MUDAJAYA CORPORATION BERHAD

METHOD STATEMENT
CABLE INSTALLATION

Reference No. : MCB-MS-01

Rev. No. : 00
Rev Date : 24 JANUARY 2019

PREPARED BY REVIEWED BY REVIEWED BY APPROVED BY

Name : Name : Name : Name :

Designation : Designation : Designation : Designation :

REVISION SUMMARY
Rev. No. Revision Details Rev. Date

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Table of Contents

1.0 SCOPE OF WORK............................................................................................................................... 3

1.1 RESPONSIBILITY ............................................................................................................................. 3
1.2 MATERIAL AND TOOLS .................................................................................................................. 3
1.3 WORK PROCEDURE ....................................................................................................................... 3
2.0 SAFETY AND QUALITY STANDARDS ................................................................................................. 7

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1.0 SCOPE OF WORK

1.1 RESPONSIBILITY

Designated Supervisors are responsible for ensuring that all construction works activities carried
out at site are meet to the project requirements stated in the drawings. The QA/QC Inspectors are
responsible for ensuring that the site carry out installation activities comply with the quality standards
established as per the Approved Drawings. The Construction Manager will verify and certify that the
construction is done as per project specification and meets project quality standards.

1.2 MATERIAL AND TOOLS

Excavator, nylon rope, winch, spade, cable jack, trailer, stands, cable stocking, swivels and
compactor.

1.3 WORK PROCEDURE

Cable Alignment

The alignment will be planned and coordinate with utility mapping drawing and information. The
alignment will be submitted for approval. The final approved alignment will be use for actual
work at site.

Excavation

Excavate the trenches to adequate width, deep and safe working conditions and will comply with
all relevant Acts, Regulations and requirements of public or statutory authorities.

Excavated material in built up areas where permitted, neatly stack reusable top layers of
material such as lawns, pavers, etc on one side of the trench and shall stack the bottom layer of
soil separately on the opposite side of the trench. Surplus material will be transported to
designated location.

Cable Lying

1. Drum Inspection and Mounting

Upon delivery, the cable drum should be visually inspected for defect, which may have occurred
during transport. The manufacturer’s seal on the inner and outer cable ends should be examined
and the condition of armouring, serving and sheath inspected for mechanical damage, corrosion
and leakage of impregnating oil. If the cable is found defective it shall not be installed and the
cable shall be returned to the supplier for replacement.

During installation the cable should be carefully examined for any sign of damage as it leaves
the drum. This is particularly important on the outer layers, where drum batten nails can cause
damage.
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If it is necessary to roll the cable drum, it should be rolled in the direction indicated by the arrow
on the drum.

The drum should be mounted on jacks, cable trailer or cable stands such that the cable is
preferably pulled from the top and always in the direction opposite to that indicated by the arrow.
Lighter cables may be laid by mounting the cable drum on its side on a truck-mounted turntable
and laying the cable directly into the trench. When pulling from large drums, i.e. over 2m in
diameter, the cable should be supported to prevent stressing the cable, from the drum to the
trench on a suitable ramp.

Alternatively, cables can be rolled directly into a trench from the drum mounted on an excavator
moving along the trench.

To limit the chance of damage to the cable prior to removing the cable drum battens,

checking should be done to ensure that the drum-spindle is level and permits even rotation of
the drum.

During pulling there is a tendency for cable slack to accumulate on the drum, slack shall be
avoided and one possible method to achieve this is to limit drum rotation by using plank brake
shoes against one or both flanges of the drum. If the inner end of the cable on the drum, referred
to as the “Z” end, protrudes through the side of the drum, then it should be watched during
pulling to ensure it is not damaged. It is advisable to tie a rope to the Z end, and pull through any
slack cable that appears. Pulling through Z end prevents buckling and possible damage to the
inner coils on the drum.

7.3.2. Drum Positioning

Cable drums shall be positioned in line with the direction of cable pull.

7.3.3 Protection of Cables from Damage

Cables being drawn into place shall be kept clear of abrasive surfaces by suitable means, e.g.
rollers, cable tiles, etc., to prevent any damage to the cable sheath. The cable must be placed in
the trench without sustaining abrasion damage, and without allowing rocks etc., to fall into the
trench.

If the cable is hand flaked directly from cable drum or coil into final position or other method that
does not drag the cable over ground cable rollers are not required.

On long cable runs where a cable changes direction, both horizontal and vertical, rollers shall be
used to ensure a smooth pull and avoid damage to the cable. Cables, which are pulled into
position by a winch, must use suitable cable stockings and swivels to prevent damage.

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2. Cable Pulling Tensions

The tensions of the pull shall not exceed that specified by the manufacturers for the type and
size of cable being pulled and shall be smoothly and continuously applied.

The trench or duct line should be set out so that any necessary deviations from a straight line
occur over the largest possible radius. When pulling cable into duct lines incorporating bends
lower maximum pulling tensions may be necessary to avoid the wire pulling rope cutting into the
side of the duct.

3. Pull Speed

To avoid damage due to overruns, the cable should be pulled just fast enough to keep the drum
rotating smoothly

Higher speeds are possible when pulling small cables into straight trenches or ducts with good
conditions at the feeding and pulling ends. Drums with long lengths of cable, however, should
not be rotated rapidly as overrun can cause cable damage if pulling is slowed or stopped
suddenly

4. Cable bending Radius

Where a 3x1 core HV cable is to be laid to transformers or switchgear, the three twisted cores
can be separated into three individual cores to reduce the minimum bending radius required.

5. Bedding and Backfill

Cable shall be bedded in clean sand.

All cables shall be firmly and uniformly bedded on sand free from rocks or other hard formation.
The cable shall be surrounded with a thickness of sand prior to backfilling, bottom by 150mm
and top by 300mm as shown in drawing.

6. Depth of Cover of Cables

The depth of cover of cables shall be 1,500mm. However, the depth of cover of cables in
nominal cable alignment shall be increased as required so that cables joints will have the
necessary depth of cover.

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7. Cable Cover and Marker Tape

Cable covers, if required and PVC marker tape shall be laid at the required levels, as shown in
drawing.

8. Cable Sealing

On completion of the pull, any pulling eyes fitted should be removed and the cable resealed
unless about to do termination. Resealing is required to repair any damage that may have
occurred to the cable seal through pulling.

9. Pulling through Ducts

Care shall be taken to avoid damaging the outer sheath of the cable where it enters and leaves
the duct. Single core bundled XLPE high voltage cables are particularly susceptible due to their
uneven shape and thin outer sheath. A suitable lubricant should be used to reduce the friction
between the cable and the duct. A tapered or belled entry shall be used at the entry end of ducts
during pulling to prevent damage to cable.

There are numerous methods by which the cable can be pulled into the final installed position.
Generally, the most economical methods employ power winches. If considering only those
pulling methods using mechanical winches, then there are four distinct methods:

Armour Pulling
This system uses the actual armour wires of the cable as the pulling medium. The armour wires,
left extended past the end of the cable, are formed into a pulling eye and the winch rope
attached to it. This method is not applicable to XLPE cables

Stocking Pulling
Cable pulling using a cable stocking is probably the most common form of installation for cable
up to and including 33kV. The cable stocking is slipped on to the end of the cable and the winch
rope attached. On applying tension, the stocking shrinks diametrically until a firm grip is
obtained. Care must be taken when using this method to ensure that pulling tension is not
excessive, otherwise sheath stretch may result.

Nose Pulling
The strength of the cable sheath limits the length and size of the cable that can be pulled by
stocking pulling. For long and large cross section cables, pulling-eyes can be fixed directly to
cable conductors for pulling the cable.

Bond Pulling
When pulling tensions exceed the tension limit of the cable, straight end pulls may have to be
replaced by bond pulls. The cable is lashed to a steel wire rope, which takes all the strain of the
pulling.

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2.0 SAFETY AND QUALITY STANDARDS

The work area shall be prepared and planned to support efficient construction/installation as well
as observation of applicable standards during the course of work.

Safety (OHS) requirements and workplace environmental regulations shall be adhered to

throughout the work period. Job Hazard & Safety Analysis (JSA) shall be used to identify
potential hazards and to implement safe work procedures. Tools and equipment, including PPE,
shall be selected and checked for serviceability and appropriateness for the task.

Quality assurance requirements are identified and shall be adhered to in accordance to job
specifications, contractual and workplace requirements.

Safety work procedure carrying out the exothermically welding works will be provided in the JSA.

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