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PROCEDURE FOR CABLE LAYING &TERMINATION.

PROCEDURE FOR
CABLE LAYING &TERMINATION

PROCEDURE NO : PROCEDURE/CABLE//03-1

9.10.2012
PREPARED BY CHECKED BY APPROVED BY
DATE (SUBCONTRACTOR/CONTRACTOR) (CONTRACOR) (CLIENT/CONSULTANT)
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PROCEDURE FOR CABLE LAYING &TERMINATION.

CONTENTS:

1. PURPOSE

2. SCOPE

3. REFERENCE DOCUMENTS

4. PREREQUISITE

5. PRECAUTION

6. EQUIPMENTS/INSTRUMENTS & ACCESSARIES

7. PROCEDURE.

8. TESTING .

9. ACCEPTANCE CRITERIA

10. CHECKLIST/FORMATS.

1 SCOPE

9.10.2012
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PROCEDURE FOR CABLE LAYING &TERMINATION.

This procedure covers the method of Laying & Terminati on of Cables HT-Power, LT-
Power, Control, Lighti ng, Fire Alarm, Telephone, Plant Communicati on &
Instrumentati on cable in the applicable areas of the plant.
2 PURPOSE

The purpose of this procedure is to provide guidelines for Laying & termination of cables in the
applicable areas of the plant.
3 REFERENCE DOCUMENTS

 Technical Specifi cati on.

 Applicable Codes and Standards and Indian Electricity Rules.
 Manufacturers Instructi on Manual if required.
 Cable Installati on detail.
 Approved Cable Schedules.
 Approved drawings.

4. PREREQUISITE:
4.1 Availability of work front and approved drawing :

 Suffi cient work front and the relevant approved Drawing of latest revision
shall be available.

 Check that cable route, size; depth of trench is as per drawing, cable trays
earthed and earth conti nuity maintained as per drawings/ specifi cati ons.

 Cable trays shall be checked and ensured free from any sharp edges,
obstructi on and foreign materials and check for the conti nuity of the cable
trays through enti re route as per respecti ve cable schedule.

 Approved cable schedule.

 The cable size and type is as per the cable schedule.

 Deviati ons, if any are observed, the changed route as suggested and approved by

9.10.2012
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PROCEDURE FOR CABLE LAYING &TERMINATION.

clients shall be recorded and as built drawings shall be submitt ed to clients.

 Ensure all the supports of the cable trays are painted before cable installati on.

4.2 Availability of materials

The required materials including consumables shall confi rm to CONSULTANT/Client

as per approved drawing and specifi cati on. Material shall be inspected and MRIR
report shall be prepared.

4.3 Availability of tools, tackles, machine and qualified manpower:-

All the tools, tackles & machines shall be in working conditi on with proper safety.
The required qualifi ed personnel shall also be available.

4.4 Availability of calibrated instruments:

All calibrated instruments relevant to the job shall be available.

5. PRECAUTION:

 Material handling shall be done properly.

 Equipment & accessories shall be stored properly.

9.10.2012
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PROCEDURE FOR CABLE LAYING &TERMINATION.

 While working at height scaff olding shall be prepared and required personal
protecti on equipments like safety belts shall be used.

 Crossing of HT & LT cables shall be avoided

 Aft er laying ends of all cable shall be taped with approved PVC end cap or rubber
insulati ng tape - if terminati ons not done immediately.

 While pulling care should be taken to avoid damage to the cables, Rollers shall
be used for pulling of cables.

 Cables as far as possible shall be laid in full uncut length from one terminati on
to the other, without any straight through joints

 Suffi cient care shall be taken while laying cables to avoid formati on of twist,
sharp, bend etc. in order to avoid mechanical injuries to cables

 Aft er cabling, in case any heavy Installati on and welding takes place on above,
cable shall be protected.

 The foreign material if available on cable trays before or aft er laying of cables
shall be removed immediately.

 Cable armour shall not be exposed aft er terminati on is complete.

 Cutti ng of the strands shall be prevented.

 Glands, Lugs and terminati on kit shall be of approved make.

 The jointi ng and terminati on of medium voltage power cables shall be carried
out by trained personnel only. Jointi ng and terminati on of high voltage cables
shall be done by skilled and experienced jointer duly approved by the engineer
in charge.

 All unused cable entries on equipment/panels shall be plugged/sealed.

 Wire numbers shall be as per schemati c/wiring/ interconnecti on diagram.

9.10.2012
PREPARED BY CHECKED BY APPROVED BY
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PROCEDURE FOR CABLE LAYING &TERMINATION.

 Cable to be properly supported below gland plate/terminal box to avoid

tension/load on gland plate/terminal box /terminals.

6. EQUIPMENTS AND ACCESSORIES:

The following equipment’s and accessories shall be provided for the works:

 Cable drum jack of various sizes.

 Crane/Hydra for lifting cable drum.
 Measurement tape.
 Cable Identification ties or tags.
 Cable rollers.
 Cable route marker.
 Cotton tarpaulin.

 Ladders/ Staging etc.

 Multi meter.
 Megger
 Tong Tester
 Conti nuity Tester.

7 PROCEDURES:

a) LAYING:

 The cables shall be supplied in drums. Insulation resistance shall be measured for
each drum and shall be recorded in drum card. Drum card shall be maintained for
each drum indicating its total cable length. Subsequently each cable number and their
respective lengths shall be entered in the drum card after cutting and laying cable
from that drum. Before cutting the cables, detailed measurement shall be taken in the
field as per routes given in cable schedule or as per site conditions. The quantity
indicated in the cable schedule is only tentative. Cutting the cable for different length
shall be such that wastage is minimum.

 Cable Drum allocation to be done properly after measuring actual length of cable
route.

9.10.2012
PREPARED BY CHECKED BY APPROVED BY
DATE (SUBCONTRACTOR/CONTRACTOR) (CONTRACOR) (CLIENT/CONSULTANT)
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PROCEDURE FOR CABLE LAYING &TERMINATION.

 Both ends of the cable shall be water sealed until termination.

 Cables shall be routed as per the cable schedule.

 Before laying parameters like type of cable, voltage grade, current ratings, No of core, Cable route
etc must be verified with the cable schedule/approved drawing or BOQ.

 Various voltage level cables will be laid in different trays keeping min. Vertical / horizontal difference
between trays as per approved cable laying and technical specification.

9.10.2012
PREPARED BY CHECKED BY APPROVED BY
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PROCEDURE FOR CABLE LAYING &TERMINATION.

 Each length of the cable shall be checked for continuity and insulation resistance
after laying.

 Sagging of the cable shall be avoided.

 Cable shall be laid in complete, uncut length from one termination to other termination. For longer
length cable shall be joined properly with specified intermediate jointing KIT if required.IR values
to be taken before & after jointing.

 Power and control cables shall be laid in separate conduits/ cable trays as per tender
specification and approved drawings.

 All cable screens/armours wherever provided shall be earthed.

 Care should be taken to avoid sharp bending and kinking of cables, damaging of
insulation while stripping the cable. Minimum radius of formed bend of an insulated
power cable shall be 15D where D is the diameter of the cable and 12 D for control
cable.

 In case of underground cable laying following points should be considered

- Cable should be laid over riddled sand bed of 75 mm thick & again covered with 75 mm thick
sand bed & bricks.

- For Voltage Grade 1.9/3.3,3.3/3.3,3.8/6.6 depth should be greater than or equal to 600 mm.

- For Voltage Grade 6.35/11,11/11 depth should be greater than or equal to 900 mm.

9.10.2012
PREPARED BY CHECKED BY APPROVED BY
DATE (SUBCONTRACTOR/CONTRACTOR) (CONTRACOR) (CLIENT/CONSULTANT)
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PROCEDURE FOR CABLE LAYING &TERMINATION.

- For Voltage Grade 12.7/22.19/33 the depth should be greater than or equal to 1200 mm.

- Gap should be maintained between power cables laid in the same level, which should be greater
than or equal to the diameter of the cable.

- There should not be any overlapping between the Power Cables.

- Check for the various Voltage level cables are laid in different trays. Vertical/ horizontal
difference between trays (min 250 mm).

b) GLANDING & TERMINATION:

 Cable shall undergo Conti nuity check before glanding. The cable shall be
terminated at electrical equipment through glands of proper size.

 The individual cores shall then be dressed and taken along the cable ways or
shall be fi xed to the panels with polyethylene straps.

9.10.2012
PREPARED BY CHECKED BY APPROVED BY
DATE (SUBCONTRACTOR/CONTRACTOR) (CONTRACOR) (CLIENT/CONSULTANT)
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PROCEDURE FOR CABLE LAYING &TERMINATION.

 If required, suitable reducer/adopters shall be used.

 All the cable entries for outdoor terminati on shall be preferably through bott om.
Outdoor cable terminati on through top of equipment shall not be permitt ed.

 Marking of the cable (for putti ng the gland) shall be done considering length
required for terminati on and fi nal dressing /supporti ng of cable.

 Place the gland over cable as per gland manufacturer specifi cati on and drawing,
insert the cable in cable gland plate, provide the check nut and ti ght.

 Aft er ti ghtening the gland check nut on gland plate, support and dress the cable
neatly.

 IR measurement shall be checked aft er glanding with megger.( for power and
control cable only).

 Crimping paste shall be applied over the conductor; install correct size of lug as
per requirement and crimp with right size.

 For cables upto 120sq.mm each lug shall be crimped at minimum two places for
cables above 120sq.mm each lug shall be crimped at minimum three places.

 Aft er crimping of lugs fi le the lugs smoothly and wrap insulati on tapes over
crimped lugs with correct colour coding for power cables. In case of control
cable, core identi fi cati on ferrules shall be provided prior to crimping the lugs.

9.10.2012
PREPARED BY CHECKED BY APPROVED BY
DATE (SUBCONTRACTOR/CONTRACTOR) (CONTRACOR) (CLIENT/CONSULTANT)
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PROCEDURE FOR CABLE LAYING &TERMINATION.

 Crimped core shall be neatly dressed up to terminals inside the panel, ti e with
PVC or nylon ti e as per requirement

 Lugs shall enclose all strands of cable core.

 Crimped core shall be connected with terminals neatly with proper phase
sequence.

 Provide fl at washer and spring washer for power cable connecti on.

 Tightness to be done carefully with torque value as recommended by

manufacturer.

 Aft er completi on of cable glanding & terminati ons works, cable shall be properly
supported with suitable clamps / supports as per drawing.

 The spare holes in gland plates shall be blocked to avoid ingress of moisture,
dust and to make vermin proof.

 Cable identi fi cati on tag shall be ensured aft er terminati on at terminati ng ends.

 In case of control cables, all cores shall be identi fi ed at both ends by their
terminal numbers by means of PVC ferrules suitable for core size.

9.10.2012
PREPARED BY CHECKED BY APPROVED BY
DATE (SUBCONTRACTOR/CONTRACTOR) (CONTRACOR) (CLIENT/CONSULTANT)
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PROCEDURE FOR CABLE LAYING &TERMINATION.

 All unused spare cores of control cables shall be neatly bunched and ferruled
with cable tag at both ends for future use .

8. TESTING & PRECOMMISSIONING:

a) General:
 Newly laid HT cables after straight through joint / end termination shall be tested as per IS 1255.
 Check the continuity of each core by shorting with earth at one end and zero resistance meters
reading at other end.
 Check the continuity of Armour as above.
b) LT cable:
 IR Test.
c) HT Cable :
 IR Test (Before DC HV Test)
Shall be measured from phase to phase, phase to neutral and from
phase/neutral to earth.
 DC High Voltage Test(for HT cable only)
shall be carried out aft er complete installati on of Gland, Lug / Terminati on Kit.
 IR Test (Aft er DC HV Test)
Shall be measured from phase to phase, phase to neutral and from
phase/neutral to earth.

9.10.2012
PREPARED BY CHECKED BY APPROVED BY
DATE (SUBCONTRACTOR/CONTRACTOR) (CONTRACOR) (CLIENT/CONSULTANT)
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PROCEDURE FOR CABLE LAYING &TERMINATION.

d) All readings shall be recorded and submitt ed to owner/CONSULTANT .

9. ACCEPTANCE CRITERIA:

 Conformity to drawings & specifi cati ons, applicable codes & standards.
 Approved cable schedules.

10. CHECKLIST/FORMATS:
 Checklist for Cable Laying- Doc No CL/CABLELAYING/03-3
 Test Report for Conti nuity, HV & IR Test-Doc No TR/HV,IR,CONTI/03-4.
 Test Report for Cable terminati on-Doc No TR/CBLTERMN/03-5

9.10.2012
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PROCEDURE FOR CABLE LAYING &TERMINATION.

REVISION

Rev. ind. Page (P) Description Date

Chapt. (C) Dept./Init.

9.10.2012
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DATE (SUBCONTRACTOR/CONTRACTOR) (CONTRACOR) (CLIENT/CONSULTANT)