Method Statement For the Installation of HV & LV Cables and Wires
Introduction:
To ensure that the installation of correct cables are installed and agreed procedures are implemented during execution. And in accordance with the contract requirements and that all quality assurance/ control activities required for the same are conducted in a systematic manner, works are inspected and conformance is verified and documented.
SCOPE:
This Method Statement defines the procedures to be followed in installation of High Voltage and Low voltage cables.
REFERENCES:
- Electrical Approved Materials & Equipment (Data sheet/ Submittal)
- Approved Electrical power Project Drawing
- Project Specification, United States Standard, IEEE Standard & Etc. Local Law 21-2011 Waste Management.
- FIRE AND LIFE SAFETY CODE OF PRACTICE July 2018.
- Federal Law No.8 Regarding the Organization of labour Relations.
- Ministerial Order No.32-The Determination of Retentive method and measures for the protection of workers from the risk of the work (the ministry of labour and social affairs)
- OSHAD-RF & SF – Specific & Relevant COPs, Elements, and Mechanisms to be listed down based on activities and scope of work which will vary for each risk assessment.
OSHAD SF COP’s Version 3.1 July 2018.
- Ref OSHAD-SF Cop 34 Safe Use of Lifting Equipment and Lifting Accessories
V 3.0 July 2016.
- Ref OSHAD-SF Cop 14 Manual Handling and Ergonomics V 3.1 June 2017.
- Ref OSHAD-SF Cop 8.0 General Workplace Amenities V 3.1 June 2018.
- Ref OSHAD-SF Cop 2.0 Personal Protective Equipment V 3.1 June 2018.
- Ref OSHAD-SF Cop 15 Electrical Safety V 3.1 June 2017.
- Ref OSHAD-SF Cop 21 Permit to Work Systems V 3.0 July 2016.
- Ref OSHAD-SF Cop 23 Working at Heights V 3.0 July 2016
- Ref OSHAD-SF Cop 26 Scaffolding V 3.0 July 2016.
- Ref OSHAD-SF Cop 35 Portable Power Tools V 3.0 July 2016.
- Ref OSHAD-SF Cop 37 Ladders V 3.0 July 2016.
- Ref OSHAD-SF Cop 15 Mechanical Safety V 3.1 June 2017.
- Ref OSHAD-SF Cop 11 Safety in the Heat V 3.1 June 2017.
- Ref OSHAD-SF Cop 8 General Workplace Amenities V 3.0 July 2016.
DEFINITION:
- LV – Low Voltage
- HV – High Voltage
- ELV – Extra Low Voltage Cables
- SMDB – Sub main Distribution Board
- DB – Distribution Board
RESPONSIBILITIES:
Project Manager:
- Overall responsible for the implementation of this method statement
- Responsible for ensuring that the work is performed in accordance with the specification and with the time & constraints.
- Coordinate with MEP Coordinator (Contractor) for obtaining the necessary resources for the project deployed as required.
- Submit progress report as per contractual requirements to Main Contractor.
- Ensure that all required submittal are made in timely manner.
- Coordination with the Contractor, Company, Engineers, Safety personnel and subcontractor for the safety and quality during the execution of the project.
Site Electrical Engineer:
- Ensure that the activities are carried out according to the Specification, drawing and approved Method Statement.
- Ensuring Submittals and Company approval on relevant MEP drawing/ Material/ Suppliers/ Subcontractors/ Method Statement and Quality/HSE Documentation.
- Arrange all materials and tools required for installation as per agreed project schedule.
- Coordinate to MEP Coordinator & Construction Manager for obtaining the necessary resources for the project & deploy as required.
- Provide all necessary information and distribute the responsibilities to his construction team.
- Monitor that all in process tests are carried out and obtained approval from Client/ Main Contractor/ Consultant.
- Monitoring & ensuring that the works is performed in accordance within the time and cost constraints.
- Coordinate with the Safety Engineer to ensure that the works are carried out in a safe working practice.
- Pass all the revised information to the site General foreman and ensure that it’s being carried out properly for entire MEP System.
- Ensure all Mechanical work activities are in conformance with approved shop drawings, contract requirements/ specification, and Method Statement.
- Ensure that relevant and required Materials are requested on time in correct quantities.
- Provide Approved Shop drawings to site Engineer for proper site Installation.
- Advising Site Engineer on all Technical aspects regarding work methods, sequence of installation, testing and commissioning.
- Follow up site activities and ensure all relevant non-conformance issues (if any) are resolved and cleared out. Communication with QA/QC Engineer and HSE Engineer for preventive and corrective actions.
- Coordinate the progress of main contractor works to ensure installations of MEP works are considering preventive and corrective actions.
- Coordination with other Contractors/ Company to provide solutions affecting design development / Coordination matters.
- Responsible for the coordination of all electro-mechanical activities, coordination with other discipline and between various subcontractors on sites.
- Reviewing of MEP daily, Weekly & Monthly progress reports.
- Ensuring MEP subcontractor Payment Certificates are reviewed and approved for payment.
- Responsible for all related activities prior to completion of the project
Charge-hand/Foreman:
- Carrying out the works and the proper distribution of all the available resources in coordination with the Site Engineer on a daily basis.
- Continuous coordination and following Site Engineers instruction to meet quality requirements during the job execution.
- Incorporate all the QC & Safety requirements as requested by the company’s representative.
- Report to Site Engineer the accomplishment and problem encountered on daily basis.
QA/QC Department:
- Ensure all Inspections are raised and conducted as per the Contract Specifications, PQP, & ITPs.
- Ensure all Inspections, proper tools & tackles and manpower are used at all stages of work.
- Ensure Call current issues of procedures, approved material and shop drawing and standards are available at the point of use.
- Ensure the works comply with the contract requirements/ approved shop drawings to serve the purpose.
- Ensure the Total quality for Installation work. He shall liaise with Company for Inspection of Installation works.
- Inspect for any damages during handling, & Storage.
- Monitor the quality of work and ensure that fulfillment of specified requirement and that all quality records related to work are completed.
- Ensure the work is completed as per quality requirements. Contractor shall inspect the same work to initiate ITR for company approval.
- Maintain comprehensive inspection and test records for any further references.
Safety Officer/ Engineer:
- Tool Box talk has to be conducted and all the hazards have to be identified before starting the work.
- To make sure that the Personnel Protective Equipment (PPE) are used by the Task Force during executions of work at site.
- Risks related to the activity shall be assessed and addressed as required.
- To provide training for the work force in order to execute the activity safely.
- Carry out regular and random inspection on site and record observations.
METHOD OF WORK:
Material:
- Power Cables ( HV, LV)
- ELV Cables
Equipment/ Tools:
- Hydraulic Crimping Tools
- Manual Crimping Tools
- Cable Rollers
- Cable Spindle and Jacks
- Cable Drum Trolleys
- Scaffolding Step Ladder
- Megger – Fluke Multi-meter
- Pulling Wires Rope, Lubricant (Soap based, wax based)
- Hand Tools-gloves, Cable cutter, measuring tape, pliers, screw drivers, puncher, cutting saw, spanner and etc.
- Personal Protective Equipment
Testing Equipment:
- HV & LV Insulation resistance tester
- Multi-meter
- High Potential Cable tester
- Current & Voltage meter
Pre-Installation Procedure:
- All workers to attend safety induction conducted by safety Engineer and given specific training on the safe installation methods by the site supervisor.
- Ensure that approved shop drawing and approved materials are available at site.
- Prior to commencement of work, area and access will be inspected to confirm that site is safe and ready to commence work.
- Check that all Chilled Water Pumps are received at site in accordance with specification and correct dimensions as per approved drawings.
- Ensure proper storing/ handling of the materials are without damaging the surface/ parts.
- All relevant documentation (drawing, checklists, method statements etc.) and material applicable to particular section of works will be checked by Site Engineer/ Supervisor prior to commencement of work.
- The Site Engineer/ Supervisor will give necessary instructions to tradesman (Unit Erectors) and provide necessary approved construction/ shop drawing of latest revision.
- The site supervisor/ Foremen will also check that proper tools and equipment are available to carry out the work and are in compliance with contract specification.
- The Site Supervisor will also explain to the tradesmen regarding safety precautions to be observed.
Handling And Storage:
- The materials received shall be offloaded in designated lay down yard store.
- During shifting or offloading material shall not be dropped off. Proper Lifting and transporting equipment shall be used as required.
- The material shall be stored according to the manufacturer’s instruction to minimize damage.
- All material shall be segregated accordingly to facilitate location of the
- Prior to moving to site, Chillede Water Pumps will be checked against data sheets to ensure conformity to the specification.
- QC inspector and Supervisor will check the following (scrutinize and examine Documents and units); Fan and Motor, type, model, ratings, components and installation complied with specifications, capacity, vibration and sound level, unit controls, unit operation, power supply, enclosure, unit openings for supply ducts, cooling coils, type of filters, all of these will be checked and recorded in MVR form, inspection will be witnessed by the consultant.
- Where equipments are to be held in a storage area, particular attention will be paid to the condition of instruments and devices installed on the panel fascias. AC Units and fans shall be stored and handled in accordance with manufaturer’s Instructions.
- Where equipment or equipment section are sealed to prevent ingress of moisture or dust, this shall not be disturbed unless physical damages observed.
- Check for mechanical damages and the operation of moving parts and check for freedom of movement.
- Equipment received at site shall be inspected and approved in accordance with Material Approval Request form.
Installation Procedure:
General Requirements:
- Cables and wires will be installed in accordance with the approved shop drawings and properly coordinated with Main Contractor site Engineer/ Construction Manager for exact locations and levels.
- Proper marking /selection of location on site will be done prior to commencement of installation works.
- Complete a mock-up installation before main works and get its approval.
Wire Pulling:
- Make sure that all conduits and boxes in both ends are free from damages and blockages etc. and installation is approved.
- Blockages shall be checked by inserting the draw wire and checking that it reaches to the other end without any disturbance.
- Once the conduit is not blocked the wires shall be pulled using the draw wires while ensuring no damage occurs while pulling.
- Pulling compound or lubricant shall be used for pulling wires where required.
- Use soap-based pulling compound for the runs greater than 20 Meters for semi conductive insulated wires.
- While pulling the wires, care will be taken to not insert the pull tension greater than manufacturer’s allowed limits.
Wiring Installation for Small Power and Lighting & Low Current Services:
- Materials will be checked against project specifications.
- Low current service wirings / cables are to be laid in trunkings separate from power wirings / cables.
- Prepare mock up installations where applicable, seek its approval prior to commence of the next other typical works.
- Required conduit sizes will be used. Conduit’s sharp internal surfaces will be removed and bends will be limited following standard practice. Sharp conduit bends will not be permitted. Placing of conduits will be embedded during the concrete casting and in block wall. Conduits can be run fixed at the offsite or to be laid on the concrete screed. Conduit laying will be as per approved drawings and specifications.
- After ensuring that conduits are in placed a guide wire or fish line will be inserted in preparation for wire pulling. Whenever a bunch of wires are to be pulled a rope and basket weave wire will be required in order to hold the conductors to be pulled together.
- Wires or conductors will be pulled simultaneously and pulling lubricant will be used when necessary. Wires or cables will have sufficient slack at both ends for convenience in connections and maintenance.
- Cables, wires and connectors, utility, junction boxes, pull boxes will be as per specified type or class. As soon as the conductors reaches the panels, boxes, raceways it will be tagged. Wires and cables will have identifications, labels or tags at both ends.
- Manufacturer’s recommendations will be followed during work execution.
- Wires or cables will have sufficient slack at both ends for convenience in connections and maintenance.
- Pulling of wires, cables will not exceed manufacturer’s recommended tension.
- Any damaged conduits during the construction stages will be reported to proper authority and the same will be repaired immediately.
- Electrical Fittings will be inspected and ensured they are securely fixed as per the installation detailed drawings.
- The location, level and alignment of fittings shall be checked, fixtures will be installed only after the approval of wiring installation or during testing only.
- Stability of fittings and fixtures assembly will always be considered.
- Insulation resistance test will be conducted as per cable manufacturer’s recommendations and test requirements. Insulation resistance between cores, earth of all LV cable will be tested with a 500V megger (Specification 16011-4).
- After the installation, insulation resistance tests shall be performed to the approval and satisfaction of the engineer. If the testing is not satisfactory, then test shall be repeated or the work shall be rectified until the correct results are acquired to the satisfaction of the Engineer. Insulation resistance Test shall be in accordance with specification section 16011-4 & 5.
Low Current System Wiring Test:
- Applicable test will be conducted for low current system wirings to ensure continuity and no shorts and grounded wires exist prior to terminations to all devices / equipment.
Cable Pulling & Termination:
- Transport and place the cable drums as per drum schedule and at the locations where space is available for working. The cable drum will be placed on a jack & spindle arrangement to ensure free rotation of the drum.
- Erect scaffolding (only those with safety tags) where required as per the site requirements.
- Cable rollers will be placed under the cable during pulling over longer distances and standoff rollers for acute bends to ensure that the cable is pulled with minimum effort and the cable outer jacket is free of scouring lines.
- The cables will be pulled using pulling means such as fish tape, rope and basket weave wire/ cable grips so as not to damage cable or its containment system. Care will be taken to ensure that the maximum pulling tension of all the cables is not exceeded at any time.
- Cable should be free of any static load i.e. to be placed side by side parallel on the cable tray or ladders. Any kind of dead weight on the cable will be avoided.
- At all times the cable schedule & section drawings for the relevant area will be referred to ensure proper location of cable on the required ladder and to ensure compliance with project specifications.
- A pulling compound / lubricant will be used where necessary as per site conditions i.e. in slabs and underground conduits etc. the lubricant in anyway should not deteriorate the cable insulation.
- The cables shall be secured to the containment system using approved cable ties for horizontal runs and cable cleats for vertical runs.
- All ELV cables will be installed at a minimum distance of 100mm from power cables unless otherwise agreed with consultant as per site conditions.
- Earth (green/yellow) cables shall also be pulled along the power cables.
- At all time of pulling, mark both power and earth cable ends to ensure correct termination on both sides of the cable.
- Before termination complete length and route of the cable shall be inspected by QA/QC Engineer after which request for inspection will be raised for consultant’s approval. Cables will be capped and sealed on both ends after installation until termination is due.
- Termination shall be done by using the approved termination materials that include glands, lugs and other accessories part of termination kit by using proper crimping tools. Matching color gland sheaths shall be provided.
- All termination will be provided with tight fit covering sleeves.
- All work to be done under the attendance of safety officer/s.
Insulation Resistance Test:
- Set the megger to 500volts DC to test the cables / wires.
- Take reading between phase, phase and neutral, phase and earth, neutral and earth.
- Note that resistance reading must not be lesser than 1 mega-ohm (MΩ).
- Check and record the resistance readings as per specification on the approved insulation resistance test form.
Cables Identification:
- Install the tags/labels as per project specifications and as per approved material submittals.
- Cables will be identified as feeders i.e. the sending and receiving ends (outgoing cables in SMDBs and final DBs) about 50mm below the gland.
- Identification labels will be provided at all positions where cable changes direction and each side of the each side of the wall or floor slab and where cables are in multiple runs.
- Cores of cables connecting control gear, thermostats, valves, etc. will also be identified and shall be fitted with identification sleeves bearing the same marking as the terminals of the apparatus to which these are connected.
- For cables at feeders, identification will be done as per specification and approved materials.
Final Acceptance Test:
- After the commissioning of the entire installation, final acceptance tests shall be carried out prior to the issuance of Performance Certificate in accordance with the programmed to be agreed with the Consultant.
- Should the results of the acceptance Test do not conform to the required performance, adjustment and modification to the system is necessary to be carried out.
- Prior to the issuance of Certificate of Completion, tests shall be carried out whenever required by the authorities having jurisdiction over the said performance tests.
Health Risk Assessment:
- All the above operations shall be executed strictly in accordance with Project Occupational Health, Safety, Security and Environmental Plan.
- Prior to the commencement of any activities, the workforce will receive a safety induction on the project site safety requirements; this safety induction will include Project HSE Policy, Project details and layout, Site management team, general site HSE requirements, emergency procedure including Emergency contact numbers, Roles and responsibilities of the workers, Site discipline, general environmental awareness, PPE requirements.
- The HSE roles and responsibilities shall be delivered to all staff (construction manager, engineer, supervisor, foremen, and charge hand).
- Work will commence as per safety regulations laid in the contract specifications and project safety plan.
- Housekeeping shall be of good standard and debris shall be removed.
- All activities will be performed according to the control measures and instructions prescribed in the attached Risk Assessment Sheets.
- Daily JSA will be done before the commencement of each shift and each new task.
- All Vehicles will have valid licenses and passes before entering the site.
- PPE shall be issued to all personnel (Mandatory PPE’s: Hard hat, Safety glass, high visibility vest, Safety shoes and cover all. Task specific PPE; Dust mask, goggles, hand gloves).
- Specific training shall be given for task specific tools and equipment’s; records shall be kept in HSE department.
- Heat stress training will be provided during summer time, records shall be kept in HSE department.
- Adequate cool drinking water, shade and hydrolyte shall be placed.
- Plant and equipment shall have back up alarms, lights and all other applicable safety devices.
- Provide Banks man when operating equipment reverse and moving the equipment where pedestrian movement is exist.
- Work on site will be supervised by a competent person (Qualified SE)
- Safety Lighting
Emergency Procedures:
- Contact numbers of personnel concerned to be displayed.
- Emergency response team to be designated and on standby:
- All emergency contact people are posted around the project and are being discussed during site safety meeting.
- Emergency routes and exists to be clearly marked.
- 1 vehicle with one driver will be available for any emergency.
- Requirement of the Project Emergency Preparedness and Response plan shall be strictly followed.
- In the event of an accident, contact the area HSE Supervisor.
- In case of Diesel Spillage contact the Environmental department.
- Easy means of access will be available at all time.
- Contact numbers of all emergency supervisors will be distributed to site personnel (Site engineer, Safety officer, male nurse and concerned authorities and emergency services).
- Injuries will have the highest priority to be directly dealt with at once.
- There are different types of situations that we need to consider under this section. These are:
- Basic first aid
- Medical
- Property damage
- Environmental releases
- Fatality
- Fire
- The nominated response team will consist of:
- Site nurse
- Safety Engineer/Officer
- Site Superintendent/Foreman
- 4no of operatives
- Basic first aids
- The injured person, if mobile, can make his way to the site clinic for treatment by a qualified site nurse that is available and logged in the first aid register.
Medical:
Under this section, there are two categories that we need to consider. They are as follows:
(1)- Conscious
If the patient is feeling un-well, he will immediately inform his supervisor and go to the site clinic to be assessed by the site nurse. The site nurse will then advise, or the patient will require further examination and he will be taken to the hospital.
(2)- Unconscious
If the patient had collapsed during his work, alarm must be raised to inform the response team. The team will then respond accordingly by the quickest possible way arriving at the location of the incident. Along with them, they will bring a first aid kit, an emergency stretcher and an emergency vehicle. Once they are on the scene, the site nurse will assess the patient and the team will then take the patient on the stretcher either to the site clinic or to the local hospital.
- Electrocution:
- If you see someone lying unconscious or “froze on the circuit,” the very first thing to do is shut off the power by opening the appropriate disconnect switch or circuit breaker. Don’t touch another person being shocked, If the power disconnect switch cannot be located quickly enough, it may be possible to dislodge the victim from the circuit they’re frozen on to by prying them or hitting them away with a dry wooden board or piece of nonmetallic conduit.
- Once the victim has been safely disconnected from the source of electric power, the immediate medical concerns for the victim should be respiration and circulation (breathing and pulse). Call nearest First aider to apply first aid to the electrocuted person. If a victim is still conscious after having been shocked, they need to be closely monitored and cared for until male nurse arrives.
- Rescue from Height:
- There will be rescue team with emergency rescue kit readily available at site in case of “Rescue from Height” is needed. The rescue team members are chosen from scaffolding team that has no acrophobia and has enough experience on working at height.
- Emergency response drill should be conducted as per Project Emergency Drill Schedule.
- Only the competent personnel will be allowed to install the system who has experience and trained by the supplier.
- Environmental:
- Working areas will be kept free as practicable from construction debris and equipment’s which are not actually in use.
- Proper access to the work areas should be maintained all the time. Particular attention to be paid to environmental hazards such as excessive dust emission, excessive noise from equipment, unpleasant odor of material or chemical to be used, etc. Hence a corresponding control measure will be performed as below mentioned but not limited on it:
- Water spraying for dust control
- Noise level monitoring
Complied with the materials safety data sheet recommendation regarding environmental aspect/impact of the material to be used.
ATTACHMENT:
- Inspection & Test Plan
- Inspection Checklist for the installation of HV & LV Cables and Wires.
- Risk Assessment
- Quality Control Procedures
