Cable Laying Work Method R.1

Doc No.
: 0601A/PLTU-HBP/XI/2019
CABLE LAYING WORK METHOD
Print dated : November 2019
Page :
1. OWNER : PT. PLN PERSERO

MAIN CONTRACTOR : SINOHYDRO CORP.
PROJECT TITLE : ADMIN BUILDING PLTU 3&4 LANGKAT - INDONESIA

CONTRACT NO :
LOCATION : ADMIN BUILDING PLTU 3&4 LANGKAT - INDONESIA
REFERENCE : DRAWING-ADMIN BUILDING-ME 01~08
STANDARD & CODES : AS PER SPECIFICATION
`
COMMENT SHEET
ISSUED NO REV REVISION DATED REMARKS/COMMENT
01 14-11-2019
SIGN
Prepared by, Checked by, Approved by,

DESCRIPTION STATUS
PT. HORAS
SINOHYDRO PLN-E PLN PERSERO
BANGUN
PERSADA Approved
Approved as note
Issued for
Not Approved
Approval
Name : Name : Name : Name : Information
Dated: Nov 14, 2019 Dated: Dated: Dated:

Doc No. : 0501A/PLTU-HBP/XI/2019
Page :
Catalog
1. Compilation basis ............................................................................................................................. - 1 -
2. Engineering survey and working range ......................................................................................... - 1 -
3. Job preparation and requirements ................................................................................................. - 2 -
4. Construction progress ...................................................................................................................... - 2 -
5. Key Quality Control Points for Work Procedure .......................................................................... - 3 -
6. Construction method and construction requirements .................................................................. - 3 -
7. Quality and Technical Standard for Acceptance ........................................................................... - 9 -
8. Safety Measures.............................................................................................................................. - 11 -
9. Environmental Protection Requirements .................................................................................... - 14 -
10. Technical records............................................................................................................................ - 14 -

Page :
1. Compilation basis
The cable layout drawing, wiring drawing and equipment manufacture drawings provided by the
design institutes of Pangkalan Susu Coal-fired steam power plant Unit 3&4 Erection
Engineering ,IEC、ANSI/NFPA 70、NEC.
2. Engineering survey and working range

2.1. Engineering survey
Indonesia Pangkalan Susu coal-fired steam power Unit 3&4 erection engineering includes the cable
layout and wiring in the areas Administration Building.
2.2. Working range

It mainly includes the cables layout and wiring of 6kV cables, 400V cables, electric control and signal
cables.
PANGKALAN SUSU COAL FIRED STEAM POWER PLANT PROJECT UNIT 3 & 4 (2*200MW)
page： - 1 -
Page :
3. Job preparation and requirements

3.1. Technical requirement
1) Personnel allocation: there shall be 10 professional technicians who are familiar with drawings,
the site and the technical craft requirements. There shall be 40 to 50 auxiliary workers.
2) The personnel shall accept specific technical and security training before starting work.
3) Complete the construction personnel's technical disclosure and safety work.
3.2. Work environment
1) The construction drawings by discipline review work instruction has been prepared, the formalities
have been done.
2) The bridges for the main tunnel of cables have been erected already. Sporadic bridges have been
erected basically. The site has been cleaned out, which does not impact cable laying.
3) The cable laying lines shall be smooth, there shall be supports for impending locations.
4) The cable connecting cabinets and controlling equipments have been installed already.
3.3. Main tools and machines
1) The main machines and tools include cable layers, winches, hydraulic clamps, cable cutters, wire strippers and
other common tools.
4. Construction progress
The cable laying and wiring shall begin from the cables of receiving part, then shall be the
chemical water system and the cables of the boiler water pressure part, that of other parts shall
be constructed synchronously in accordance with plans.
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Page :
5. Key Quality Control Points for Work Procedure

5.1. The cable laying and the appearance inspection of cables shall be witness points(W).
5.2. The inspection of cable wiring craft.(W)
6. Construction method and construction requirements

6.1. Construction flow chart
Preparation works for construction
cable laying
settlement and fixation of cables
cable heads fabrication and wiring
inspection and acceptance
page： - 3 -
Page :
6.2. Cable laying
1) The leaders shall reasonably arrange personnel according to the situation on site and cable laying
sheet. When cable lines are relatively long, it shall be divided into different sections, team leaders
shall be appointed for construction.
2) Cable laying shall be commanded by the specialized, actions shall be uniform, there shall be
specific communication signals.
3) Cable laying begins, the rotation direction of cable reels shall be the same as cable twining
direction. The erection of cable reels shall be in a balanced state, the distance between edge of
reels and the ground shall be more than 100mm, which cannot be too high as well. The cables
shall be drawn from the upper part of reels.
4) When working on overhead bridges, there shall be platforms or grid rows , personnel cannot climb
or suspend on cables, cannot walk on bridges as well.
5) When laying cables on equipments body, footholds cannot be instruments or electrical
equipments that are easy to be broken. Shelves or working platform shall be erected when it is
necessary.
6) When using machinery for cable laying, strictly prevent cabled getting damage from machinery.
Meanwhile, pay attention to personal and equipment security.
7) When cable are laying at inlet and the holes at power supply boxes, there shall be protection
measures, in case of scratching the insulation layers of cables.
8) Cabled shall be laid on bridges uniformly, the middle parts of which shall be tied up with cable ties,
avoiding arching.
page： - 4 -
Page :
6.3. Settlement and fixation of cables
1) The cable settlements shall be fixed with cable ties at the following locations: that shall be on
each support for vertical laying, that shall be at two ends of straight parts for horizontal laying, that
shall cross the two ends of protection tubes for cable bending locations, that shall be at
150mm-300mm from the lead wires and front terminal rows, that shall be about 1m from the seal
heads of terminal heads, that shall be fixed on the locations that are slightly higher than the
ground when vertically crossing the ground.
2) Enough long cables shall be reserved for reasonable cable settlement when laying cables. The
cable labels shall be fixed at the lower parts of cable wiring sides.
6.4. Fabrication of cable heads and wiring
page： - 5 -
Page :
1) Construction flow of high pressure cable heads
 Place cables at reserved locations and peel the operation sets.
 Peel the sarking and expose the armour, scrub the dirt on the surfaces of protective sets from
the stripped locations downwards.
 Twine the grounding wire at the root of three-core copper shielding belts and draw it out
downward.
 Twine the second layer of adhesive tapes at the external of the first adhesive tape, making the
grounding wire in the middle, in case that steam may permeate along the grounding wire.
Twine several layers of PVC tapes in the whole grounding area and adhesive tapes, cover
them all.
 Measure and draw lines according to the height of wiring locations, cut off the rest length.
 Peel the semi-conductor layer from the end of copper terminals with care, press and connect
cable lugs on copper wires with wire crimpers.
 Scrub the main insulation with cleaning agent.
 Sleeve heat-shrinkable articles, then heat the articles with heaters, making articles shrink.
 Suspend signboards, the fabrication is finished.
2) Low pressure power cable heads construction flow
page： - 6 -
Page :
 Measure and draw lines on the cables in accordance with the grounding location.
 Cut off the rest cables.
 Sleeve cable lugs, press the cable lugs and copper wires with hydraulic clamps.
 Sleeve heat-shrinkable rubber tubes first, then twine the press and connecting locations with
self-adhesive tapes.
 Then sleeve the heat-shrinkable rubber tubes into the bundling locations, heat the bushing with
heaters, making it shrink.
 Sleeve cable lugs at wiring locations with screws, the screws shall be crossed from down to up,
tighten screws with wrenches.
 Suspend signboards, the fabrication is finished.
3) The fabrication of controlling cable heads and the wiring construction flows
page： - 7 -
Page :
 The settlement of the cables getting into the reels shall be arranged neatly without any cross.
 Peel cables.
 Peel the external protective layer.
 Peel the inside protection liner, steel shielding belts and the electric semi-conductor layers.
 Sleeve the grounding wires with small plastic tubes.
 The fracture sections on the cable external protective sleeves shall be added with
heat-shrinkable articles, heat the articles with hairdryers.
 Cable heads shall be strapped and fixed in the clamps.
 Twine the cable core plates on the supports of cabinets.
 Sleeve the number of loops on the terminals of cable cores whose loops are checked already.
 Cable cores shall be fixed on the cable supports in reels with ties from down to up.
 Cable cards shall be neatly, correctly and clearly suspended on cable heads.
page： - 8 -
Page :
7. Quality and Technical Standard for Acceptance

7.1. Quality and technical standard
1) The models and specifications of cables shall conform to regulations: the signal boards shall be
complete, correct and clear.
2) The fixation of cable, bending radius, the relevant distance, the wiring of single-cored power cable
metal sheaths, and their arrangement shall conform to the requirements.
3) The insulation of cable terminals and cable heads shall be in good condition. The installation shall
be tight.
4) The grounding shall be in good condition.
5) There shall be no sundries in the cable ducts, the cover plates shall be complete. There shall be
no sundries in the tunnels, and the lighting, ventilation, drainage etc., shall conform to the
designing requirements.
6) The anti-fire measures shall conform to the designing requirements, and the construction quality
shall be qualified.
7.2. Technological Requirements’ Standard
1) The layout and wiring of cables shall conform to designing requirements.
2) Cables shall be arranged fixedly and neatly without any cross, the forms of fixing clipsshall be
accordant, the fixation strength shall be tight.
3) The specifications of cable boards shall be accordant, the content shall be complete and correct,
the suspending locations shall be neat and firm.
4) The bending radius and arch of cable cores shall be accordant.
5) The appearance of core insulation layers shall be complete without any damage. The bundling of
insulation plastic tapes shall be dense and firm. The twine length in the same reels shall be neat
and accordant.
page： - 9 -
Page :
6) The wiring of grounding lines shall be in good condition and firm.
7) Cable lugs shall match with core wires, the connection shall be good, without any cracks or
broken wires.
8) The fireproof and sealing of cables shall be dense and neat.
page： - 10 -
Page :
8. Safety Measures
Identification of hazards
Accidents may
Operation Hazards Corresponding measures
happen
Don`t take measures to fix cables Vehicles get turned Security and technical disclosures,
when transporting them over take measures to fix cables.
Cable reel get
The supports of cable reels are not Choose flat locations and take
dumped and hurt
stable when placing cables fixation measures.
personnel
Don`t wear safety belts for cable
Falling from height Strict supervision and check
laying at height.
The personnel get close to pipe
orifices to check on the cables Security and technical disclosures,
Personal injury
Cable before cables get through from the specialized are for monitoring.
laying pipelines.
Don`t manage work permit for Manage work permit before
cable laying in the areas with Electric shock construction, security and technical
electricity. disclosures.
Security and technical disclosures,
The construction personnel stand at
personnel stand at the outside of
the inner side by the bending when Personal injury
bends.
laying cables at bends.
Cable get in touch with cabinets Electric shocks Security and technical disclosure,
and the parts with electricity short circuit taken insulation measures
8.1. Cables shall be bundled tightly when they are in shafts, prevent cable falling to hurt personnel.
Ensure the locations for personnel standing when laying cables, and set the temporary work
platform for personnel standing, prevent take risks for operations.
8.2. It is prohibited to stand in front of cable reels(along the rotation direction of cable reels) and push
cable reels, pay attention to the rotation speed when cable reels are rotating. Avoid abrupt stop
and turning.
page： - 11 -
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8.3. The personnel getting into the site must wear security helmets correctly, and correctly use safety
belts and other protection supplies. The reserved holes in construction areas shall be blocked well,
in case that construction personnel miss their steps during working process and get injuries.
8.4. Before cable layout, the sundries in cable ducts and the inter-layers shall be cleaned out, there
shall be sufficient lighting.
8.5. When laying cables at height, operation personnel must wear safety belts, and safety belts shall
be suspended on upper fixed and reliable locations.
8.6. At cable bending locations, construction personnel shall stand at the external side, preventing
extrusion wound.
8.7. When cable cross holes, protective tubes and floor entrances, prevent cable getting stuck and
hands getting into holes, the personnel at outlet shall avoid getting cables head on, prevent
extrusion wounds or puncture wound.
8.8. When using cable layers, the operators cannot wear gloves, buckle up the fasteners on uniforms,
in case of being involved in machines.
8.9. During the commissioning period, strictly perform the work permit system, set electric warning
fence around the equipments on site, the working communications between erection personnel
and commissioning personnel shall be good, avoid getting into the areas with electricity. Suspend
“Equipments are with electricity, dangerous” signal boards, the personnel that are not for
construction cannot enter the site with electricity.
8.10. When the wiring personnel are working, prevent cutting injury from knives. No smoking, fire
precaution, civilized construction, clean the site after work is done.
8.11. The cabinet doors shall be locked up in a timely manner for the cabinets whose wiring is in
process or has been completed.
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Page :
8.12. For the circuit check of cable cores, battery lights or tools cannot be suspended at the wiring
bending of terminal rows.
8.13. During the commissioning process, don`t pull at random when removing the wires and changing
the wiring. The wiring craft shall be accordant when recovering them.
8.14. When entering the site with electricity for wiring, work permit shall be managed, and get the
permission from the operation personnel, do good works in preventing accidents, security
isolation, monitoring, inspection, management of work permit, controlling and protection works.
Prohibit work omissions, avoid personal injury and electric shock accidents.
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8.15. Tool-box meeting is needed for everyday; the monitor must make good work arrangement every
day and give safety technical disclosure for each work; as to those dangerous operations, it is a
must to establish safety construction scheme and transact work sheet and make summary about
the relevant work activity every day.
9. Environmental Protection Requirements

9.1. Strengthen the environmental protection management and raise the environmental protection
awareness, establish environmental protection measures within the construction design and
construction scheme, make good arrangement before construction and implement it seriously
during the construction;
9.2. Publicize the environmental protection awareness of “prevent pollution and make continuous
improvement” to all staffs, thus to let them be in self-awareness of environmental protection and
be abide by relevant provisions and procedures;

9.3. Cable reels shall be stacked neatly after daily work is done. The empty cable reels shall be
recycled.
9.4. Clean up the site after the cable wiring work is finished, especially the internal of reels, which shall
be dry and clean, the rest cable waste shall be recycled.
9.5. Keep to the principle of “project complete, materials used up, and site clean”.
10. Technical records

10.1. Drawing review records
10.2. The Construction technology and safety clarification records
10.3. Installation records
10.4. The acceptance record
page： - 14 -

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Doc No.

1. OWNER : PT. PLN PERSERO

PROJECT TITLE : ADMIN BUILDING PLTU 3&4 LANGKAT - INDONESIA

ISSUED NO REV REVISION DATED REMARKS/COMMENT

Prepared by, Checked by, Approved by,

Name : Name : Name : Name : Information

Dated: Nov 14, 2019 Dated: Dated: Dated:

1. Compilation basis ............................................................................................................................. - 1 -

2. Engineering survey and working range ......................................................................................... - 1 -

3. Job preparation and requirements ................................................................................................. - 2 -

4. Construction progress ...................................................................................................................... - 2 -

5. Key Quality Control Points for Work Procedure .......................................................................... - 3 -

6. Construction method and construction requirements .................................................................. - 3 -

7. Quality and Technical Standard for Acceptance ........................................................................... - 9 -

9. Environmental Protection Requirements .................................................................................... - 14 -

10. Technical records............................................................................................................................ - 14 -

Engineering ,IEC、ANSI/NFPA 70、NEC.

2. Engineering survey and working range

2.2. Working range

3. Job preparation and requirements

3) Complete the construction personnel's technical disclosure and safety work.

3.2. Work environment

have been done.

3.3. Main tools and machines

other common tools.

5. Key Quality Control Points for Work Procedure

5.2. The inspection of cable wiring craft.(W)

6. Construction method and construction requirements

Preparation works for construction

settlement and fixation of cables

cable heads fabrication and wiring

inspection and acceptance

6.2. Cable laying

shall be appointed for construction.

specific communication signals.

shall be drawn from the upper part of reels.

or suspend on cables, cannot walk on bridges as well.

5) When laying cables on equipments body, footholds cannot be instruments or electrical

Meanwhile, pay attention to personal and equipment security.

measures, in case of scratching the insulation layers of cables.

6.3. Settlement and fixation of cables

ground when vertically crossing the ground.

6.4. Fabrication of cable heads and wiring

1) Construction flow of high pressure cable heads

 Place cables at reserved locations and peel the operation sets.

the stripped locations downwards.

cable lugs on copper wires with wire crimpers.

 Scrub the main insulation with cleaning agent.

 Suspend signboards, the fabrication is finished.

2) Low pressure power cable heads construction flow

 Cut off the rest cables.

heaters, making it shrink.

tighten screws with wrenches.

 Suspend signboards, the fabrication is finished.

 Peel the external protective layer.

 Sleeve the grounding wires with small plastic tubes.

heat-shrinkable articles, heat the articles with hairdryers.

 Cable heads shall be strapped and fixed in the clamps.

 Twine the cable core plates on the supports of cabinets.

7. Quality and Technical Standard for Acceptance

complete, correct and clear.

metal sheaths, and their arrangement shall conform to the requirements.

4) The grounding shall be in good condition.