This Procedure is applicable to all electrical item installation activities at site, which are to be installed on the [PROJECT TITLE & LOCATION].To ensure that all electrical installation is carried out safely, and in accordance with good working practice, as per [PROJECT TITLE & LOCATION], job specifications. This procedure is intended to provide general application guidance and establish controls during preparation and installation.
Cable Pulling, Splicing, Termination, and Testing
Cable Pulling
1. Confirm cable size, type, and quantities are available and meet the required specification and capacity.
2. Verify / identify actual pulling points which to be accessed by lifting equipments, i.e. 40 -Tonner Crane, Bed Trailer, Forklift… against IFC drawings and cable schedules.
3. Clear the area of which the cable is to be unloaded. If it is required, a polyethylene sheet should be provided and utilized to protect the cables from dirt and sharp objects prior to unloading. Cable should then be placed and guided by cable rollers for an easy pulling.
4. Raise RFI for cable continuity and meggering prior to cable pulling. Review the cable routing, cable cutting schedule and counter check the cable length.
5. Cable reel stand should also be provided to support cable drums during unrolling of cables. Forklift or a 40 -Tonner Crane should be used to lift a cable drums to cable reel stand depending on the availability of this two lifting equipment. Cable reel should be positioned in a flat and firm location.
6. Cable pulling should be done manually. Worker should be posted at the curve location and assisted the cable not to be damaged during pulling. Also at cable drum location, someone should have to assist by turning the drum while pulling was still on progress. A recommended pulling tension should be exerted.
7. Minimum bending radius of 12 times the outside diameter of pulled cables should always be observed (SES E22 – C01).
8. After cables are pulled and routed up to the intended equipment and sufficient length was provided including ample allowance, it should be cut at its adjacent end and arranged as per shown in IFC drawing and fix with an approved tie wraps. The cutted ends should be taped first by a rubber tape then followed by plastic tape to prevent in-coming of moisture and dirt.
9. Cables should then be tagged by an approved taggings.
1. Confirm cable size, type, and quantities are available and meet the required specification and capacity.
2. Verify / identify actual pulling points which to be accessed by lifting equipments, i.e. 40 -Tonner Crane, Bed Trailer, Forklift… against IFC drawings and cable schedules.
3. Clear the area of which the cable is to be unloaded. If it is required, a polyethylene sheet should be provided and utilized to protect the cables from dirt and sharp objects prior to unloading. Cable should then be placed and guided by cable rollers for an easy pulling.
4. Raise RFI for cable continuity and meggering prior to cable pulling. Review the cable routing, cable cutting schedule and counter check the cable length.
5. Cable reel stand should also be provided to support cable drums during unrolling of cables. Forklift or a 40 -Tonner Crane should be used to lift a cable drums to cable reel stand depending on the availability of this two lifting equipment. Cable reel should be positioned in a flat and firm location.
6. Cable pulling should be done manually. Worker should be posted at the curve location and assisted the cable not to be damaged during pulling. Also at cable drum location, someone should have to assist by turning the drum while pulling was still on progress. A recommended pulling tension should be exerted.
7. Minimum bending radius of 12 times the outside diameter of pulled cables should always be observed (SES E22 – C01).
8. After cables are pulled and routed up to the intended equipment and sufficient length was provided including ample allowance, it should be cut at its adjacent end and arranged as per shown in IFC drawing and fix with an approved tie wraps. The cutted ends should be taped first by a rubber tape then followed by plastic tape to prevent in-coming of moisture and dirt.
9. Cables should then be tagged by an approved taggings.
Splicing and Termination
600 volts and below
10. All conductor and cable termination kits, splicing kits, and other associated hardware should be approved by OWNER, for the cable construction and conductor material (copper) on which they are installed. Secure an approved termination drawings and visually checked the termination point of equipments.
11. Conductor should be spliced or joined with splicing devices suitable for the use or by brazing, welding, or soldering. Soldering splices should be first to spliced or joined as to be mechanically and electrically secured.
12. All splices and joined and the free ends of the conductors should be covered with an insulator, and if possible, an insulation equivalent to that of the conductors or with an insulating device certified by OWNER for the purpose (NEC Article 10).
13. Wire marker should be marked first prior to installing terminal lugs and crimping.
14. Connect conductors to terminal parts by means of pressure connectors, that is crimp or compression type (including set screw type), welded lugs, or splices to flexible leads. Care should be taken for ensuring not to damage the terminated conductors.
Above 600 volts
15. All workmen who install terminations or splices greater than 600 volts should be certified by the contractor (or OWNER). This certification should be current and approved by OWNER or by their appointed representative.
600 volts and below
10. All conductor and cable termination kits, splicing kits, and other associated hardware should be approved by OWNER, for the cable construction and conductor material (copper) on which they are installed. Secure an approved termination drawings and visually checked the termination point of equipments.
11. Conductor should be spliced or joined with splicing devices suitable for the use or by brazing, welding, or soldering. Soldering splices should be first to spliced or joined as to be mechanically and electrically secured.
12. All splices and joined and the free ends of the conductors should be covered with an insulator, and if possible, an insulation equivalent to that of the conductors or with an insulating device certified by OWNER for the purpose (NEC Article 10).
13. Wire marker should be marked first prior to installing terminal lugs and crimping.
14. Connect conductors to terminal parts by means of pressure connectors, that is crimp or compression type (including set screw type), welded lugs, or splices to flexible leads. Care should be taken for ensuring not to damage the terminated conductors.
Above 600 volts
15. All workmen who install terminations or splices greater than 600 volts should be certified by the contractor (or OWNER). This certification should be current and approved by OWNER or by their appointed representative.
Cable Testing
16. Cable should be laid or installed in final position with all splices completed.
17. Terminations to motors, switchgears, and transformers should be lefted unfinished, otherwise isolate both ends of cable prior to megger and hi-pot test. Cable cores should be insulated from the ground for insulation resistance of the cables.
18. Use the calibrated Milti-Tester, 5kV Insulation Resistance Tester, and DC Hi-Pot Machine for medium voltage cable for testing power cables, control, and instrument cables.
19. Using the calibrated 5kV megger tester, test line to line for all 3 cores and line to ground for all 3 cores for power cable, and all cores for instrument cables. Record the results. This should be conducted prior to Hi- Pot testing to determine insulation resistance of cables.
19.1 Test voltage should be as follows or specifically in accordance with the project specification.
- 600 V cables : 1.0 kV
- 2300 V cables : 2.5 kV
- 5000 V cables and above : 5.0 kV
19.2 Minimum acceptance value of cable insulation resistance should be 100 mega ohms or as stated in project specification.
19.3 Any cable failed to meet the required value, submit the report to OWNER for final disposition.
20 After megger test and in the same conditions, apply DC Hi-Voltage Test to each phase while the two remaining phases are grounded.
20.1 DC test voltage (KV) -1.6 x (2x rated voltage of cable) +1 kV or in accordance with OWNER recommendations.
20.2 The DC high voltage should be applied in a minimum of four steps (each in an order for the rated voltage of cable) of one (1) minute duration except for the minimum allowable test level which should be maintained for a minimum of 15 minutes for shielded cables and 5 minutes for non-shielded cables.
20.3 The leakage current as recorded versus the duration of time should be steady or sloping downward when plotted (see figure 1, 2, & 3) for the cable insulation to be acceptable.
20.4 Upon test completion, cables should be lefted with all cores and screens grounded for about an hour to allow residual charge to dissipate.
Would you like to have a full copy of the native file of the Construction Procedure for All Electrical Works Installations such as;
1. General Requirements
7. Cable Pulling, Splicing & Termination, and Testing {this article}
8. Electrical Lighting Fixture Installation
9. Aircraft Warning Light Installation
10. Transformer Installation
11. Motor Control Center
12. Switchgear
13. Metal Enclosed Bus Duct
14. Batteries, Battery Chargers, and UPS System
15. Oil Processing and Filing of Power Transformer
9. Aircraft Warning Light Installation
10. Transformer Installation
11. Motor Control Center
12. Switchgear
13. Metal Enclosed Bus Duct
14. Batteries, Battery Chargers, and UPS System
15. Oil Processing and Filing of Power Transformer
Also includes: Applicable Codes & Standards, Responsibilities, Quality Control and Assurance, and Safety & Precautions.
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