220 KV SWITCHYARD PACKAGE

FOR

REVIVAL OF
RAMAGUNDAM FERTILIZER COMPLEX
(Bidding Doc. No.: SM / A747-301-EB-TN-0015/1015)

JOB PROCEDURES
FOR
CABLE LAYING & TERMINATION

PROJECT NO.: A747

For Approval
JOB PROCEDURE FOR CABLE LAYING
AND TERMINATION

PROJECT :REVIVAL OF RAMAGUNDAM FERTILIZER PLANT

NAME OF WORK :220 KV SWITCHYARD PACKAGE

JOB NO :A747

LOA NO : SKS/A747/LOA/T/0015/1016/2016 – 17/05 dtd. 09/11/2016

OWNER :M/S RAMAGUNDAM FERTILESERS AND CHEMICALS LTD.

CONSULTANT :M/S ENGINEERS INDIA LTD.

CONTRACTOR :M/S L&T

L&T L&T EIL EIL

SIGN SIGN SIGN SIGN

NAME NAME NAME NAME

DATE DATE DATE DATE

Prepared by Approved by Reviewed by Approved by

CONTENTS

1.0 PURPOSE -4
2.0 CODES & STANDARDS -4
3.0 GENERAL INSTALLATION PROCEDURE -4
4.0 TERMINATION -6
5.0 TESTING AND COMMISSIONING -8
 Name of the Work : 220 KV SWITCHYARD PACKAGE FOR REVIVAL OF RFCL
Job No : A 747
Job Procedure No : L&T/RFCL/A747/E/JP 05 R-0

PROCEDURE FOR CABLE LAYING & TERMINATION

1.0 PURPOSE:

This Job procedure describes the installation of cable laying and termination for
wherever applicable installation and testing commissioning of cable installation.

2.0 Codes & Standards

The earthing installation conformes to the following latest standards/statutory provisions.
IS:1255, IS:10810(Part-43&45), OISD173

2.1 REFERENCES:

1. EIL specification – 6 – 51 – 0082 Rev 4

3.0 INSTALLATION PROCEDURE FOR HV CABLES

1. Prior to start the installation of high voltage cables, refer to the approved shop drawings related to
the area of installation and ensure that required materials are available at site as per approved
material submittals.
2. Ensure the materials are stored properly and there is no mark of damage or deformity of any  kind
before issuing the material from site store.
The cable drum will be inspected prior to shifting to site for any mechanical and structural damage during
transportation.
3. Ensure the installation of HV Cables are carried out in accordance with manufacturer’s and local
authority  installation recommendations, requirement of applicable standards and in accordance with
recognized industrial practices and specified in project specification to ensure that installation complies
with requirements

3.1 INSTALLATION PROCEDURE FOR UNDER GROUND HV CABLES

 The total cable route shall be inspected to ensure that the routing is complete, as per
approved layout and free from any sharp edges ,etc. and it is coordinated with other external
services.

 Size and length of the cables to be checked by the Engineer In charge and Supervisor
before cutting the HV cables. As per cable cutting schedule, site electrical supervisor will ensure
that the cable drums are shifted to the required locations.

 Cable drums are to be positioned on jockeys and cable end to be left from the top.

 Rollers are to be placed in regular intervals according to cable route while pulling the cables
and rubbing of cables on ground shall be avoided to protect the cable insulation.

50
 Cable laying shall be started by rotating the drum in a direction, recommended and marked side of
the cable drum and cables are pulled, accordingly.

 Insulation resistance of HV Cable should be checked by using 5 kv megger after installation

and before termination of cables and readings shall be submitted to the consultant.

 The width of the cable trench shall be maintained minimum 800 width and 1000 mm
depth according to the number of cables for buried cables.
  Install a cable marker at each change in cable direction, joint position and entry points to buildings.

 Cables installed in ground shall be laid in a single, horizontal layer spaced 450mm apart.

 Obtain Consultant’s approval before cables are covered and trenches back-filled.

 All cables shall be installed with approved identification bands at each end and over their
entire length at 30mtr intervals.

 HV cable termination should be done as per approved specification and by authorized /

certified technician under the supervision of Engineer in charge.

 Site Engineers or Site Supervisors should ensure the approved shop drawings of latest revision are
followed and approved materials are used for installation.

3.2 INSTALLATION PROCEDURE FOR HV and LV CABLES ( IN TRAY )

 The total cable route shall be inspected to ensure that the routing is complete, as per
approved layout and it is coordinated with other services.

 Size and length of the cables to be checked by the Engineer In charge and Supervisor
before cutting the HV cables. As per cable cutting schedule, site electrical supervisor will ensure
that the cable drums.

 Cable drums are to be positioned on jockeys and cable end to be left from the top.

 Rollers are to be placed in regular intervals according to cable dia while pulling the cables
and rubbing of cables on ground shall be avoided to protect the cable insulation.

 Cable laying shall be started by rotating the drum in a direction recommended side of the
cable drum and cables are pulled.

 Insulation resistance of HV Cable should be checked using by 5 kv megger after installation

and before termination of cables and readings shall be submitted to the consultant approval.

 The trays shall be curved enough at the right angles to allow the cable with correct bending radius.

 Where more power cables are run together, Adequate cable tray should be provided considering the
spacing as per specification. Spaced apart by at least one cable diameter (of larger
cable) throughout the length of the cable run.

 Cables shall be identified at the both ends by identification bands as per approved material
and approved cable schedule.

50  Cables shall be dressed properly ,secure cables to cable tray using cleats where the cable is
fixed to a vertical cable tray or ties where the cable tray surface is horizontal without
any overlapping and it will be ensured that the cable distance is maintained as per approved  shop
drawing.

 Earth conductor shall be laid parallel along with cables. Where cables passes through a floor or fire
barrier, fire stopping material should be provided and that area should be sealed properly from both
sides.

 On completion of cable laying and dressing, continuity and insulation resistance tests with
( 5kv) Megger shall be carried out and shall be recorded subject to approval. Cable ends shall be
earthed and sealed properly.

 All conductors requiring bolted connections shall be terminated with compression lugs, using
an automatic compression crimping tool.

 Cable lugs shall be tinned copper compression heavy duty type. Terminations to be carried out as
per standard and approved procedure. Wiping type Cable glands to be used of approved quality as
  HV Cable Earthing shall be done as per local authority regulation, specification and
approved drawings. After inspection of HV Cable and approval by authority and Consultants, proper
care will be taken to protect the unit from dust by suitable covering, and shall further be released for
the Testing work.

 Cables shall be neatly arranged in the trench/trays in such a manner that driss-crossing is avoided
and final take off to the switchgear is facilitated.

 Arrangement of cables within the trenches/trays shall be in line with cable layout drawings. Cable
routing between the trench and equipments shall be taken through GI pipe sleeves of adequate
size. pipe sleeves shall be laid at an angle of maximum 45 to the trench wall. bending radi of the
pipe shall not less than 12D.

 Both end of the pipe end shall be sealed approved weather proof sealing component after cabling.

 All the cables shall be identified close to their termination point by cable tag number as per
schedule. Cable number shall be punched on a aluminum/lead strips (2mm thick, 20mm wide and of
enough length) securely fastened to the cable and wrapped around it.

 All temporary ends of the cable shall be protected against dirt and moisture to prevent damage to
the insulation. the end of the cable shall be covered PVC cap or rubber insulation tape.

3.3 CABLES LAIED IN CONCRETE TRENCH

Cables shall be laid in 5 or 6 tiers in concrete trench as shown on layout drawings. concrete cable
trenches shall be filled with sand dust in the hazardous area to avoid accumulation of hazardous gases
and oil. RCC covers of trenches shall be effectively sealed to avoid ingress of chemical and oil in process
area.
Minimum depth of the concrete trench shall be 500mm for all voltage grades with 300mm clearance
between the bottom of the trench cover and top of the cable.The depth and width of the cable trench
shall be depend on layer of the cable and provide bending radius as per specification.

3.4 CABLE LAYING IN ABOVE GROUND

 Cables installed above grade shall be run in cable trays, clamped on walls, ceiling or structure and
shall be run parallel or at right angle to beams wall or columns.

 Cable routing shall be planned to be away from hot pipes, oil pipes and water pipes etc. each cable
tray shall be contain one layer for power cables.

 Individual cable or small group of cable upto 3 cables shall be run along structures/ walls etc.shall
be clamped by means of 16SWG GI saddles on 25x6mm saddle bar. The saddle shall be made
300mm interval.

 All cable trays and support angle shall be painted before laying the cable.

50  The cable rise from the trench, lighting panel or control panel shall be taken in GI pipe for
mechanical protection for cables as per approved layout drawings.

 GI pipe buried in the soil shall be bitumen coating applied.

 For 1 cable in a pipe - 53% of pipe cross section area occupied by cables.
 For 2 cables in a pipe- 31% of pipe cross section area occupied by cable.
 For 3 cables in a pipe- 43% of pipe cross section area occupied by cables.
 4 and above cables in a pipe- 40% of pipe cross section area occuiped by cables.

4.0 TERMINATION

 All the cable up to above the 1100V grade and higher levels shall be terminated at the equipment by
means of compression type cable gland suitable for the cable size. All the cable entry for the
outdoor termination shall be bottom entry.

 Power cable wherever colour coding is not available shall be provide RYB PVC tapes.

 Copper and aluminum connection are made necessary bimetallic washer shall be used.
  All unused spare cores shall be ferruled and bunched in both ends for future use.

 The cable shall be terminated at electrical equipments/switchboards through glands of proper size.
cable shall not be exposed after termination is completed.

 Crimping of lugs to cable leads shall be done by hand crimping hydraulically operated tool as per
requirements. Insulation of the leads shall be removed before crimping. Conductor surface shall be
cleaned and shall not be left open.

 The number of joints shall be restricted to minimum as soon as possible.

 The location of the joints shall identified with permanent marker.

 The joints and termination of HV and MV cables shall be carried out by trained personnel only.

 Cable glands installed in the outdoor shall be provide shrouds with suitable size.

5. TESTING AND COMMISSIONING

 Field testing and commissioning of electrical installation shall be carried out as per EIL
specification.

 Before energizing, the insulation resistance of every circuit shall be measured from phase to phase
, Ph to N and from PH/N to earth.

 Where splices or termination are required in circuits rated above 650V insulation resistance of each
length of cable shall be measured before splicing and or/ terminating after completion of splices
and/or termination measurements shall be repeated.

 The insulation resistance of directly buried cables shall be measured before cable trenches are
backfilled. Measurement shall be repeated after back filling. For cables upto grade 1000 V megger
and for HV cables 2.5/5 kv megger shall be used.

 DC high voltage test shall be conducted on cables for 1100 volts power cable which is straight
through joint made and all the cable above 1100V.

 During the high volt test all other electrical equipments bus bars, instruments etc clearance shall be
maintained.

 All checks and test shall be made as per EIL standard test performa available with site engineer.
 All the test reports shall be recorded and submitted to EIL in triplicate sets.
 Cable schedule, cable layout drawings, interconnection drawing shall be revised and AS BUILT
STATUS shall be submitted to EIL.

DOCUMENTATION

50 CABLE LAYING DOC NO- L&T/RFCL/A747/E/ITP-04 R-0

CABLE TERMINATION DOC NO- L&T/RFCL/A747/E/ITP-04A R-0