18002I-EA-ECD-002-02-132kV HT Cable Laying Methodology PDF

DOCUMENT TITLE:
132 KV HV Cable laying methodology

No of Pages: Page 1 of 1
PROJECT: Sakaka 405 MWp dc PV
132 KV HV Cable Laying Methodology
Document No.
18002I-EA-ECD-002-02
2 For Approval 02.04.2019 SM SM SG
Rev Purpose of issue Date Prepared by Checked by Approved by

GH-QAQC-CMS-P-0025
Issued by QUALITY DEPARTMENT
METHOD STATEMENT – Installation of MV &HV Power Cables
Date APRIL 1, 2019 Revision Version 03
Revised
CONSTRUCTION METHOD STATEMENT
FOR INSTALLATION &TESTING

OF
MV & HV POWER CABLES
Date Rev Prepared By Reviewed & Checked By Concurred By
Engr.Hussain
Engr Shankar Menon Engr Fouad.AL-Zahrani
Motabagani
1/4/2019 03 Issued for Approval
QC ELECTRICAL CORPORATE QUALITY
QA Manager
TEAM MANAGER
Signatures
Approved Issue Date Revision # Section/page Description of revision Reviewed by

date revised
1/04/2019 03 All Issue for approval HMM
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TABLE OF CONTENTS
TABLE OF CONTENT PAGE NO

1) Scope And Purpose 2
2) References 2
3) Responsibilities 3
4) Work Procedure and Sequence 5
5) Bonding cable and earthing 23
6) Cable jointing and termination 24
7) Testing and Commissioning 26
8) Risk Assessment 27
9) Tools And Equipment 28
10) Site Health and Safety 29
11) Material Storage and Handling 30
1.0 SCOPE AND PURPOSE

This Method Statement describes the method and scope of Installation of Power cable (HV&MV) at the
substation
2.0 REFERENCES
IEC STANDARD
IEC 60502-2 LV and Power cable with extruded insulation and their
accessories 1 Kv to 30Kv Um = 36kv
IEC 60228 Conductor insulator cables
QCEA P45 482 Short circuit performance of metallic shield and sheath of
insulated cables
AEIC CS8 Specification for extruded dielectric shield power cables 1Kv
46Kv
IEC 60502-2 All test report is meeting the client requirements.
IEC 61442 All test report is meeting the client requirements.
IEC-60060-1&2 High voltage test techniques
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IEC 60230 Impulse test on cable and their accessories
IEC-60466 AC Insulation –enclosed switchgear and control gear for rated

voltage above 1Kv and up to and including 38Kv.
IEC-60502-1,2&4 Power cables with extruded insulation and control gear for rated
voltage from 1Kv (Um=1.2Kv) up to 30Kv (Um =36Kv)
ASTM –E28 Standard Test Method for softening Point of Resin Derived from
Naval Stores by Ring and Ball Apparatus.
ENA TS09-13 Mechanical and Physical testing for splices and terminations MV.
IEC 60287 Electrical cable calculation of the current rating.
IEC 61236 EMC requirements for Electrical requirements
IEC 61000 Electromagnetic capabilities
IEC 60068 Environmental testing
IEC 61508 Functional safety of electromechanical

ASTM B-3 Annelid copper wire
ASTM B-8 Concentric lay standard copper conductors
ASTM B 33 Tinned soft annelids copper wire for electrical proposal
ANSI /NFPA 70 National electrical code
IEEE C37.122 Guide line for Gas insulated substation
IEC60287-1-1 Current rating equation and calculation of loses-General
3.0 RESPONSIBILITES
3.1 PROJECT MANAGER: The Project Manager shall have overall responsibility to ensure
implementation and adherence to the Method Statement.
3.2 SITE MANAGER:

• Planning and acquisition of resources.
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• Ensuring the smooth and on-time execution of the works, according to the schedule.
• Liaising with the company Representative regarding the progress of the worked.
• Construction manager is also responsible for HSE Compliance
3.3 SITE ELECTRICAL ENGINEER:

• Shall report to Site manager and responsible for supervision of the job at site.
• Electrical Engineer shall be responsible to ensure the proper installation of the Power
cables in accordance with the project specification, hazardous area classification
requirements, standard practices at site including permits and safety procedures.
• Shall be responsible for co-ordination with Company regarding activities at site.
• Shall have overall responsibility to ensure safety at site for working group as well as the
public and environment.
• Shall provide and monitor the schedule target to be achieved for Daily, Weekly, Monthly
basis.
3.4 ELECTRICAL FOREMAN:

• Shall report to Site Electrical Engineer and responsible for supervision at job site.
• Shall be responsible for Installation works and lead the construction team for safe work
execution at site meeting the production target.
• Shall be responsible to report Site Electrical Engineer in case of any shortage or damages.
3.5 QA/QC Engineer/Inspector:
• Shall be responsible to ensure works are carried out as per all project requirements and
ensure all steps on the ITP are duly followed in the sequence described and all quality
related reports are generated and completed accordingly.
• Shall verify all material conforming to the Drawings / standards drawings, tag number and
material traceability record.
• In process inspection, monitoring & testing of all electrical activities in the field.
3.6 STORE KEEPER:

• Storekeeper shall ensure that requested material/equipment is already accepted at
receiving stage and copy of receiving inspection report and manufacture document are
available with store.
• Preparing all necessary equipment and tools required for the job.
• Shall deliver all electrical installation material to site upon request of electrical engineer.
• Receiving, handling and preservation of all items use for construction.
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3.7 Materials Storage and handling.

• ON recipient of the LV and MV.HV power cable materials at site necessaries precaution
shall be taken for unloading and shifting and storage as follows.
• The materials shall be stored in a covered dry space at the all-time to avoid being
damaged.
• All the material received at the site shall be inspected and ensured that the materials are
as per the approved material submittals.
• Any Discrepancies damages etc. found will be notified and reported for further action.
• Material found not suitable for site use will removed from site immediately,
• Check and ensure the LV.MV, HV, power technical Data should be verified as per
manufacturer recommendation.
• To avoid the dust if covered in a proper materials.
• To lift Cable drums as suitable cranes and skating equipment’s and store proper place.
3.8 SAFETY OFFICER/ENGINEER:

Ensure safety requirements are implemented and adequate safety measures are undertaken
to prevent any damage to the work group, public, environment as well as properties.
3.9 ELECTRICIAN:
• Shall carry out electrical activities as per the supervisor’s instruction and approved method
statement.
• All then Electrical actives supervised by the concern supervisors and concern site manager.
4.0 WORK PROCEDURE AND SEQUENCE
4.1 Preparation before Installation of MV HV power cable at the substation switch yard.
The following point are cross verifiey at the power cables
• Check and Ensure the Manufacturer have been approved from client.
• Ensure the cable are shielded armored cables ensure the dielectric strength
• Conformity of the main international standards...
• Verify the insulation levels of each number of the stand HV, MV LV cables.
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• Verify the insulation oil level and leakage outside the sheath…
• Ensure the constant accuracy in all service condition while heavy load current condition.
• Ensure the Maintenance free for all particles from the electrical stand.
• Ensure and confirm Heat resistance level of the each cable stands
• Verify the no partial discharge test on the cables.
• Ensure the easy installation and commissioning has to be maintained on the equipment’s.
• Ensure the cable line length and test the equipment’s.
• Ensure the cable drum is stand at proper located place as manufacturer recommendation
and given to proper located place without affecting environmentalist.
• Ensure the proper Cable drums are kept at rotating stand and ensured the stand balance
load.
4.2 Special optional are request to supplier.
• Cable has to be store under the shed to avoid the exposed sun.
• Ensure the cable life is more than two years refer the date of the manufacturer
confirmation and check this
• Cable lifted stand are associate with the entire project.
• Check and ensure the testing of the cable is requested by the client requirements.
• Ensure the voltage with stand able test is indicated sheath voltage limits.
• Conductor cable shall be Aluminum or copper conductors to verify.
• Check and ensure the functional of the cable is ensure the voltage ratings or operating the
cables as client requirements.
• Test reports are meet the client requirements.
4.3 Installation Procedure-

• Ensure the cable testing is meeting the client requirements as following criteria.
A) Ensure the cable are designed by the international standards
B) Ensure the client standards specification and construction standards specification is
meeting at the cable.
C) Cable pending radios is not more the 20 MM and cracking effort are more the 20mm.
D) Ensure the insulation resistance valve as mentioned on the technical data sheets.
E) Endure the bending radius are meet the specific all requirements.
• All the materials and documentation relevant to the particular section of the work will be
checked by the construction departments prior to commence of work ensuring that these
are of the type as reviewed by the clients.
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• Prior to the commencement of any construction activity area access will be inspect
confirm of work ensuring that they are in suitable condition for construction work to
commence.
• Compare the cable drum name plate data with drawing with spectacular specification.
• Inspect the physical and mechanical condition.
• Verify the correct connection of the direction with specific systems.
• Ensure the specific connection points and termination link of the connection for the final
termination.
• Verify the unit of cable surface are cleaned while installation at the site.
• Verify the adequate clearance exist between primary and secondary cables ,
• Inspect the bolt electrical connection of high voltage cable joints are highly tightly on the
chambers.
• HVC are placed in to the chambers or trench are cleanly maintained while installation at
the time.
4.4 Equipment of the installation :-

• Some of the equipment and arrangements used to install cable are illustrated in the
• Following figures:
a) At the feed-in, the curvature of the cable feed is in the same continuous arc with no
Reverse bends. At the pull-out, the pulling rope exits the duct directly to a pulling sheave.
• Some of the equipment and arrangements used to install cable are illustrated in the
• IEEE 532-1993 “Guide for Selecting and Testing Jackets for Underground Cables.”
b) The cable is fed from the cable reel directly into the conduit at floor level. The cable is
fed from the bottom of the reel so that its curvature is continuous with no reversed bends.
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c) From cable reel to cable tray, the cable is fed from the top of the reel to maintain
Require curvature and Sheaves or a shoe, may be used to guide the cable into the tray.
d) Cable sheaves or a shoe may be used to guide cable into the desired direction,
Maintain minimum bend radius, and reduce friction. Examples of proper and improper
sheave arrangements are illustrated in the following figures.
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• The training radius is the final positioning of cable ends after the cable has been
Place in the raceway. These limits should not be used for cables subjected to pulling
Tension during of installation. Larger bend radii shall be considered for conduit bends,
sheaves, or other curved surfaces around which the cable may be pulled under tension
while being installed, due to sidewall bearing pressure limits of the cable.
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Refer the cable table:-
• A non-shielded cable can tolerate a sharper bend than a shielded cable. When bent too
Sharply, helical metal tapes can separate, buckle, and cut into the insulation. This problem
Is compounded by jackets and concealing such damage, Corona problems related to
Metal shield damage may be initially masked by the semi conductive shielding bedding
Tapes or extruded of the polymers.
4.5 Safety in Pits and Trenches
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• All pits and trench work shall comply with Work Safe requirements, in particular the
Work Safe Code of Practice: Excavation. They may include but is not limited to:
i) When a pit is to be left open overnight, proper barrier mesh and flashing lights, etc
as required or the pit must be covered.
ii) Soil must be piled safely back from the edge of the pit.
iii) Pits or trenches deeper than 1500mm in normal soil may require a ladder for access
and require shoring, benching or sloping of the sides of them.
iv) Pits or trenches may require shoring if less than 1500mm deep and the soil is
unstable.
v) Undermining walls, foundations, streets or pavements are to be avoided otherwise
appropriate shoring is required.
vi) All shoring, benching and sloping must be installed.
vii) Barriers shall be erected to vehicles inadvertently falling into the excavation. Local
councils may have more onerous conditions that need to be met.
viii) Collapse or flooding of trenches.
ix) Lack of ventilation or suitable lighting.
x) Dangerous gases.
xi) Confined working space.
xii) High temperatures.
xiii) Traffic hazards.
4.6 Under ground Trench or pipes
• Whenever a crossing is made of an existing pipe or cable, such pipe or cable shall be
securely supported during the progress of the work.
• The minimum spaces required between services are contained in the Utility providers Code
of Practice, summarized as follows:
• Electricity is to pass under gas and water at reticulation crossings.
• Cover bedding and backfill requirements for water reticulation shall be in accordance with
Water Corporation requirements.
• All reticulation shall be laid within plus or minus 100mm of the indicated center line and
secured against movement with initial backfill.
4.7 Drilled Tunels
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• A maximum of one 1 X 1200 MM^2 HV cable can be installed in a common drill tunnel if
there will be no tee or service joints along the cables.
• Multiple high voltage triplex cables (35mm2, 50mm2, 95mm2, 185mm², 240mm² or
400mm²) shall not be combined into a single drill tunnel.
4.8 Digging Entry and Exit Pits
• An appropriate entry and exit pit are required for directional drilling.
4.9 Protection of Cables in Special Terrain
• Where terrain consists of solid rocks or broken rocks, or was a land-fill site, cables installed
by directional drilling must be protected by suitable poly-pipes.
4.10 Drilling and Pulling

• During construction continuous monitoring and plotting of the pilot drill and back reamer
progress shall be recorded to ensure compliance with the required alignment and depth.
The monitoring may be accomplished either be manual plotting based on the location and
depth readings provided by the tracking system or by computer-generated track logs fed
by this information. The tracking method may be by walkover, wire-line, or wire-line with a
wire surface grid. The tracking system shall provide information on.
• Clock and pitch
• Alignment and depth
• Position XY
• Azimuth where walk over is not possible.
• The bore logs shall show a depth and bore position from a known boundary every 3m
along the bore line. These records shall be made available to Western Power electronically
as a permanent record.
• To prevent collapse of the borehole, drilling mud or similar rather than just water shall be
used for both drilling and back reaming operations.
• The pilot hole shall be reamed to provide free sliding of the cable or conduit inside the
borehole.
• Drilling, back-reaming speeds, and fluid flow shall be set so spoil is removed without
putting unacceptable pressure on the surrounding soil (e.g. surface humping).
• Pull-back tension shall be set so as not to stretch the cable or conduit beyond its design
limit. See Error! Reference source not found. For maximum pulling tension for various
cable sizes. It is not acceptable to use the drill rig to pull back the cable by ‘feel’ or by
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monitoring un-calibrated controls. The pull-back tension must be monitored by one of the
following
• Pulling tension logs of the borer which have appropriate maintenance calibration.
• Load cell
4.11 Capability of Ploughing Equipment
• Ploughing equipment shall have the capability of installing cables in various arrangements:
• Three (3) single core cables (not twisted) in flat or trefoil (triangular) formation, refer to
Figure 1 and Figure 2 below
• Triplex (twisted)
• The three (3) single core cable arrangements allow Western Power to get longer lengths of
cable in this manner, resulting in a longer cable run. Longer cable runs result in fewer joints
to be introduced into the Western Power network resulting in a more cost effective
installation.
• Installation time, cost and logistics will also be a great advantage when opting for three (3)
single core cable installations over the other various arrangements. Installation time will be
minimized with longer cable runs due to less frequent stoppages (less drum changes
required).
4.12 Core Arrangement
• Each core in a three-phase circuit can be placed in two different formations, trefoil
(triangular) and flat formation. The choice between these depends on several parameters
including conductor area, available space and loss factors.
• In most cases, for cable ploughing to be cost effective, the cable shall be installed in the flat
formation with the maximum allowable separation of 30mm between cores. This reduces
the number of joints and allows for longer continuous plough runs.
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• For flat formation, to ensure losses are evenly distributed across all three (3) phases
the cores must be transposed at every cable drum change as show in Figure
3. This
• A position also minimizes any net induction into other services in the vicinity
(e.g. HV cables).
Illustration of a transposed system
4.13 Backfill Requirements
• When cables are ploughed in, the cables must be bedded in clean sand. Backfilling
shall comply with the published “Material selection guidelines for bedding sand,
backfill sand, general backfill around cables” or “Subdivision Design Guideline –
Number 4, Bedding Sand and Backfill Around Cables and General Backfill for Cable
Trenches
• All cables shall be firmly and uniformly bedded in sand free from rocks or other hard
formations. The cable configuration must be surrounded with clean backfill sand all
around and the thickness of sand shall be:
• Bottom: 150mm
• Two sides: 50mm
• Top: 300mm
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Illustration of thickness of backfill

sand around cables (Flat Formation)
Clean back sand Cable Marker
300 MM
• This is consistent with the Underground Distribution Schemes (UDS) manual and
practiced by other utilities.
4.14 GPS Coordinates
• The cable route shall be mapped by onboard GPS technology offered by the cable
ploughings contractors. During the cable run the GPS coordinates shall be monitored
and noted. These GPS coordinates shall then be plotted and supplied with the as-
constructed drawings.
4.15 Cable Pulling Tensions
• The tensions of the pull shall not exceed that specified by the manufacturers for the
particular type and size of cable being pulled and shall be smoothly and continuously
applied.
• When stocking grips are used to install un-armoured cables, the maximum
recommended pulling tensions are shown in Cable Installation Data
• The trench or duct line should be set out so that any necessary deviations from a
straight line occur over the largest possible radius. When pulling cable into duct lines
incorporating bends lower maximum pulling tensions may be necessary to avoid the
wire pulling rope cutting into the side of the duct.
• Any winch used to pull cables shall have either a facility to automatically limit the
pulling tension applied to a cable or a continuous reading dynamometer incorporated
in the pulling arrangement to enable the actual pulling tension to be monitored.
• Cable pulling pits are required at each significant change in cable route direction.
4.16 Pulling Speed
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• To avoid damage due to overruns, the cable should be pulled at a speed to keep the
drum rotating smoothly and be easily controlled by the operator.
• Drums with long lengths of cable, however, should not be rotated rapidly as overrun
can cause cable damage if pulling is slowed or stopped suddenly.
4.17 Bedding and Backfill
• Cable shall be bedded in clean sand, which shall extend 100 mm around the cable.
• Backfilling shall comply with the published material selection guidelines for bedding
sand, backfill sand, general backfill around cables, available on Western Powers
website.
• All cables shall be firmly and uniformly bedded on sand free from rocks or other hard
formations. The cable shall be surrounded with a thickness of sand prior to backfilling,
bottom by 150mm and two sides by 100mm, top by 300mm. The upper 300mm of the
backfill shall also meet the local client requirements.
4.18 Depth of Cover of Cables
• The depth of cover of cables shall not be less than 750mm and to a maximum depth
of 1500mm. The depth of cover of cables shall be increased as required so that
cables joints will have the necessary 750mm depth of cover.
• The requirements below are to be followed with regards to depths and cable markers
•
• Alignment • Description and Depth
Category
• Cable within • Cable to be installed with a
standard 0- minimum cover of 750mm. A
500mm maximum depth of 1500m
alignment shall be applied unless
• Cable within • Cable to be installed at a
2.4-3.0 m minimum cover of 750mm. A
alignment maximum depth of 1500m
shall be applied unless
Cable outside road Cable to be installed at a minimum
reserve cover of 750mm. A maximum depth of
1500m shall be applied unless specified
on a design drawing.
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Cable outside road Cable to be installed at a depth of

reserve (in remote areas 1200mm. A maximum depth of 1500m
where there are no other shall be applied unless specified on a
services or infrastructure design drawing.
in the vicinity)
4.19 Substandard Depth Cables
The installation of a cable at a substandard depth must be a last resort and all other avenues for
installation shall be exhausted. During the design risk mitigation strategies must be developed
and guidance provided to construction for the safest possible installation. The most common
application of a substandard cable depth is where cables are within concrete structures, such as
bridges. An example of risk mitigation is the use of suitably etched brass labels continuously
attached to the concrete surface along the cable route
4.20 Cable Cover and Marker Tape
. Where more than one cable is installed, the PVC maker tape or cable cover must be wide
enough to fully cover the cables, otherwise additional maker tapes and covers shall be installed.
A cable cover shall consist of a mechanical barrier to protect the cable. Western Power typically
uses concrete slabs or corrugated plastic cover for cable covers. If there is a requirement for
Alignment Category Description and Depth
Cable within PVC Marker tape shall be applied. The

standard 0- 1000 exception to the PVC Marker tape is when
mm alignment the cable is directionally drilled and tape
Cable within 2.4-3.0 PVC Marker tape shall be applied. The
m alignment exception to the PVC Marker tape is when
the cable is directionally drilled and tape
Cable outside road Mechanical protection must be applied. If
reserve ducts have been used a PVC Marker tape
shall also be applied. The exception to the
PVC Marker tap are as follows;
when the cable (and in this case duct) is
directionally drilled and tape cannot be
installed or
when a cable cover has been used for
mechanical protection and as a PVC
Marker
t l t
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Cable outside road PVC Marker tape or equivalent corrugated

reserve (in remote plastic covers shall be applied in all cases,
area where there are including ploughing a cable. Directional
no other services or drilling should not be applied in this case.
infrastructure in the Ducts are highly advisable but not
vicinity) necessarily required due to the increased
4.21 Above Ground Cable Markers

Permanent above ground cable markers are installed along a cable route in order to mark the
location of cables. The exact placement of above ground cable markers should follow the basic
guidelines below:
Road crossing
Steel makers are to be placed at both sides of the road.
Boundaries:
Wherever the cable route enters/exits a boundary line (i.e. road reserve, property boundary, etc)
a cable marker should be placed, as close as is practically possible to the cable installation.
Paddocks and Open Spaces:
When markers are used in open areas they should be placed to minimize the possibility of
damage to or from livestock or machinery.
It is preferable to keep the cable installation close to fences and/or boundaries so markers do
not have to be installed in open paddocks.
When a cable has to be run through paddocks or open spaces, markers should be placed on the
fence line or boundary.
Distances between markers:
Any change in direction of the cable route shall be marked, i.e. if the cable deviates from the
straight line route.
From any cable marker, you should be able to see the adjacent markers, both in front and at the
back.
Even where visibility between two cable markers is satisfactory, a maximum distance between
markers shall be 1500m.
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4.22 Cable Sealing
On completion of the pull, any pulling eyes fitted should be removed and the cable resealed
unless terminating that day. Cables shall be sealed by abrading the outer sheath with sand
paper, cleaning and then capping. The sealing and resealing of cables after pulling is required to
maintain cable integrity during construction, ultimately preventing water ingress.
4.23 Exposed Underground Cables
The cable must be blinded with clean backfill sand as soon as practical after installation, to
reduce the chance of damage or theft and then backfilled to full cover as soon as practically
possible. All open cable trenches and joint holes must be inspected daily.
4.24 Terminated Cables
When cables that are terminated to switchgear irrespective of whether this equipment is live
must not, the following must be applied;
be left unattended in excavations without approved barriers and signs;
be accessible to the public and Remain without having been fully backfilled to ground level of the
remaining levels.
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4.25 Live End Seals
Cables for both HV &MV may be extended beyond a subdivision scheme boundary for future
extension into the next stage. In this case a Developer shall ensure these working end cables
are terminated into live end seals as defined in the UDS.
4.26 Conduits
Conduits and ducts complying with IEC Standards as reference and shall be used to protect
cables installed in the following situations:
Cables installed outside the 0-500mm or 2400-3000mm standard alignments.

Cables installed in an easement.
Exit cables of a distribution substation that is set back from road or property boundary.
Cables near to retaining walls.
Cables crossing roads.
Cables crossing water course and drain.
Cables crossing high pressure gas pipelines.
Cables crossing under railway.
Cables within bridge crossings.
4.27 Buried direct

Direct buried cables outside the 0-500mm or 2400-3000mm standard alignments require ducts
or cable covers to be installed as per Section 14.11. .
4.28 Encased ducts

In some locations PVC ducts may be encased in concrete ducts or concrete. Cables shall never
be installed in concrete ducts.
4.29 Sealing
All spare conduits must be sealed against the ingress of water and any foreign material that may
hinder in the pulling of future cables.
Sealing of the conduits must be carried out to prevent blockage, and flooding of cable pits and
basement-type substations and switchroom.
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There have been a significant number of instances where distribution feeder cable entries in
zone and distribution substations buildings were incorrectly sealed and resulted in the
underground basement being flooded. In most cases expanding foam has been used and this
can become dislodged over time.
It is now a requirement to seal conduits into basement substations using wall inserts split press
seals.
4.30 Coupling
PVC cement shall be used to join ducts to prevent entry of water and foreign matter into the
conduit.
4.31 Installation of Ducts
All ducts shall have a minimum cover of 750mm to the top of the duct and no ducts shall be
installed with more than 1500mm to the bottom of the duct, except railway crossing in Section
8.1.1. Where cables in a trench are all installed in ducts, local soil excavated from the trench can
be used for bedding and backfill, provided it is free of organic matter and rocks of 75mm
diameter or larger.
Ducts are to be laid in horizontal formation, up to four in parallel, and thereafter in tier formation.
Road crossing ducts shall be installed in accordance with Section 8and client requirements
standards
All ducts shall be plugged with suitable end caps. Draw wires shall be provided in spare ducts.
When the ducts are installed prior to the main cable trenching, marker tape shall be installed
300mm above the duct, and brought out to ground level at each end with a marker peg at one
end. Marker pegs are not required for Greenfield subdivision developments.
The most economic method shall be used to install conduits across roads. Subject to cost,
boring is preferred for all single or double conduit crossings, where conduits of 100mm size or
larger are to be installed. For locations where more than two ducts are to be installed together,
open excavation methods may be used for crossing roads.
4.31 Pulling through Ducts
Care shall be taken to avoid damaging the outer sheath of the cable where it enters and leaves
the duct. Triplex or three by single core bundled XLPE high voltage cables are particularly
susceptible due to their uneven shape and thin outer sheath. A suitable lubricant should be used
to reduce the friction between the cable and the duct. A tapered or belled entry shall be used at
the entry end of ducts during pulling to prevent damage to cable.
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There are numerous methods by which the cable can be pulled into the final installed position.
Generally, the most economical methods employ power winches. If considering only those
pulling methods using mechanical winches, then there are four distinct methods:
4.32 Armour Pulling

• This system uses the actual armored wires of the cable as the pulling medium. The armor wires, left
extended past the end of the cable, are formed into a pulling eye and the winch rope attached to it.
This method is not applicable to XLPE cables.
4.33 Stocking Pulling

• Cable pulling using a cable stocking is probably the most common form of installation for cable up to
and including 33kV. The cable stocking is slipped on to the end of the cable and the winch rope
attached. On applying tension the stocking shrinks diametrically until a firm grip is obtained. Care
must be taken when using this method to ensure that pulling tension is not excessive, otherwise
sheath stretch may result.
4.34 Nose Pulling
• The strength of the cable sheath limits the length and size of the cable that can be pulled by stocking
pulling. For long and large cross section cables, pulling-eyes can be fixed directly to cable
conductors for pulling the cable.
4.35 Bond Pulling
• When pulling tensions exceed the tension limit of the cable, straight end pulls may have to be
replaced by bond pulls. The cable is lashed to a steel wire rope, which takes all the strain of the
pulling.
4.36 Pillars and Pits
General
• Service pillars must be located within the lot boundaries at the corner as shown in the Utility
Providers Code of Practice. Service pits are an alternative to pillars and should be used as a last
resort. Pillars are Western Power’s standard supply arrangement.
• Service pits which replace pillars shall only be used where it is impractical to install a pillar, such as
in a narrow driveway. Service pits shall only be used in brownfield applications where the final
ground level is clearly defined.
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• Locate the service pit in the preferred location taking into account:
• Available space
• Trafficable areas
• Proximity of other utility pits.
• Determine final ground level.
• Install pit so that top of pit is flush with final ground level.
• Install pit so that top of pit is flush with final ground level
• Install utility service cable conduit
• Leave ground open for installation of customer service/s and street lighting cable conduits
• Partly backfill and compact soil around pit
• Install insulating barrier
• Fit pit lid and keyhole plug.
• When customer service/s and street lighting cable conduits have been installed complete backfilling
and soil compaction around pits.
•
•
• BONDING AND EARTHING
•
• For 110 kV cable circuits, a suitable cross-bonding or combination cross-bonding and
• special bonding system shall be utilized in order to minimize sheath circulating
• currents.
• Where existing circuits are being modified then the existing bonding and earthing
• Arrangements shall be retained as far as possible and any modifications shall be
• Compatible with the existing arrangements and comply with the design criteria.
• All necessary inters heath and sheath to earth bonding conductors shall be of insulated
• Copper either concentric or single core of 500 mm2 cross-sectional are.
• All inter-sheath and sheath-to-earth connections shall be made through links which
• When removed will allow for the voltage testing of the outer anti-corrosion serving to
• prove its integrity at voltage levels and durations specified in the relevant clause of this
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Revised
• Specification.
1. At terminations the sheaths of the cables comprising a circuit shall be solidly
Bonded together and to earth.
2. At the first joint out from each substation the sheaths of the cables comprising a
Circuit shall be bonded together but shall be isolated from earth.
3. Where the circuits are over 5km in length then the sheaths of the cables
Comprising a circuit shall be solidly bonded together and to earth at the
Approximate mid-point of the circuit.
4. Where existing circuits are being modified then the existing bonding and ear thing
Arrangements shall be retained as far as possible and any modifications shall be
Compatible with the existing arrangements and comply with the design criteria.
5. All necessary inter-sheath and sheath-to-earth bonding conductors shall be of insulated
Copper of 300 mm2 cross-sectional area.
6. All inter-sheath and sheath-to-earth connections shall be made through links which
When removed will allow for the voltage testing of the outer anti-corrosion serving to
Prove its integrity at voltage levels and durations specified in the relevant clause of this
Specification.
1. Link Boxes
1. At positions of cross-bonding and bonding and earthing of the cable sheaths, suitable
Link boxes, with associated sheath voltage limiters (SVL‟s), where necessary, shall be
Installed.
2. These shall be installed in precast reinforced concrete link box pits and
Located close to the relevant joint bay.
3. Where earthing of cable sheaths is required
Within the substation the links and SVL‟s shall be installed in a link box mounted on
the support steelwork.
4. Substation over ground pad lockable link boxes with swing doors and schematic
Diagrams will be installed. Provision is to be made for attaching phase and circuit
Identification labels.
Page 24 of 31
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5. METHOD OF STATEMENT FOR CABLE JOINTING AND TERMINATION WORKS:
Before termination of cable, continuity and insulation resistance shall be checked for cable core confirmation
and healthiness.
Qualified and experienced personnel shall only be employed for the cable termination works.
Prior to termination of the cable, confirm that the equipment terminal where the cable is to be terminated is
made dead and no damage, coatings which will act as insulator.
Control cables are terminated with approved termination chart and cable identification provided.
The cable termination shall normally be of the crimped type using compression type cable lugs. Proper dies
and tools shall be used for crimping.
Termination of the HV cables shall be carried out by PDO certified cable jointers using approved / suitable
termination kits.
Ensure that the armor of the cable is rigidly clamped inside the gland and the electrical continuity is
established between armor of the cable and the earthling system through the gland body.
Ensure that the gland plates for single core cable shall be of non-magnetic material and tambour is earthed
only at one end of the cable.
An adequate length of cable tail shall be left to allow remaking and termination of each core for all control,
power cables.
Cable identification, Phasing and core identification check shall be carried out before completing termination
for HV, LV power cables.
After completion of HV power cable terminations pre-commissioning test to be carried outing presence of
PDO representative.
Preparation:
Check the materials are complete and suitable for the cable to be fitted on.
Check the relevant tools required for the following installation work are available on site.
Check the site conditions are adequate to provide the correct working environment for the correct and clean
fitting of the product.
Cable Preparation:
Cable overlapping – Lay the cables in their final position overlapping (Using heating mats and alignment rails,
heat and straighten the cables)
Check the prepared cable insulation is not flat sided and the eccentricity is within the acceptable limits
according to the requirement.
Check the diameter of the prepared insulation is within the limits according to the appropriate parts.
Page 25 of 31
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Revised
Cable Jointing:
Marks on cables have been done according to the requirement and locate the silicone sleeve on final
positioning – Cutting and grinding should be done according to the requirement.
Using gloves apply grease inside the sleeve and over the cable and place a split bucket into the sleeve and
using mounting tool place the silicon sleeve onto cable.
Mount the (Sicon) torque control connector positioning it with a max. 2mm spacing between the insulation
shoulders on either side.
Remove carefully temporary protection and ensure associated cable and pre-molded silicone sleeves are
without damage and clean
Conductor Jointing
The 220 kV copper conductors may only be jointed or terminated by compression.

The method proposed shall be to the approval of the Engineer and shall not cause any
Undue effect on the flow of oil through the duct (for LPOF) or the integrity of the
Insulation.
.
Insulation Application
The insulation of the XLPE joint assembly and the transition stop joint assembly shall
be performed using pre-fabricated‟ moldings’ of an approved material.
Joint Enclosure (Coffin Box)
All completed joints shall be fitted with suitable insulating boxes in accordance with
IEC 62067 and IEC 60840 standard for 220 kV cable system respectively.
All completed joints shall be filled with suitable compound to protect the joint casing
from corrosion. The compound and box shall withstand sheath standing and surge
Voltages and shall also withstand commissioning and annual voltage testing of the
cable sheath anti-corrosion serving.
The compound shall be removable by the use of a normal heating method.
Joint Installation
Joints shall generally be installed on a concrete base in a precast reinforced concrete

Joint bay. In the event of joints being required along a length of trough then special
Page 26 of 31
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Revised
Provisions will apply. All the joints shall be supported by concrete supports.
Sliding silicon sleeves into final position:
Prepare mounting equipment

Grease cable with silicon using gloves
sleeves into final position and remove tape carefully and completely
Screen connection and housing:
• Make the screen connection and PP Housing

• Apply sealing tape in tow screen seal positions
• Straighten screen wires out around circumferences of cable the silicone sleeves
• Apply sealing tape on outer sheath
• Bend back screen wires over shrink sleeves
• Fix bonding cable connection
• Ensure the incoming bonding cable are sealed against moisture at the compression sleeves as
indicated
6. Testing & commissioning of HV, MV, Cables
• Some of the available test methods are listed below:

Dielectric Withstand:
Direct current (DC) dielectric withstand voltage
Very low frequency (VLF) dielectric withstand voltage
Power frequency (50/60 Hz) dielectric withstand voltage
Baseline Diagnostic Tests:
Power factor/ dissipation factor (tan delta):
Power frequency (50/60 Hz)
Very low frequency (VLF)
DC insulation resistance:
Off-line partial discharge:
Power frequency (50/60 Hz)
Page 27 of 31
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Revised
Very low frequency (VLF)

• Insulation Resistance Test Values Electrical Apparatus and Systems
• In the absence of consensus standards dealing with insulation-resistance tests, the Standards
Review clients and Test results are dependent on the temperature of the insulating material and the
humidity of the surrounding environment at the time of the test.
• Insulation-resistance test data may be used to establish a trending pattern. Deviations from the
baseline information permit evaluation of the insulation.
7. Material Handling/Transportation to construction location:

• Material issued from stores shall be loaded / unloaded by using suitable slings.
• Material will be separated area wise so that it could easily be identifiable.
• Material shall be inspected against the dispatch particulars for any transportation damage.
• All material shall be placed off the ground.
• Hand tools.
7.0 Possible causes of damages during the inspection are:

• Damaging of gaskets during the installation and painting damage during the fitting of the other
accessories etc.....
8 .0 Possible hazards during the inspection:

See point8.1, Risk assessments
8.1 Risk Assessment.
Page 28 of 31
GH-QAQC-CMS-P-0025
Revised
According Risk Assessment form
• Before commencing work, a pre-start assessment by all involved parties (including the civil contractor
etc.) shall be carried out to address hazard management and work practices and shall include but not be
limited to –
i) Identify hazards.
j) Access risks that may result because of the hazard,
k) Decide on control measures to prevent, or minimize the level of the risks,
l) Implement control measures,
m) Particular attention shall be given to, but is not limited to:
n) Traffic management, refer to Main Roads Departments Code of Practice (on the MRWA Website), and
also Section 5.4 for particular requirements in congested traffic areas such as the CBD.
o) Public and worker safety.
p) Potential Weather conditions during the work.
9.0 TOOLS AND EQUIPMENTS
1. Megger for Resistance - 1 set

Manufacturer: Type:
Last calibration:
2. Omicron Kit - 1 No.
Manufacturer: Type:
Last calibration:
3. TAN DELATA TESTER - 1 No.
Manufacturer: Type:
Last calibration:
4. Measuring Meter - 1 No.
Manufacturer: Type:
Last calibration:
5. Hand tools for Electrician - 1 Set
6 Screw drivers and Instrumental materials 1 No

Manufacturer: Type:
Last calibration:
7 Exo-thermic welding tool kits. 1 No
Manufacturer: Type:
Last calibration:
Page 29 of 31
GH-QAQC-CMS-P-0025
Revised
8 Step-up Transformer 1 No
Manufacturer: Type:
Last calibration:
9 Megger for insulation resistance. 1 No
Manufacturer: Type:
Last calibration:
10.0 SITE HEALTH AND SAFETY
• PTW (Permit to Work), JHA (Job Hazard Analysis) and Risk assessment shall be implemented.
• TBT Tool Box talk shall be conducted regularly about safety and environmental matters related
to construction activities at site.
• Method of statements for all activities shall be in place and discussed with all workers & staff.
• Safety sign boards to be displayed clearly at all Locations.
• The minimum Personal Protective Equipment is as follows:
• Safety Helmet
• Ear Defenders/Earplugs
• Safety footwear
• Safety glass
• Coveralls
• Leather Gloves
• Fire Blanket
• Full Body Harness
• Any other equipment as specified in PTW for the task.
10.1 Working at Height
• Scaffolding shall be erected, altered and dismantled by experienced men working under the
direction of the competent person which must be certified and tagged.
• Body harness is a mandatory requirement while working in high elevated areas or in scaffold.
• Scaffolds shall be inspected regularly by a competent supervisor, to ensure that the scaffold has
not been altered and is in safe working condition.
• Proper tagging for scaffolds are mandatory requirements. All tools and materials shall not be
thrown or dropped from heights. Carrying any materials in your hand while going up the scaffold
were strictly prohibited, use pulley or a rope to lift any materials in high elevated areas.
Page 30 of 31
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11.0 Materials Storage and handling.
• All Storage and handling of Material shall be done as per ALGIHAZ Quality procedure GH-00- QAQC-
PROC-0006 Material Inspection, Receiving & storage and handling procedures.
Page 31 of 31

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DOCUMENT TITLE:

132 KV HV Cable laying methodology

132 KV HV Cable Laying Methodology

2 For Approval 02.04.2019 SM SM SG

1 For Approval 11.03.2019 SM SM SG

0 For Approval 02.02.2019 SM SM SG

Rev Purpose of issue Date Prepared by Checked by Approved by

CONSTRUCTION METHOD STATEMENT

FOR INSTALLATION &TESTING

Date Rev Prepared By Reviewed & Checked By Concurred By

Approved Issue Date Revision # Section/page Description of revision Reviewed by

TABLE OF CONTENT PAGE NO

1.0 SCOPE AND PURPOSE

IEC 61442 All test report is meeting the client requirements.

IEC-60060-1&2 High voltage test techniques

IEC 60230 Impulse test on cable and their accessories

IEC-60466 AC Insulation –enclosed switchgear and control gear for rated

IEC 60287 Electrical cable calculation of the current rating.

IEC 61236 EMC requirements for Electrical requirements

IEC 61000 Electromagnetic capabilities

IEC 60068 Environmental testing

IEC 61508 Functional safety of electromechanical

ASTM B 33 Tinned soft annelids copper wire for electrical proposal

ANSI /NFPA 70 National electrical code

IEEE C37.122 Guide line for Gas insulated substation

IEC60287-1-1 Current rating equation and calculation of loses-General

3.2 SITE MANAGER:

3.3 SITE ELECTRICAL ENGINEER:

3.4 ELECTRICAL FOREMAN:

3.6 STORE KEEPER:

3.7 Materials Storage and handling.

3.8 SAFETY OFFICER/ENGINEER:

4.0 WORK PROCEDURE AND SEQUENCE

The following point are cross verifiey at the power cables

4.3 Installation Procedure-

4.4 Equipment of the installation :-

Refer the cable table:-

4.5 Safety in Pits and Trenches

4.6 Under ground Trench or pipes

4.7 Drilled Tunels

4.8 Digging Entry and Exit Pits

4.9 Protection of Cables in Special Terrain

4.10 Drilling and Pulling

4.11 Capability of Ploughing Equipment

4.12 Core Arrangement

Illustration of a transposed system

4.13 Backfill Requirements

Illustration of thickness of backfill

4.14 GPS Coordinates

4.16 Pulling Speed

4.17 Bedding and Backfill

4.18 Depth of Cover of Cables

Cable outside road Cable to be installed at a depth of

4.19 Substandard Depth Cables

Alignment Category Description and Depth

Cable within PVC Marker tape shall be applied. The

Cable outside road PVC Marker tape or equivalent corrugated

4.21 Above Ground Cable Markers

Paddocks and Open Spaces:

Distances between markers:

4.22 Cable Sealing

4.23 Exposed Underground Cables