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Cables & Wires Handling Storage and Pulling Method Statement Procedure

To protect cables from physical damage  and the environment, store indoors and protect from  moisture, construction  equipment,  falling objects, chemical spills, moving  vehicles, and other hazards. When the cables are received inspect the protective covering on the cable for evidence of shipment damage. Leave the  factory-applied   protective   cover   in  place   until   removal   is  absolutely necessary. Where possible, check the copper sheath for evidence of shipment damage. 

Store cables indoors in a dry location. Do not stack reels. Ensure that both ends of the cable are securely fastened to the reel flange. Do not remove heat shrinkable end caps  until ready  to terminate the cable.

Care While Moving Coils  and Reels

  • Handle and install cables within suitable temperature limits
  • Handle coils and reels utilizing equipment designed for that purpose.
  • Do not  drop  coils  or  reels  from  any  height,  particularly  from  trucks  or  other transporting equipment.
  • Lift or handle  coils  and cable  reels  in such  a manner  that the  lifting / handling device does not make direct contact with the cable or its protective covering. Coils should be placed on a skid.
  • Handle reels in a manner that prevents deterioration of and physical damage to the reel and to the cable.
  • Take precautions to ensure that the flange of one reel does not impact the cable on another reel.
  • If a coil  or reel is dropped or the protective covering is damaged, examine the cable for damage. Damaged cables may need to be repaired or replaced.

The following lifting methods for reels are recommended:

Insert a suitable properly-secured  shaft through the reel arbor hole and lift with slings using a crane or boom-type equipment. Use a spreader or other device to minimize sling pressure against the reel flange.

Move smaller, narrower reels using a forklift. Place fork tines so that lifting pressure is on both reel flanges, not on the cable.

Cable installations must be pre-planned to ensure a successful installation. It is important to ensure that personnel are properly trained and qualified for the specific task they are performing. 

When installing cables, all appropriate precautions should be followed, including HSE and other applicable national  safety  regulations. Therefore, in  addition to observing  standard safety practices, observe the following:

  • Take reasonable  precautions  to prevent  damage  to the cable from severe  blows with sharp instruments and pulling over sharp objects.
  • Do not pull cables  around corners that have sharp edges, or other obstructions.
  • Pull all cable diameters, one at a time, by hand.
  • Hand feed cables around corners using large sweeping bends.
  • When  changing direction from horizontal to vertical, use  properly-sized sheaves or pulleys.
  • Protect  exposed cables  from  any  nearby  or overhead work  that  could  damage the cable.
  • Do not pull cables around a radius  smaller  than the minimum pulling  radius.
  • Make sure all equipment used during  cable installation is in good operating condition.

Plant / Equipment Requirements for installation of work

  • Electrician hand tools
  • Steel pull spring
  • Cable rollers
  • Cable drums jack
  • Handling equipment of drums
  • Calibrated megger & millimetre
  • Hydraulic cable cutter
  • Winch motor where as required location
  • Cable basket
  • Cable pulling compound
  • Screw driver
  • Power Supply: Single-phase normal power where it is needed.
  • Working platforms: scaffolding as required within the specific work area.

Installation Procedure of Cables & Wires in Conduit & Trunking:

All electrical wiring  will be in accordance with the specifications requirements and approved load schedules. All cables  will be approved and material inspection will be completed in advance of installation. If winch motor to be used in all where as required location in cable pulling use a cable basket for gripping the cable.

Cable installation will be carried out by skilled  and suitably experienced electricians under the supervision of highly competent site supervisors and engineers to ensure  the correctness and quality of installation. Prior to commencement of work, conduits shall be inspected to make  sure that they have not been damaged or blocked. Trunking will be raised  for inspection as well to ensure correctness.

No wires will be drawn through unless  conduit and trunking  installations have been completed and inspected and cleaned. Wiring will only be carried  out after the conduit  installations and plaster  work is completed. Where single core PVC insulated wires are enclosed within the conduit and trunking, care will be taken that no damage will occur to the wires during  their installation.

All wiring contained in conduit  and trunking  will be manually pulled  by means  of approved pulling  material such as nylon cord and pull spring so that cable will not be damaged. Conductors will be identified by means of color coding  in accordance with the local regulation.

Proper color coding  will be maintained throughout the installation. Color coding  will be observed as follows:

Red                           Phase 1

Yellow                    Phase 2

Blue                         Phase 3

Black                       Neutral

Green/Yellow    Earth

Measure the conduit and trunking length and check the correct size of the cable (as per approved drawings or load schedules) before cutting the wires. Only consultant approved lubricants made for the purpose of pulling wires will be used to assist the drawing of wires.

Tie the cut wire to the rope and pull it until it reaches the end points. No more than one circuit will run in one conduit unless otherwise specifically permitted. Wires will be pulled simultaneously to conduit or trunking.

While preparing cable ends, ensure that conductor  strands are not damaged and the strands are twisted together with pliers to ensure neat and firm connection.

Provide a name tag sticker in easy visible location on the trunking, tray etc. for identification reference prior to the ceiling final closure and inspection.

While removing the conductor  insulation, ensure that no excess exposed conductor left.Wires would be in drums and to be fixed in cable stands holders and site engineer to check wire length and wire splicing will not be allowed throughout the installation.

Once the circuits are pulled in the trunking, pull box and panels, side will be grouped by using the appropriate cable ties.

All cables will be clearly marked on both ends with the suitable cable markers or masking tape indicating the source and destination.

Once cable pulling is completed, trunking cover and end cap will be provided as well as cable tray end cap. All unused holes in the trunking,if not required to be covered and grommeted. 

After the completion of installation, inspection request will be raised to the consultant to ensure accuracy and quality of work. Cable testing will be carried out afterward in accordance to approved test plan.

Installation Procedures for Power Cables

In cables of different voltages, if the insulation is lower than the voltage run of the adjacent cable they would be installed in a separate raceway or containment.

Heat resistant cables will be used for wiring from lighting fixtures to lighting points and from all spur outlets to equipment’s served like FCU’s and kitchen equipment’s.

Fire resistant cables will be used for power supply cable feeding power to electrical and mechanical equipment’s such as emergency lights, elevators, smoked fans, pressurization fans among others. Fire resistant cables will be installed in all fire safety corridors. Instrumentation, automation and control cables will be installed in compliance to BS 5308 or equivalent.

All horizontal and vertical installation of cables to cable trays and cable ladders will be supported using approved cable tie for LV and cable cleats for MV. Care will be taken during installation so that cables are not subjected to tension and or mechanical stresses. Pulling lubricant to be used with UL listed category and consultant approved in pulling the cables in conduit.

If cables are cleated directly on the soffit, the cleating supports will be installed at regular intervals.

Cable drums will be positioned as close as possible to the installation area. Care will be taken care during transportation of cable drums. Where cable rollers to be used, it will be position at suitable intervals and secure them for installation on cable tray.

For long runs where recommended tension values may be exceeded, intermediate pulling will be implemented by arranging the cable in loop Tension indicator will be provided. Where change of elevation or direction take place, cables will be supported and guided by corner type of rollers to prevent stress or damage during the pulling.

Cables will not be bended to a radius smaller than values recommended  by the manufacturer. Also it will be ensure that no twisting of armored cable take place.

Care will be taken to ensure that external sheath is not damaged during cable pulling. Cable tags will be installed on both ends of the cable. All installed cables to be sealed at both ends by proper end caps shrouded to avoid dirt, debris and water accumulation.

Cable passing through fire rated walls will be sealed with fire barriers of approved type.

Segregation and correct distance between cabling run will be maintained according to the normal practice and standard.

If surface run for the cabling works, protective cover to be used to avoid direct sunlight exposure.

Ample length for the final cut allowance for the cable will be provided as required:

  • 2.5mm2 to 6mm2 = 15cm
  • 10mm2 to 16mm2 = 25cm
  • Larger than 16mm2 = 45cm

Indoor trenches cabling will be segregated and run on trays or bracket secured to the trench wall. No cable will be allowed to be laid directly on the indoor trench.

20% of spare capacity will be provided to all containment for future use as per BS 7671 requirement in wiring regulation.

After the completion of installation, inspection request will be raised to the consultant to ensure accuracy and quality of work.

Cable testing will be carried out afterward in accordance to approved test plan.

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