraulic Crimping Tool(upto 1000mm2 cables) and ‘Knock out’ Punch, Winch Machine Shilling Rope and Lift belts Cable Cutter (Hydraulic, Manual) Grinder Combination Plier Nose Plier Side Cutter Screw Driver Set Flat File Spanner Set Hack Saw Hammer Hole Saw Set Wire Stripper Measuring Tape Cable Knife Insulation Tape, Masking Tape, Scotch Tape Other accessories (cable ties, clamps, lubricants) Belt Wrench, Hi- Pot Tester, Heat Gun, Vacuum Cleaner, Air Blower,

GENERAL REQUIREMENTS

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The material received at site shall be inspected upon receipt and approved by Company.

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Approved procedures for material issuance process, cable pulling and cutting methods to be followed.

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The company shall approve the test / inspection procedure for the cables before and after installation.

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The test equipment shall be calibrated and the records shall be maintained.

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The Electrical Supervisor shall conduct all the tests and the test shall be witnessed by Electrical QC.

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Where required as per the ITP the tests shall also be witnessed by company.

6.4

STORAGE

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Cable received at site should be inspected and stored according to manufacturer recommendations.

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The cable drums shall be stored on a well-drained, hard surface, so that the drums do not sink in the ground causing rot and damage to the cable drums.

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The drums shall always be stored on their flanges, and not on their flat sides.

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Both ends of the cables should be properly sealed to prevent ingress/ absorption of moisture by the insulation during storage

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The location must be accessible to forklifts and trucks, if available space prohibits separation, suitable barriers should be erected to prevent damage from moving equipment.

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Material must be stored in an area where they cannot be damaged by falling objects, chemical spills including oil and grease, open flames or welding operations, and excessive heat.

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Ensure that the Cable and its accessories are properly packed to permit the ease of handling.

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Verify the Cable and its accessories are according to the latest approved technical documents and specification.

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Ensure that there is no damage during off-loading.

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The storage area shall be clean and free from foreign materials to protect the equipment against damage.

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The Cable and accessories should be stored in the warehouse in a separate allocated section location.

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After verification of the availability of the needed materials, a material request form should be submitted to the contractor 24 hours prior to materials dispatched to the installation zone.

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After material delivery to the installation zone, proper steps should be taken to keep the materials away from blocking any roads or walk ways, for the sake of both materials and workers safety.

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If a portion of the cable is used, the open end of the cable remaining on the reel should immediately be re-sealed in a manner equivalent to the factory seal to prevent the entrance of moisture.

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HANDLING

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When the cable drums have to be moved over short distances, they should be rolled in the direction of the arrow marked on the drum.

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For manual transportation over long distances, the drum should be mounted on cable drum wheels, strong enough to carry the weight of the drum and pulled by means of ropes. Alternatively, they may be mounted on a trailer or on a suitable mechanical transport.

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For loading into and unloading from vehicles, a crane or a suitable. The lifting equipment, lifting belts, lifting chains shall be provided with third party certificates that shall be inspected. Each lifting item shall be coded with color as per safety color matrix.

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Small sized cable drums can also be rolled down carefully on a suitable ramp or rails, for unloading, provided no damage is likely to be caused to the cable or to the drum.

6.6

INSTALLATION OF CABLES (UNDER GROUND, IN DUCT/CONDUIT, IN CABLE LADDER) PREPARING OF LAYING (UNDER GROUND, IN DUCT/CONDUIT, IN CABLE LADDER)



The cable laying Site Supervisor has to check thoroughly cable laying schedule, sectional drawings and cut length schedule for the designated route where the work is to be started.

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Cable rollers both straight and V-rollers are to be used for pulling cables in trenches to reduce friction and prevent damage to the cable sheath.

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Cable rollers shall be inspected prior to commencement of work ensuring they are free running and have no damage to the roller, which could affect the cable sheath.

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Cable drums to be shifted to site and jacked up for laying out. The drum jacking arrangement is to be suitable for the size and weight of the drum. Unrolling of the cable is as per direction shown on drum.

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The cable-laying Supervisor shall obtain data sheets for any cable being pulled prior to proceeding and check the manufacturer’s recommendation for maximum cable tension when using a tugger (winch) and cable pulling winch shall be inspected.

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Sufficient No. of skilled & unskilled workers are to be employed to lay the cable by taking care that cable does not touch or scratch against any object damaging it in any way.

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Hydraulic cable cutter for large size cables and manual cable cutter for small size will be used.

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The temporary cable tag numbers is to be marked by using masking tape, scotch tape or metal markers. ROUTE INSPECTION (UNDER GROUND, IN DUCT/CONDUIT, IN CABLE LADDER)

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Trench shall be prepared for all underground cables in accordance with the respective cable route diagrams. All installations shall be carried out as per “specification for power cable installation”.

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It will be ensured that there are no stones or sharp objects or material inside the trench prior to commencement of the cable laying.

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Site supervisor has to check the routing i.e. cable trench width, depth, sand bed and curves as per drawings and specification, cable tray bends, risers, vertical & horizontal drops and also sharp edges to avoid any kind of damage.

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The cable ducts should be clear and clean while handing over for cable pulling activity.

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It will be confirmed that there are no stones or sharp objects or material inside the duct/pipe prior to commencement of the cable laying

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Any loose item at cable ladder shall be removed to avoid any damaging.

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The cable ladder should be clear and clean while handing over for cable pulling activity.

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It will be ensured there is no any sharp edge, welding spot or any metallic strip in the cable ladder route. CABLE PULLING IN TRENCH (DIRECT BURRIED)

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The cable drum will be placed in a position so as the drum wing indication for the cable pulling is towards the pulling direction.

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The packing of cable drums would be removed and stored so as to avoid any contact of nails etc to the cable.

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Maximum allowable pulling tension and bending radii of cables shall be as per manufacturer recommendation.

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The cable does not stray away from the route and remains on the rollers.

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The cable does not touch or scratch against any object damaging it in any way.

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The cable is pulled uniformly all along the route and shall be bent as per manufacturer recommendation along curved path.

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Cable shall be completed from start point to end point for complete route first; and then moved to the next complete route.

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Cable shall not be laid for incomplete route.

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When cable pulling is done by mechanical means, A cable pulling winch equipped with pulling tension meter and tripping device will be deployed and set to discontinue pulling if the pulling tension exceeds the maximum value as given by cable manufacturer.

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For large size cables, proper sized cable pulling sock and rope is to be used to hold the cable end to be pulled.

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During pulling, a close watch is to be kept on the cable to protect it from damage by straying away from rollers, rubbing against sharp objects.

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Electronic and signal cables shall be separated from power cables and electrical equipment to minimize interface.

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Where signal cables cross the power cables the conduit of recommended specification shall be used for cable installation.

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After completion of pulling at designated route, cable dressing and tagging will be started as per drawing and specification.

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Adequate bed of sands shall be provided to avoid unnecessary slack and damage.

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The cables after installation shall be continuity tested using a digital multimeter to ensure its continuity followed by insulation testing using megger to ensure the integrity of its insulation.

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After completing the cable lying and inspection procedure, the trench shall be backfilled as per approved specifications by civil contractor.

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CABLE PULLING IN TRENCH (IN DUCT/CONDUIT) 

The cable drum will be placed in a position so as the drum wing indication for the cable pulling is towards the pulling direction.

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The packing of cable drums would be removed and stored so as to avoid any contact of nails etc to the cable.

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Maximum allowable pulling tension and bending radii of cables shall be as per manufacturer recommendation.

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Approved cable pulling lubricants shall be used .Lubricants data sheets shall be provided to safety for approval.

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During pulling, a close watch is to be kept on the cable to protect it from damage by straying away from rollers, rubbing against sharp objects. CABLE PULLING (IN CABLE LADDER)

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The cable drum intended for cable pulling shall be identified as per that indicated in the drum schedule.

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Depending on the weight and size of the drum, suitable size of the cable rolling shaft (Spindle) shall be placed inside the central axis of the drum.

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Suitable jacks shall be placed firm ground and jacked-up to allow clearance from the ground depending on the size of the cable drum.

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The drum shall be lifted by required equipment and placed on the jacks.

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The cable drum will be placed in a position so as the drum wing indication for the cable pulling is towards the pulling direction and cable drums shall be unpacked.

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The packing of cable drums would be removed and stored so as to avoid any contact of nails etc to the cable.

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Cable winch shall be positioned in proper place for cable pulling and required number of persons will be posted at the winch and near the drum.

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The cable shall be fixed the winch by means of a cable sock or gripper.

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The cable pulling is to be started from source end to destination end or from sending end to receiving end.

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Maximum allowable pulling tension and bending radii of cables shall be as per manufacturer recommendation.

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The cable does not touch or scratch against any object damaging it in any way. It shall not touch exiting pulled cables.

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The cable is pulled uniformly all along the route and shall be bent as per manufacturer recommendation along curved path.

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The cable advancement in cable ladder shall be critically monitored to avoid any insulation damaging.

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Cable crossing shall be avoided during cable pulling to ensure proper cable dressing.

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After reaching the other end’ the length of the cable required for reaching the specified location, cable will be measured and cut as per cable schedule.

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In case of cable length exceeding a single drum length the cable pulling start from the source and destinations ends and followed by cable pulling from the joints location.

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Before cutting the cable, both ends must be inspected to ensure sufficient length is for proper dressing and end termination.

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The open ends will be sealed till termination.

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Soon after completion of every cable the cables will be tested as per approved procedure.

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The cables after installation shall be continuity tested using a digital multimeter to ensure its continuity followed by insulation testing using megger to ensure the integrity of its insulation.

7. PRECAUTIONS 

Suitable fire extinguishers shall be provided in electrical/instrument panel rooms preferably CO2.



The electrical supply to powered hand tools must be protected by ELCBs (Earth leak circuit breakers) at sending source side.

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Electrical lighting for use in confined spaces shall not exceed 24 volts. Powered hand tools used in confined spaces shall, be air operated. Where this is not possible, all such tools shall be equipped with a dead man’s switch.

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The temporary electrical network installed for job would be protected by ELCBs (Earth leak circuit breakers) to avoid any accidental contact.

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Scaffolding shall be used where appropriate using Safety “Tag” system

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Cable cutting/scrap shall be removed from work front on a daily basis

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Only persons under full time supervision by a competent qualified electrician/fitter shall be permitted inside permitted area.

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Entry to and work in existing areas will only be permitted under P.T.W system and full cooperation with the Contractor operations

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A competent qualified fitter only shall carry out installation, modification or work in the immediate vicinity of any electrical equipment under full time supervision



Where it would be required to work in the vicinity of electrical equipment all necessary precautions will be taken to avoid accidental contact with live conductors



No one shall be allowed to work in the immediate vicinity of any existing electrical installations or equipment without a valid permit to work. This applies to both temporary and permanent electrical installations and equipment.

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8. ATTACHMENTS

.  

Cable Route Cable Schedule

 

Inspection Report Approved material request form

 

Lubricants data sheets Task Risk assessment

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