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METHOD STATEMENT FOR MEDIUM VOLTAGE CABLE PULLING PROCEDURE

Rev. 00

.

Revision

Description

Proj. Engineer Date

Construction Dept.

Prepared By:

QC Manager Checked By:

QA Manager Reviewed By:

Proj. Manager Approved By:

TABLE OF CONTENTS ITEM NO.

DESCRIPTION

PAGE NO.

1.0

SCOPE

3

2.0

PURPOSE

3

3.0

REFERENCE

3

4.0

DEFINITION

4

5.0

RESPONSIBILITIES

6.0

GENERAL REQUIREMENTS

7.0

WORK PROCEDURE – MV Cable Pulling from Existing Manhole

4-7 8

Page 1 of 10

8 - 10

8.0

ABOVE GROUND CABLE PULLING

10 - 11

9.0

ORGANIZATION OF MANPOWER

12

10.0

EQUIPMENT and TOOLS

12

11.0

ATTACHMENT

12

1.0 SCOPE The scope of this procedure shall be MV Cable (15KV, XLPE; size 3C x 120mm2 ) pulling from Switchgear (ampere rating: 1200amps circuit breaker @ Switchgear) to Shipper Pump Motor with 400 Horsepower.

2.0 PURPOSE The purpose of this procedure shall be in accordance with Schedule Q Att. VI table 5.2 revised from Attachment IV table 2.1 as Special Process Procedure and requires SA Inspection Department (ID) for review and comment at least 30 calendar days prior to start of work.

3 .0 REFERENCE Sch. Q SAES-P-104 SAES-P-114 15-SAMSS-502 16-SAMSS-520 SAIC-P-3211 SAIC-P-3212 SAIC-P-3214 SAIC-P-3250 SAIC-P-3325 SAIC-P-3337 SAES-Q-001 SAES-A-114 QA/P1361 QA/P1331 SATIP SAIC SATR

- Quality Requirements - Wiring Methods and Materials - Power System and Equipment Protection - MV Power Cable 5KV through 35KV - Cable Bus - MV UL/NEC Cable, Material Receiving - MV IEC Cable Material Receiving - MV Cable Installation and Pre Commissioning (Rated 25KV through 35KV) - MV Cable Bus Installation and Pre Commissioning - Conduit EMT and FMC Raceway System (NHL) Installation and Pre Commissioning. - Duct bank/Manhole/Hand-Hole Grounding and Bonding, Installation and Commissioning. - Criteria for Design & Construction of Concrete Structure - Excavation and Backfilling - Inspection and Testing for Electrical Works - Inspection and Testing of Concrete Works - Saudi Aramco Typical Inspection Plan - Saudi Aramco Inspection Check Lists - Saudi Aramco Test Report

Page 2 of 10

4.0 DEFINITION: SAPMT PID SAES

- Saudi Aramco Project Management Team - Project Inspection Division - Saudi Aramco Engineering Standard

PM CM EPE QAM QCM PQCS

- Project Manager - Construction Manager - Electrical Project Engineer - Quality Assurance Manager - Quality Control Manager - Procurement Quality Control Supervisor

PQP Inspection C HSE MS MV

- Project Quality Plants Project Quality Plan Project E Plan - Health, Safety and Environment - Method Statement - Medium Voltage

5.0 RESPONSIBILITIES Project Manager 5.1.0 Project Manager (PM) shall be responsible for the overall implementation of the Company Safety Plan and this Work Procedure. Ensure compliance by all parties to this procedure, the quality assurance manual, QC inspection plan and relevant customer specifications drawings and industry codes.

Electrical Project Engineer 5.1.1 Management of major work packages, covering project phases for successful delivery of the project to the Client within the budget and schedule 5.1.2 Develop relevant various project electrical procedures, review and check all assigned project electrical installation drawings for compliance with Client Standard requirements, project specifications, international standards and regulations, (electrical equipment, location drawings, plan drawings, details, schematics, wiring diagrams, etc.) and vendor /manufacturer’s technical recommended instruction for installation and post-installation requirements. 5.1.3 Assist in the development of project schedules and manpower requirements. 5.1.4 Coordination of works throughout the project phases to ensure successful completion of the work activity.

Electrical Field Supervisor Page 3 of 10

5.1.5 Electrical Field Supervisor shall ensure that foreman, electricians and labors comply with the requirements of the approved procedure, latest revision of IFC drawings, inspection test plans, safety requirements, availability of all required tools, calibrated testing equipment and all necessary work permits secured / obtained before start of work. 5.1.6 Participate during pre-commissioning, verification of test requirements and assist in electrical equipment check-out and startup.

Quality Control Manager 5.1.7 QC Manager ensures implementation of the approved Project Quality Plan, Schedule Q requirements ; checks project specific procedure/s prior to submittal for client approval ensuring that all client inspection and test, standard requirements have been identified. The documents are complete wherever necessary and the appropriate inspection and approved QC discipline inspectors are available at site.

Procurement QC Supervisor 5.1.8 PQCS is responsible in implementing the requirements of Att. III Quality Requirements for Contractor Supplied Materials and crossed reference to the approved PQP. Perform review of MRs of various project materials, 9COM verification, inspection levels, preparation of IAPs. Coordinate with Vendor/Manufacturer, SA Approved TPIs & SAVID for all related vendor inspection activities. Also, Inter act with Engineering, SAPMT, SAVID in the review and final approval process for all MR’s for thorough evaluation, verified for suitability, performance reliability to specific engineering design, operability to comply with the standard requirements.

Quality Control Discipline Inspectors 5.1.9 QC Discipline Inspectors shall ensure the proper implementation of the approved PQP & procedure. 5.2.0 QC Discipline Inspectors shall conduct pre-inspection activity verifying the compliance corresponding to the appropriate SAIC and readiness for the inspection. Appropriate RFIs to cover the stages of the MV Cable Pulling installation activities shall be raised. PID participation is necessary to verify and ensure that the process is satisfactory and in line with the requirements. 5.2.1 Full inter-active coordination with Construction Field Electrical Supervisor related to ongoing and forecasted activities to ensure coverage of various activities relevant to achieving satisfactory finish product. 5.2.2 QC Discipline Inspectors shall continue site monitoring of the activities carrying out surveillance, preventive actions in the process for potential non conformities, corrective actions to prevent recurring standard violations. Should Non-Conformity have been committed; INCR shall be raised and reported within 48 hrs to client with the necessary corrective actions. 5.2.3 QC Discipline Inspectors shall prepare the necessary daily inspection reports using the appropriate SATR. QC Inspection reports and records shall be properly filed for easy reference and retrieval.

SAFETY – Safety Supervisor 5.2.4 SAFETY Supervisor shall ensure that all work permits (i.e. confined space, hot, cold works, etc) are available prior to commencement of any work at the site. 5.2.5 Investigate unsafe conditions reported to you, and ensure that corrective action is taken without delay. Page 4 of 10

5.2.6 To conduct tool box meeting stressing to each and every individual in observance of safety working conditions at all times, compliance tor safety requirements, i.e. use of proper PPE. To remind everyone to avoid unsafe practices at the project site. 5.2.7 Heavy Equipment shall be inspected and approved for use in the project by the client. This equipment shall undergo monthly inspection. 5.2.8 Heavy Equipment operators shall be certified and approved by the client 5.2.9 To liaise with Field Supervisor ensuring that work is carried out in accordance with the Project Safety Plan. a. Physical Safety of Worker on the Site b. Job Safety Analysis c. Safety at Work 5.3.0 Plan of precaution for the hygiene and physical Safety Worker on the Site. 5.3.1 Safety for people pulling cables will be insured by providing adequate platforms, using safety belts/harness while working at high elevations, having accessible equipment for deployment at urgent notice etc. 5.3.2 All the workers shall be provided with safety equipment’s ensure that the same worker himself is using them in a proper way. 5.3.3 Our staff has the responsibility to check workmen are wearing proper PPE on site daily 5.3.4 If the worker will be found not wearing proper PPE, the supervisor will stp him and make sure he wears it immediately. 5.3.5 The item issued to the worker must be periodically inspected and changed if it is damaged or does not respect the specified conditions. 5.3.6 Personal Protection Equipment. 1. Earing protection Ear Muff or Plugs. (If Required) 2. Helmet, Hard Hat 3. Hand Globes (Leather or Cotton) 4. Dust Mask respiratory protection (If Required) 5. Glasses splinter Proof 6. Safety Belts/Harness (If Required) 7. Safety Shoes 8. Summer/Winter Clothing 9. Equipment and Clothing for body protection 5.3.7 Safety and Environmental Consideration must be ensure that all final electrical connections to MV-LV equipment workers to takes place in a safe manner, contractor will consider the suitability of: A- The workers B- Work on height C- Power tools D- Cable drum/s setting A- The workers –were trained and certified for the job. The workers must be healthy. The workers must be trained for safe working. Page 5 of 10

Personal safety equipment will be used all the time. Safety Officer 5.3.8 The Safety Officer is responsible for monitoring and assessing hazardous and unsafe situations and developing measures to assure personnel safety, i.e. correct PPE is worn. 5.3.9 Participate in planning meetings to identify any health and safety concerns inherent in the operations daily work plan. 5.4.0 The Safety Officer will correct unsafe acts or conditions through the regular line of authority, although the Safety Officer may exercise emergency authority to prevent or stop unsafe acts when immediate action is required. 5.4.1 The Safety Officer maintains awareness of active and developing situations. 5.4.2 The Safety Officer ensures the Site Safety and Health Plan is prepared and implemented. 5.4.3 The Safety Officer ensures there are safety messages in each Incident Action Plan.

6.0 GENERAL REQUIREMENTS 6.1.0 Ensure that all IFC drawings are of latest revisions and have been issued to field supervisors handling the underground cable pulling installation. 6.1.1 All materials and documentation relevant to a particular section of works will be checked by the Construction Department prior to the Commencement of works ensuring that these are of correct type as reviewed. 6.1.2 Before commencement of any permanent works pre-inspection will be carried out on all materials prior to them leaving the storage area. Prior to the commencement of permanent works, areas and access will be inspected to confirm they are in a suitable condition for permanent works to commence. The Client is invited to attend this inspection 6.1.3 Ensure that all related work procedures are approved by the client and has been issued to the field supervisors to start the work. 6.1.4 Underground duct banks and concrete trenches shall be constructed and duct banks are mandrel tested prior to start of the cable pulling. 6.1.5 Check and ensure that cables to be installed are correct size, type, length, and are in conformance with the cable schedule, cutting list and project specification. 6.1.6 Generous applications of lubricant are expected at the start of a cable installation. Constant lubricant application is ideal, based on raceway and conductor factors. Lubrication is inexpensive compared to trying to free up a jammed cable during the cable pulling. 6.1.7 Ensure that cables which are to be laid have been MEGGER Tested. 6.1.8 The installation must be carried out carefully, avoiding any impact on the

properties of the cable. 7.0 WORK PROCEDURE- MV Cable Pulling from Existing Manhole 7.1.0 Cleaning and complete removal of sand, debris, dust inside the existing manhole to ensure safe working environment.

Page 6 of 10

7.1.1 Insert guide wire/rope in the spare conduit to be used relevant to Cable pulling by winch from SIB building onwards to Shipper pump equipment. 7.1.2 The entire route shall be inspected to ensure that the routing is complete, proper bends are used and free from any sharp edges. 7.1.3 Cable rollers shall be placed as required on the cable route. 7.1.4 Cable winch shall be positioned in proper place for cable pulling. 7.1.5 The cable drum intended for cable pulling shall be identified as per indicated in the drum schedule. 7.1.6 The cable drums shall be un-packed. Note: Using of 20 tones telescopic Crane shall have spreader bar to avoid damage of cable drum. 7.1.7 The cable shall be fixed to the winch, if used by means of a cable sock or gripper. 7.1.8 Required number of persons will be posted at winch and near the drum. 7.1.9 Cable lying will generally start from one end of the route length or at any suitable point if required. 7.2.0 In case of cable length which is more than one drum length, all cable which can be laid from original position will be completed. And then the cable pulling set-up will be re-positioned to the next location, from where the next length will be pulled. 7.2.1 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. 7.2.2 Suitable cable stand shall be placed firmly on the ground and jacked-up to allow clearance from the ground depending on the size of the cable drum. 7.2.3 The drum shall be lifted by required equipment and placed on the cable stand. 7.2.4 The cable drum will be correctly positioned and the direction of cable pulling as indicated by arrow on the drum shall be complied. 7.2.5 Cables will be laid / pulled by hand and / or winch. 7.2.6 During pulling with winch, the tension on the cable will not exceed the recommended instruction manufacturer and this will be monitored by means dynamometer. 7.2.7 Cables will be pulled according to drum cable cutting schedule and as shown in the relevant drawings. 7.2.8 Bending radius of cables shall comply with cable manufacturer’s recommendation. 7.2.9 Before cutting the cable, both ends must be inspected to ensure sufficient length is for proper dressing and end termination. 7.3.0 The open ends will be sealed till termination. 7.3.1 Soon after completion of every cable pulling the cables will be tested for insulation resistance. 7.3.2 Cable identification tags shall be installed soon after the cable pulling. 7.3.3 Cable tags shall be installed as per client specification-identification. 7.3.4 The cable schedule and drum schedule will be updated with the information on cable pulling. Page 7 of 10

7.3.5 Daily progress report will be submitted for the activity as well as summary of used cable for each drum. 7.3.6 After completion of the cable pulling installation, all cables in the same route shall be dressed and clamped. 7.3.7 Inspection of installation and punch list shall be carried out accordingly. 7.3.8 Cable joint position, if any will be shown on the drawings. 7.3.9 As built markup drawings certified by contractors supervisor and engineer will be prepared. 7.4.0 Empty cable drums will be transported back to the store.

8.0 Above Ground Cable Pulling 8.1.0 Cables shall be laid mainly above ground in cable trays perforated and ladder type. 8.1.1 Cable rollers shall be placed at every 6-12 meters or less if required to avoid touching of the cable to tray. 8.1.2 Cable winch if used shall be positioned in proper place for cable pulling. 8.1.3 The cable drum intended for cable pulling shall be identified as per that indicated in the drum schedule. 8.1.4 The cable drums shall be unpacked. 8.1.5 The cable shall be fixed the winch by means of a cable sock or gripper. 8.1.6 Required number of persons will be posted at the winch, if used and near the drum. 8.1.7 Cable lying will generally start from one end of the route length from other suitable point if required. 8.1.8 In case of cable length which is more than one drum length all cables which can be laid from original position will be completed. And then the cable pulling set up will be re-positioned to the next location, from where the next length will be pulled. 8.1.9 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. 8.2.0 Suitable jack shall be placed firm ground and jacked-up to allow clearance from the ground depending on the size of the cable drum. 8.2.1 The drum shall be lifted by required equipment and placed on the jacks. 8.2.2 The cable drum will be correctly positioned and the direction of cable pulling as indicated by arrow on the drum shall be complied. 8.2.3 Cables will be laid / pulled by hand and / or winch. 8.2.4 During pulling with winch, if required the tension on the cable will not exceed that given by the manufacturer and this will be monitored by means dynamometer. 8.2.5 Cables will be pulled according to drum cable cutting schedule and as shown in the relevant drawings. 8.2.6 Bending radius of cables shall comply with cable manufacturer’s recommendation. 8.2.7 Unless the length exceeds the maximum drum length joint shall be avoided.

Page 8 of 10

8.2.8 Before cutting the cable, both ends must be inspected to ensure sufficient length is for proper dressing and end termination. 8.2.9 The open ends will be sealed till termination. 8.3.0 Soon after completion of every cable the cables will be tested for insulation resistance. 8.3.1 Cable tags shall be installed as per client specification no. 8.3.2 The cable schedule and drum schedule will be updated with the information on cable pulling. 8.3.3 Daily progress report will be submitted for the activity. 8.3.4 After completion of all cables in the same route the cables shall be dressed and clamped. 8.3.5 Interval of clamping will be as per client specification no. but will not exceed 10 meters for the horizontal runs and 1.0 meters for vertical runs. 8.3.6 When single core cables are used the laying shall be in three-foil formation (trefoil). 8.3.7 Inspection of installation and punch list. 8.3.8 Cable joint position, if any will be shown on the drawings. 8.3.9 As built markup drawings certified by contractors supervisor and engineer will be prepared. 8.4.0 Empty cable drums will be transported back to the store.

9.0 ORGANIZATION OF MANPOWER      

Project Manager Project Engineer Project Supervisor Group Leader 3 Electrician 30 Persons Cable Laying Team (Approximately) Depending on the type of cable and length.

10.0 EQUIPMENT and TOOLS In general the main equipment and tools to be used for the cable pulling installation are listed below:  1 Crane 20 tones Capacity, telescopic shall have spreader bar to avoid damage of cable drum.  1 Truck / Trailer Page 9 of 10

             

1 Pick Up 1 Set Cable stand 10 Tons Cable Pulling Winch 1 - 5KV Insulation Resistance Tester MEGGER Tester Multi Tester Slings Crowbars Measuring Tape 50 meters Cable Cutter Hacksaw Frame and Blades Drum Jacks Spindle Lubricant Cable Roller

Note: Using of 20 tones telescopic Crane shall have spreader bar to avoid damage of cable drum.

11.0

ATTACHMENT 11.1

Drwg. No: VA-014237-002 Rev.03A

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