EPC of Gasoil tanks, LPG Tanks, and related

infrastructure Project Number: PD-0113.018-2

Document Number Document Title Page 1 of 11

PTJ-EL-MST-008 Method Method Statement for 22 Kv Cable Installation
Rev. C01
Date 06/05/2019

Method Statement for 22 Kv Cable Installation

Project : EPC of Gasoil tanks, LPG Tanks, and related infrastructure

Client : SONKER BUNKERING COMPANY

Contractor : PETROJET

Company Project No. : PD-0113.018-2

Document No. : PTJ-EL-MST-008

Document revision Status : C01

Document Class :2
C01 26/05/2019 Issued for review/comment M. Badr Ahmed Nagy M. Amin

C01 06/05/2019 Issued for review/comment M. Badr Ahmed Nagy M. Amin

B01 01/05/2019 Issued for Internal Review M. Badr Ahmed Nagy M. Amin

REVISI PTJ PTJ PTJ QA/QC CLIENT

DATE DESCRIPTION
ON NO. ORIGINATOR CHECKED MGR APPROVED

TABLE OF CONTENTS

1. PURPOSE

2. SCOPE

3. REFERENCES

4. DEFINITIONS & ABBREVIATIONS

5. RESPONSIBILITIES

6. MACHINERY / EQUIPMENT

7. PROCEDURE

7.1 INSTALLATION REQUIREMENTS

 EPC of Gasoil tanks, LPG Tanks, and related
infrastructure Project Number: PD-0113.018-2

Document Number Document Title Page 2 of 11

PTJ-EL-MST-008 Method Method Statement for 22 Kv Cable Installation
Rev. C01
Date 06/05/2019

7.2 EXCAVATION

7.3 REFILLING OF EXCAVATION

7.4 CABLE INSTALLATION

7.5 FIBER OPTICAL CABLE INSTALLATION

7.6 CABLE GLANDING AND TERMINATION

7.7 TESTING

8. INSPECTION

9. ATTACHMENTS

1. PURPOSE:
The objective of this work instruction is to provide general guidelines for materials,
tools, equipment, manpower and adequate supervision are available during execution
22Kv Cable Installations outside/inside sonker terminal, located at Ain Sokhna. Also, to
ensure that work steps area analyzed and all safety measures are taken so that work can
be done in a safe and timely manner.

2. SCOPE:
This document covers the following activities:
- 22Kv Cable Installation OSBL from 66/22Kv substation to Sonker SSO1.
- 22Kv Cable Installation inside Battery limit.
- Precautions.
- Testing.
- Inspection.
 EPC of Gasoil tanks, LPG Tanks, and related
infrastructure Project Number: PD-0113.018-2

Document Number Document Title Page 3 of 11

PTJ-EL-MST-008 Method Method Statement for 22 Kv Cable Installation
Rev. C01
Date 06/05/2019

3. REFERENCES:
- IFC Drawing
- Project Quality plan PQP
- Technical Employer Requirements
- Cable Routes Specification ILF-EL-SPC-0824
- Cable Routes Cross Sections - Typical Drawings ILF-EL-DWG-0515
- 22 Kv Cable Route Layout OSBL SONK-2015-10-D-0-EL-300.
- ILF-CI-DWG-0573 Underground Installations
- ILF-DC-SPC-0006 – Tagging Procedure
- ITP for Electrical Installations.

4. Definitions & Abbreviations:

Contractor : PETROJET
Employer : SONKER
PMC : Tebodin
PIM : Pre-inspection Meeting
PM : Project Manager
CM : Construction Manager
SM : Site Manager
DE : Discipline Engineer
PQP : Project Quality Plan
QCM : Quality Control Manager
IFC : Issued for Construction
ITP : Inspection Test Plan

5. RESPONSIBILITIES

- Contractor will provide positive confirmation of all works carried out and
comply with approved ITPs.
- Contractor shall employ professionals with good experience for all
installation activities, ensuring best workmanship while taking into account
all required safety precautions.
- PM/SM: it is his responsibility to organize resources to perform
construction activities as per project specification, in compliance with
quality, schedule & safety requirements.
 EPC of Gasoil tanks, LPG Tanks, and related
infrastructure Project Number: PD-0113.018-2

Document Number Document Title Page 4 of 11

PTJ-EL-MST-008 Method Method Statement for 22 Kv Cable Installation
Rev. C01
Date 06/05/2019

- CM: It is his responsibility that construction activities are executed

according to the relevant project specifications, in compliance with quality,
schedule & safety requirements.
- DE: will ensure that all the works are performed safely as per latest
Approved for Construction (IFC) drawings & specifications.
- Q.C: inspector will ensure that all work is executed according to PQP and
that requirements of quality dossier are full filled.

6. MACHINERY / EQUIPMENT
 Hand tools.
 Rollers, Cable Jack.
 Crane.
 Trailer.
 Forklift.
 Tractor.
 Cable winch.
 Cable cutter.
 Hydraulic crimping tool.
 Scaffolding.
 Multi Tester.
 Hi-Pot Tester.

7. PROCEDURE

7.1. Installation Requirements

1.1.1. All cable Drums received at site shall be inspected, handled and
stored in a secure and dry location, and follow manufacture
requirements for storage.
1.1.2. Conduct insulation resistance test on drum prior to cable pulling.
1.1.3. Prepare the tools and materials needed for cable installation.
1.1.4. Scaffolding/step ladder may use where possible during cable laying.
1.1.5. Test equipment shall have valid Calibration Certificate.
 EPC of Gasoil tanks, LPG Tanks, and related
infrastructure Project Number: PD-0113.018-2

Document Number Document Title Page 5 of 11

PTJ-EL-MST-008 Method Method Statement for 22 Kv Cable Installation
Rev. C01
Date 06/05/2019

1.1.6. The tensions of the pull shall not exceed that specified by the
manufacturers for the particular type and size of cables.
1.1.7. All cable route system elements sharp edges have to be covered with
rubber plugs to avoid possible cable damage.
1.1.8. The minimum spacing between instrument and power cables, as
defined in specifications for Instrument Installations shall be strictly
adhered to.
1.1.9. Any deviation/exceptions to the requirements of the project
specifications and drawings will require prior approval by Employer
via an officially issued field design change.
1.1.10. Cable route systems materials used for different system applications
shall be as per approved specifications.

1.2. Excavation
7.1.1. Permit to Work (PTW) shall be raised for the excavation clearly
mentioning the location of work, size of excavation and levels.
7.1.2. Prior to star of any excavation, the area shall be checked for the
existing services/utilities by obtaining the approvals with reference to
the relevant drawings.
7.1.3. Excavations area shall be surveyed and marked to the lines and
levels as shown on the drawings.
7.1.4. Required sign boards such as “DEEP EXCAVATION” “MEN
WORKING” “DANGER” and warning boards will be placed to
indicate the excavation work.
7.1.5. Fences and minor structures of any character or upon within the
limits of the works and not necessary for the construction shall be
removed carefully and stored neatly for reinstating after the
construction works.
7.1.6. Check the indication marks, signs, manholes nearby area and find
out the path of services.
7.1.7. In open areas the excavation shall be carried out by using the
machineries, the exact location of each trench and pit being subjected
to the prior approvals.
7.1.8. Excavation near the existing electrical cables, instrumentation and
control cables, sewer line, gas lines and any other service line shall
take all necessary precautions to protect the services with proper
supports & covers.
 EPC of Gasoil tanks, LPG Tanks, and related
infrastructure Project Number: PD-0113.018-2

Document Number Document Title Page 6 of 11

PTJ-EL-MST-008 Method Method Statement for 22 Kv Cable Installation
Rev. C01
Date 06/05/2019

7.1.9. Manual excavation will be carried out to expose the existing

utilities, if any, which has to be identified.
7.1.10.While performing the work the trenches shall be straight, free from
any sharp objects/edges likely to injure the cable or accessories and
filled with soft sand and sieved sand to form smooth bedding before
the cables are laid.
7.1.11.Where ever there is a crossover of the existing services/utilities,
these shall be protected with utmost care with the prior permission of
concerned authorities and approved methods. The contractor shall
obtain the necessary approval from the client / consultant or the
concerned authorities to according to the scope of the work.
7.1.12.The formation of the trench shall be in accordance with specification
ILF-EL-SPC-0824 Cable Routes - Specification and ILF-EL-DWG-
0515 Cable Routes Cross Sec-Typ.Dwgs, and SONK-2015-10-D-0-
EL-300.
7.1.13.The trench shall be excavated up to the required depth of 1.2m from
the existing ground level.
7.1.14.Dune sand bedding shall be done for a thickness of 100mm at the
bottom of the trench from approved dune sand, prior to the installation
of cables.
7.1.15.Cables and the 2” HDPE pipes for the FO Cables are laid over the
dune sand bedding.
7.1.16.approved sand is filled in the trench to the required level as per
approved drawing.
7.1.17.Cable protection tiles are laid above the dune sand filling and ensure
the Concrete Cable Tiles are securely placed.
7.1.18.Selected materials from the excavated soil shall be backfilled for a
thickness of 250mm above the cable protection tiles.
7.1.19.Install 22kV Cable Warning Tape at a depth of 200mm from top of
the trench.
7.1.20.Backfill to the required level in similar way.
7.1.21.Reinstate the area as to its original situation.

7.2. Refilling of Excavation

7.2.1. The refilling of excavations shall be started as soon as practicable
after the permanent works have been tested and approved by the
ENGINEER
 EPC of Gasoil tanks, LPG Tanks, and related
infrastructure Project Number: PD-0113.018-2

Document Number Document Title Page 7 of 11

PTJ-EL-MST-008 Method Method Statement for 22 Kv Cable Installation
Rev. C01
Date 06/05/2019

7.2.2. Refilling of trench can be start partially after complete a section of

trench, not to waited till finishing all the route or jointing, in order to
avoid any incidence particles on the cables.
7.2.3. Refilling of trenches over pipes shall be done by hand to a depth of
300 mm above the crown of the pipe with dune sand or lightly selected
excavated material free from large stones, rock, clay lumps or other
substances which may cause damage to the permanent works.

7.3. Cable Installation

7.3.1. Manufacturer’s instructions for installation have to be followed up.
7.3.2. Insulation resistance of the cables shall be checked before laying
cables.
7.3.3. After the test, the end of the cable shall be sealed to prevent the
ingress of moisture.
7.3.4. Loading of cable drum has to be done by using suitable crane. There
after it is transported by means of cable trailer/jack. The access up to
the trench should be checked before transportation.
7.3.5. Location of cable drum should be planned before transportation of
cable drum. (Practically could differ at one or two places for easy
installation of cable).
7.3.6. The cable drums shall be inspected for mechanical or physical
damages and check the cables to be used at site prior to the start of the
installation process. Any sort of damage shall be noted in a report.
7.3.7. The trench shall be inspected before the cable pulling work begins.
sand bedding shall be filled in smoothly and any objects as stones
/gravels which have fallen from the ground to the surface of the
bedding layers shall be removed.
7.3.8. Cables must not be bent to a radius of less than 12 times the overall
diameter of the cable, or as per vendor recommendations.
7.3.9. Rollers must be used where cables are installed in an open trench
using a pulling rope and eye, cable rollers are to be used at frequent
intervals to support the cables.
7.3.10. The rollers are to be placed securely to prevent movement.
7.3.11. The pulling rope must be equipped with a swivel and be attached to
the cable by a stocking grip with pulling eye.
7.3.12. Cable laying will generally start from one end of the route length or
at any suitable point, as necessary.
 EPC of Gasoil tanks, LPG Tanks, and related
infrastructure Project Number: PD-0113.018-2

Document Number Document Title Page 8 of 11

PTJ-EL-MST-008 Method Method Statement for 22 Kv Cable Installation
Rev. C01
Date 06/05/2019

7.3.13. 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.
7.3.14. Suitable jacks shall be placed firmly on the ground and jacked-up to
allow clearance from the ground depending on the size of the cable
drum.
7.3.15. The drum shall be lifted by required equipment and placed on the
jacks.
7.3.16. The cable drum will be correctly positioned and the direction of
cable pulling as indicated by arrow on the drum shall be complied.
7.3.17. The drum has to be moved by hand in order to avoid a stress on the
cables.
7.3.18. Cable in the trench shall be arranged properly as per drawing, cable
ties shall be used to securely fix the cable in trefoil arrangement.
7.3.19. Close to cable connections to consumers or junction boxes, cable
loops allowing spare length have to be provided before leaving the
earth or the duct.
7.3.20. The cables have to be marked every 20 m within cable support
systems and when entering and leaving switchgears, switchboards,
cabinets, junction boxes, equipment, conduits, etc. Cable markers
shall also be installed at entry and exit points of buried ducts, exits
from building.
7.3.21. Use pulling compound or lubricant where necessary. Excessive force
should not be applied while pulling the cables.
7.3.22. The pipes shall be checked for straightness before filling the dune
sand.
7.3.23. Sand backfilling can be started partially once a portion has
completed and inspected, even before jointing works starts, in order to
avoid any drop particles above the cables.
7.3.24. After sand filling a proper protection shall be installed as mentioned
in specification and ILF-CI-DWG-0573-002 Underground
Installations.
7.3.25. Warning tape will be placed 20cmm below grade level and shall be
blue for LV cables and red for MV cables with written sign for each
as per the voltage level.
 EPC of Gasoil tanks, LPG Tanks, and related
infrastructure Project Number: PD-0113.018-2

Document Number Document Title Page 9 of 11

PTJ-EL-MST-008 Method Method Statement for 22 Kv Cable Installation
Rev. C01
Date 06/05/2019

7.3.26. Concrete blocks for cable trench route identification (30 mm above
grade level), shall be placed directly above the cable route, every 20 m
along the route, at all changes of direction and at road crossings.

7.4. Fiber Optical cable Installation

7.4.1. HDPE conduit shall be installed on trench after completing 22Kv
cables, pulling pits shall be placed at intervals to allow the splicing to
be inside the pits and as per approved drawing.
1.2.1. Cable drum shall be offloaded at an open area in an upright position.
7.4.2. Fiber optical cable laying can be done manually or by using air
blowing method.
7.4.3. Before making the pipe joint, ensure that both the pipe and the sealing
ring are clean.
7.4.4. Additional FOC loop 15-20 meter shall be left coiled inside the
splicing manhole.
7.4.5. Termination of Fiber cable ends at patch panel and jointing shall be
done by an authorized technician.
7.4.6. Testing of Fiber Optical Cable shall be done by Special Tester.
7.4.7. Fiber optic cable fusion splicing provides the lowest-db loss. Special
equipment called Arc fusion splicer is used to perform the fiber
fusion splicing.

7.5. Cable Jointing / Glanding and Termination

7.5.1. Al the necessary materials like the joint/termination kits, long barrel
ferrule...etc. shall be used as per the approved specification.
7.5.2. Supervisor shall be assigned to monitor the work full time during the
complete MV Cable straight joint and termination.
7.5.3. The cable termination shall be undertaken only by competent cable
jointer.
7.5.4. Prior to installation, the cable glands will be checked to ensure they
are as per the schedule and of the correct size and type for the cable
on which they are to be fitted.
7.5.5. Particular attention shall be paid to glands intended for steel-wire
armored cables to ensure the correct sealing and clamping
components are supplied with the gland.
7.5.6. Where glands are to be installed in a hazardous area, the certification
of the gland shall be verified and then be sealed accordingly.
 EPC of Gasoil tanks, LPG Tanks, and related
infrastructure Project Number: PD-0113.018-2

Document Number Document Title Page 10 of 11

PTJ-EL-MST-008 Method Method Statement for 22 Kv Cable Installation
Rev. C01
Date 06/05/2019

7.5.7. Each cable termination / jointing work shall be started and finished on
the same day. Phase identification shall be ensured before the
commencement of the termination work.
7.5.8. Mark the measurements and cut the cable to the required length as
specified in the vendor manual.
7.5.9. Strip the outer sheath, armour wires as per the instruction manual and
mark Red, yellow, Blue on cable cores.
7.5.10. Lift armour wires to insert the support ring underneath and secure
the armour wires with the binding wire.
7.5.11. Remove the bedding to within 100mmof the end of armour wires.
7.5.12. Prepare the core as per the dimension given in the instruction
manual for cable with metal tape shield and / or with wire shield.
7.5.13. Before tightening and sealing the gland, the assembly shall be
inspected for the following: -
o The cable tails are of the correct length and undamaged during stripping.
o The steel-wire armour is stripped to the correct length such that it mates
with but does not protrude through the clamping ring.
o The shield and Mylar is stripped to correct length with sleeve installed.
o Earth tag is fitted as required.
o Ensure that sealing washer is fitted external to the equipment.
o Serrated washers shall be installed in junction Boxes requiring check nuts.
o The outer sheath of the cable is contained within the gland.
o The gland shroud is properly fitted.
7.5.14. After assembly and tightening, the gland shall be checked to ensure:
o The body is securely fitted to the enclosure.
o The gland is mechanically sound.
o The clamping on the steel-wire armour is secure.
o The outer sheath is sealed.
o The gland shroud is properly fitted.
7.5.15. After completion of Glanding, the cables will be checked for
resistance and insulation resistance with panel circuits isolated from
cable loop.
7.5.16. Cables termination shall be performed in an orderly manner. Cable
cores shall not be interwoven, and with screw terminals the
connections should be limited to one per terminal. Common terminals
shall be made by using terminal manufacture's bridging arrangements.
 EPC of Gasoil tanks, LPG Tanks, and related
infrastructure Project Number: PD-0113.018-2

Document Number Document Title Page 11 of 11

PTJ-EL-MST-008 Method Method Statement for 22 Kv Cable Installation
Rev. C01
Date 06/05/2019

7.5.17. Termination materials shall be in accordance with project

specifications.
7.5.18. Ensure that cable lugs are crimped and terminations are fastened
tightly.
7.5.19. All spare conductors shall be marked with terminal number and
connected to terminals, if there are no spare terminals left in the
cabinet, all spare conductors shall be covered with yellow /green
sleeves and marked with relevant cable number
7.5.20. In addition to cable identification, cable cores shall be positively
identified at every terminal point, in accordance with the drawings.
7.5.21. Core markings shall be strictly in accordance with the drawings,
where references are not provided, a system shall be adopted as
agreed with the Customer and recorded on the "As Built” drawings.
7.5.22. Cable jointing shall be as per vendor approved method statement
(Cross Bonding System Installation).

7.6. Testing
7.6.1. Cable joints to be tested by checking insulation resistance of cables
using appropriate Megger/Hi-pot tester.
7.6.2. Cable continuity and phase identification also to be checked.
7.6.3. Test record shall show: Identification of cable including approx.
length, High potential value + leakage current value versus test
voltage + time data.
7.6.4. FOC Cable test: -
 The OTDR Function provides the capability of Measuring
connection loss, fiber loss, and distance of an Optical Fiber.
 wave length will be used by the test equipment (850nm /
1300nm).
 Test result, both graphical and test values, will be saved to the test
equipment for later printing.

8. INSPECTION
 Inspection and test plan (ITP) specific to project requirements shall
be made by PTJ and inspection activities are recorded on the
format as given in Para related documents or client supplied
formats may be used.
 EPC of Gasoil tanks, LPG Tanks, and related
infrastructure Project Number: PD-0113.018-2

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PTJ-EL-MST-008 Method Method Statement for 22 Kv Cable Installation
Rev. C01
Date 06/05/2019

9. ATTACHMENTS:

9.1. CABLE TRENCH CHECK SHEET (PTJ-EL-FRM-

058).
9.2. MV CABLE PULLING WORKS CHECK SHEET
(PTJ-EL-FRM-059).
9.3. FIBER OPTIC CABLE PULLING WORKS (PTJ-
EL-FRM-060).
9.4. MV CABLE JOINTING / TERMINATION (PTJ-EL-
FRM-061)
9.5. MV CABLE INSULATION RESISTANCE TEST
(PTJ-EL-FRM-062).
9.6. High - Potential Test (PTJ-EL-FRM-063)
9.7. Fiber Optic Cable Test (PTJ-EL-FRM-064)
9.8. Job Safety Analysis.