SCOPE
2 REFERENCE DOCUMENTS
3 DEFINITIONS AND ABBREVIATIONS
4 AUTHORITIES AND RESPONSIBILITIES
5 METHODS AND GENERAL GUIDELINES FOR CABLE GLANDING AND
TERMINATION
5.1 General Requirements
5.2 Preparation, Glanding and Dressing
5.3 Termination and Torque Test
6 TOOLSANDEQUIPMENT
7 INSPECTION /TESTING
Low Voltage Cable Glanding and Termination Procedure & Method Statement
This Method Statement covers the installation for Cable Glanding, Dressing and Cable Termination of low voltage cable to be carried out in SEC Construction of Electrical Installation Works. This method was prepared as guideline for effective enforcement of work thus; construction personnel have to determine the applicability and feasibility of this MS in accordance to single line and interconnection drawing and cable schedule, Project specifications and standards and relative quality documents.
2 REFERENCE DOCUMENTS
a) Applicable I Approved International Standards
b) Issued For Construction Drawings
c) Manufacturer Instructions
3 DEFINITIONS AND ABBREVIATIONS
List of Abbreviations
IEC International Electro-technical Commission
NEC National Electrical code
NEMA National Electrical Manufacturers Association
RFI Request for Inspection
MRR Material Receiving Report
NCR Non-Conformance Report
4 AUTHORITIES AND RESPONSIBILITIES
Site Manager – Determine all requirements needed in order to comply with contractual requirements and safety standards.
Construction Manager – Lead all construction activities and enforce strict adherence to all project requirements.
Electrical Superintendent -Ensure that work once started is carried out as planned and that the applicable standards are complied with. Check working methods and precautions tobe taken by the supervisors/foreman before commencing work.
Field Engineer — Ensure that all related works are carried out in accordance with approved Released for Construction drawings, specifications, schedule, quality and safety. Report to Construction Manager.
Safety Officer — Ensure that “Safety, Fire, Loss Prevention” program or Safety Plan was been implemented and monitored.
Supervisor / Foreman – Supervise all field installations Reports to Electrical Superintendent.
QC Inspector – He shall be responsible for conducting surveillance and inspection duties for work and ensuring quality compliance and efficient recording and reporting of results as required. He shall review all relevant documents, material conformance certificates and non conformance reports and shall receive all internal requests for inspection from various sections of implementing work and prepare (RF!) Request for Inspection as per schedule work priorities and proceeds the Quality inspection with the client, owner representative as required.
5 METHODS AND GENERAL GUIDELINES FOR CABLE GLANDING AND TERMINATION
5.1 General Requirements
a) All cables to be terminated in dry conditions regardless of whether the installation is internal or external to buildings.
b) Cables to be terminated at each end by a compression gland, with each conductor being connected using a compression type lug.
c) Glands when ever specified will be protected with LSF shrouds:
d) Cores of all control cables shall be long enough to allow a second termination at a future date.
e) Wiring ferrules will be of the interlocking type, be unaffected by oil or damp, and be clearly and durably marked.
f) The details for the termination can be as described below:
• Each conductor of cable shall be long enough to reach the most distant terminal point in the equipment being installed. Loop and tie The conductors in a bundle.
• Strip cable jackets as far back as needed to accommodate the termination of the Conductors. For cabinets with a high density of cable jackets may be stripped to the point of entry of the cabinet.
• No soldering of wires is permitted.
• Self-insulated, locking fork type lugs to be used on wiring terminations on terminal strips and at motor terminal boxes. Crimping tool used must be approved by the terminal lug manufacturer and shall crimp both the conductor and insulating sleeve.
• Motor lead terminations shall be bolted together with the ring tongue type terminals and tin plated bolts of the appropriate size.
• A ratcheting type crimping tool shall be used that will not release until the proper size crimp has beencompleted.
• Removal of insulation from cables to be performed using company approved stripping tools. For large cable sizes, the removal of insulation may be by hand. In baring conductors, care to be taken to avoid nicking strands.
• All loose ends of cables, wires, and instrumentation cables shall be sealed with three laps of tape or a heat shrink or cold shrink cap to prevent moisture damage. Loose ends of cables on reels, in junction boxes, manholes, trays, and other areas shall be sealed until final termination is complete.
5.2 Preparation, Glanding and Dressing
a) Prepare all the necessary materials/ tools required. Verify cable glanding materials, terminal lugs and cable sleeve are of correct size and conforms to project requirements. Check materials for any physical damage.
b) Check availability of all approved Released for Construction drawings and schedules.
c) Ensure that a worksite location has been released and ready for safe work execution.
Cable Glanding and Termination is carried out by technically qualified and competent personnel.
Note: Safety precaution must always takes place during termination activities which includes verification of cable in de-energized condition and strict compliance to Lock-Out/Tag-out procedures.
d) Generally, cable gland has to be installed in cables and dressed as close as possible to the equipment. Check if the equipment to which cables are to be glanded is in final location and is permanently bolted down.
e) Check if the cables to be glanded are correct by carrying out a continuity check on all cables. Make sure that the cable gland used for the cable is the correct size.
f) Remove the equipment gland plates. Using the list of cables to be glanded and if possible the panel layout showing position of terminal blocks; mark-out and cut the required holes plus a few spares and refit the gland plates.
g) Dress the final portion of the cable up to the equipment and mark the position of the gland. Leave sufficient cable to reach the furthest termination point in the equipment.
h) Fit the moisture seal and tighten the lock nut with special spanner. If applicable, slide the gland shroud into position to cover the gland. Closed any unused holes in the gland plate.
i) Immediately after cable glanding, fix a permanent cable number marker.
j) For Power cable termination, spread and shape cores to terminal leaving sufficient core length to disconnect and reconnect without undue stress to the core insulation. Apply heat shrinkable sheath at the stripped end to protect and dress the cable.
k) Select cable lugs that suits the conductor, terminal size and segregation. Apply the cable lugs to the core; be aware that MV lugs are different than low voltage lugs even for the same cable core section.
I) Mark the cable end for stripping of the insulation by considering length of the Jug’s barrel. After stripping the cable, suit the cable lug to the core and crimp. It is imperative to use the correct crimping equipment with the correct die sets and correct punch.
m) Check lugs for any loose and sharp edges and apply insulation tape to the crimped part and the core insulation end.
n) For Control Cable terminations, solid copper cores in multi-pair cables may not have crimped terminations. These cores can be terminated directly into screw clamp terminals. Strip only sufficient insulation to allow conductor contact in the terminal.
o) Carry out test on control cables to prove its integrity. When testing is complete, install the cable end protective sleeve, loom cores up to terminals using trunking where available, or tie wraps to tie looms to support bars or trays.
5.3 Termination and Torque Test
a) Before permanently connecting the cable core to the terminal, ensure that the test for continuity and cable insulation has been done. On successful completion of cable test, connect cores to terminals using correct fasteners (bolts, nuts & washer) tightened to torque settings as applicable.
b) Published torque setting by the manufacturer/Contractor will be used and:
• Torque wrench must be calibrated
• Correct size and die to sit on the bolt
• Terminal lugs were checked for correctness and loose
• Tightened the bolt and once the click sound was heard check the termination for any damage or loose
• Mark the bolt after passing the torque test
c) Terminate Control Cables according to latest revision of connection diagrams, apply core markers and spare cores shall be left long enough to reach the most remote terminal in a panel, loomed together by cable and dressed neatly within the loom or trunking.
d) On completion on any termination works, ensure that the panel, marshalling box or equipment is cleared of all debris and that trunking covers are replaced.
e) Marked-up/ As-built drawings for any changes made.
f) Clean the area.
6 TOOLS AND EQUIPMENT
a) General tool kit
b) Cable cutting tools (hydraulic cutter, manual cable cutter, and hacksaw)
c) Cable stripping tools
d) Crimping equipment – Manual
e) Crimping equipment – Hydraulic
f) Torque Wrench
g) Cable and core marking system
h) Continuity Tester
7 INSPECTION/ TESTING
All inspections to be coordinated by QA/QC Inspector, who will implement the inspection program and notify all parties involved in advance of the scheduled dates of inspection to enable them to participate. Relevant records will be signed by all the required parties. Originals will be kept by Site QA/QC Department.
Final erection checks to be carried out in accordance with approved ITP. Erection Check Sheets and Tests sheets to be completed and signed. Inspections will be done per level, area or drawings.
Please note that any test equipment or tool serial numbers, such as megger, continuity tester, torque wrenches, must be included on the relevant test and check sheets with valid calibration certificate to comply with the quality plan.
Step by Step Guide of Low Voltage Cable Glanding and Termination
Explain in detail the steps that must be taken to ensure that the task is carried out safely (include drawing and sketches where required, include pre commencement of work activities and the work itself in a chronological manner).
A. Verify IFC drawings availability
B. Verify Documents for QC material receiving inspection
C. Preparation of Tools and Materials
D. Installation of Cable Glands
E. Dressing of Cable
F. Final Termination of Cable
A. Preparation of Tools and materials (Ensure pennit to work must be obtain, prior to start the activity. Conduct toolbox talk prior to the task to be done. And wearing of PPE to all personnel. All tools and equipment is in good condition)
8. Installation of Cable Gland (Competent person to perform the task. Ensure wearing of proper PPE. Area must be barricade during testing and tools and equipment must be inspected and good condition. Proper positioning technique. Use Full Body Harness and 100 % tie off when working at elevated areas)
C. Cable Dressing (Arrangement of cable to panel/equipment, personnel must use PPE and when using Portable ladder it must be 4: I slope and one person holding to secured the ladder. use Full Body Harness 100% tie off when using scaffolding. Conduct housekeeping all cable ties must be collected and put on garbage bag)
D. Testing Insulation resistance (Area must be barricaded conduct toolbox talk prior to do the task only authorized personnel on the area during testing proper coordination must be observed. Test equipment calibrated and in good condition).
E. Final Termination (Only certified electrician should do the tennination use proper PPE when working use proper tools for the tennination all tools must be inspected. Torque wrench calibration).
F. Daily housekeeping (Full supervision on the area remind personnel for safe working and good housekeeping on the area should be done before and after the work ).