Main contractor :

ROTARY ENGINEERING FUJAIRAH FZE

Electrical Contractor :

SCAN ELECTROMECHANICAL CONT.CO.LLC

Client :

FUJAIRAH OIL TERMINAL FZC

Consultant :

Pyry Switzerland Ltd.

Project Title : 33/6.6kV SUBSTATION (MRSS) AND 33kV EXTERNAL CABLE WORKS FOR FUJAIRAH OIL TERMINAL

Document Title : METHOD STATEMENT FOR POWER CABLE TESTING

00 10/17/2015 ISSUED FOR APPROVAL Salman Siyas M.Aly

Rev. Date Revision Description Prepared Reviewed Approved

SCAN Document Number : MS-CABLE TESTING/1

Project Location : Fujairah, UAE Format

PAGES
A4 20
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Revision History

Revision Revision Date Page Scope of Revision

00 10/17/2015 ALL ISSUE FOR APPROVAL
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TABLE OF CONTENTS

1. PURPOSE 4

2. SCOPE 4

3. RESPONSIBILITIES 4

4. HSE REQUIREMENTS 4

5. SAFE WORKING PROCEDURE 5

6. EQUIPMENTS/TOOLS 20

7. SUPERVISORY REQUIEMENTS 20

8. PROGRAM 20

9. WASTE MANAGEMENT AND HOUSEKEEPING 20

10. ENIVIRONMENTAL ISSUES 20

11. ANNEXURE 20
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PURPOSE
The purpose of this method statement is to identify
1. the responsibility of each project and site personnel
2. the safety requirements,
3. the safe working procedures and

In order to test power cables while fulfilling the safety and quality requirements.
SCOPE
This method statement addresses the power cable testing in terms of procedures and
precautions to be carried out when and where necessary.

RESPONSIBILITIES
Project Manager has the overall responsibility to ensure timely completion of the project and
all construction activities executed safely and to the prescribed quality requirement thought out
planning, coordination, and supervision of work.
Site Manager shall assist Project Manager in any site duties in terms of coordination,
execution and supervision of work. Ensure all approved drawing, specifications and
instructions are available for the working party.
Site Engineer is responsible for closely monitoring the site activities designated to him.
Ensure all instructions are followed and all necessary work permits and safety documents are
in place prior to the commencement of work. He shall keep daily record of the work, collect
required activity information from the site supervisor and prepare respective report/ record for
Engineer /client review and approval.
HSE Engineer is responsible for ensuring all construction activities comply with the project
safety plan and client safety requirements. He shall formulate safety policy, identify and
resolve safety issues, prepare safety inspection report, prepare risk assessment; conduct safety
briefing and safety induction training.
HSE Officer is responsible for assisting the HSE Engineer and coordination with the Site
Engineer and Subcontractor concerning the safe working procedures at site.
Supervisor is responsible for the execution of work activities in a safely manner and strict
compliance to the prescribed drawings and instructions.
Skilled/Non Skilled manpower has a general responsibility to the safety at work and to keep
the site tidy.

HSE REQUIREMENTS
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All applicable work permits supported with necessary document shall be secured prior
to the commencement of work.
Site meeting shall be held prior to the commencement of work to establish the
intentions of all parties involved.
Tool box talk shall be carried out and necessary safety information shall be circulated
and implemented.
Key work members shall be given a method statement briefing, detailing the scope of
works, emergency procedure, dangers, local hospitals etc.
The HSE officer shall ensure that all work is carried out safely & that all plant /
materials are sited and stored in a safe manner to avoid damage to persons or property.
A risk assessment shall be conducted and safe manual handling techniques will be
employed.
No individual shall handle weights greater than 25kg.
Mechanical assistance will be provided where appropriate if the materials or equipment
cannot be safely moved.
PPE shall he used by all operatives on site. These include the following PPE;
Hard hat
Safety hoots
Hi-Visibility clothing
Safety glasses or visor (where required)
Cloves (where required)
Ear protection (where required)
Face mask (where required)
Care shall be taken to prevent mobile phone usage and consumption of food in the
working area.
Care shall be taken to prevent dust at site.
Care shall be taken to protect all existing structure and facilities.

SAFE WORKING PROCEDURES

The material receive shall be stored in designated area of store. Arrangements shall be made to
protect against effects of weather and environment.

I. Test procedures

1. PHASING CHECK AND INSULATION RESISTANCE

a) Test device

Megger with 5kV DC

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b) Safety and precaution

Test is conducted by the testing engineer in communication with a person posted at the
opposite end. After testing the cable will be discharged and earthed. Test operator, test
operation manager and consultant will have exclusive access to the cable test part to witness.
Others people will be kept away from the conductor live part.

NOTE:
Before switching on, make sure that no one can get within reach of parts of the cable system
where the high voltage is applied. Put up warning tapes and/or signs, which state the situation.
Also station someone at the other cable end.
Before disconnecting the megger make sure the cable is discharged by applying an earth lead

c) Phasing check

After complete installation, cables are to be identified with respect to their phases and are to be
reaffirmed whether they are marked correctly or not. This test is to be conducted in the
presence of client and consultant.

d) Procedure

1. The screens of all cables at one end are to be shorted and grounded.
2. The conductor of the cable under test is to be connected to the negative pole of the
Megger
3. The positive pole of the Megger is connected to ground.
4. Through a switch ground other conductor will be grounded at the opposite end of the
circuit.
5. Insulation resistance of the cable under test will be measured.
6. If the resistance is very high, the phase identification is correct. Confirm with people at
the opposite side that the cable is marked with the correct color coding.
7. To cross check; test other phase conductors; the tester will NOT increase the voltage
and the reading resistance will be negligibly small.
8. Similarly repeat the test for the other phases and verify the correctness of the color
coding
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e) Insulation resistance

The phasing of the circuit shall be confirmed before measurement of insulation resistance.

Before and after the High Voltage Test the insulation resistance of the whole cable circuit per
phase shall be measured.

Before starting the measurement make sure that the test circuits is prepared correctly as shown
below:
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2. DC TEST ON OUTER SHEATH

a. Test device:

DC power generator

b. Test acceptance criteria

Cable sheath shall withstand the DC test for l min without any breakdown at the voltage levels
of 10kV for the new cable circuit

c. Safety and precaution

Test is conducted by an authorized person, responsible for safety and in communication with a
person posted at the opposite end. Prior to the test the testing perimeter must be isolated and
cordoned with appropriate warning tapes. After testing the cable will be discharged and
earthed.
Before switching on make sure that no one can get within reach of parts of the cable system
where the high voltage DC is applied. Put up warning tapes and/or signs which warn about the
presence of High Voltage. Also post a guard at the remote cable end.

d. END TO END test procedure

In order to perform this test it is necessary to disconnect the bonding links from the earth at the
substations to isolate the metal sheaths of the cable length to be tested.
Also disconnect the metal sheaths from the earthling points along the cable route and in the
substations.
Connect the cable conductor to an earthing point to prevent the charging of the insulation
The metal sheath of the cable under test shall be connected to the high voltage connection
point of the device. The metal sheaths of the other cables shall be grounded.
Gradually increase the DC voltage to the specified test level and hold for one minute.

Note the leakage current at the beginning and at the end of one-minute period.

After switching off, earth the metal sheath of the cable under testing, before removing the
connector from the cable.

(Repeat the same testing, procedure for to the other two phases).
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3. INSULATION RESISTANCE

a. Test Equipment

5 KV megger testers

b. Test acceptance criteria

Insulation resistance measured should be more than 500Mohm

c. Safety and precaution

The far end power cable termination conductor contacts are isolated from all other
conductors and ground. The area around the terminations is segregated by warning tape and a
watchman is posted to prevent approach by other persons to the hazardous area.
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d. Test procedure

At the near end the terminations are isolated from all other conductors and ground. Yellow
and Blue Phase termination conductor contacts are grounded by means of jumper leads. The
5KV Megger is connected (+ve terminal) to ground and (-ve terminal) to Red Phase
termination conductor contact. The watchman at the far end of the circuit will be contacted by
telephone to warn him that testing is about to begin and to confirm that his end of the circuit is
safe to receive high voltage. At the near end of the circuit the test set operator is responsible
for safety and will not start testing until he is satisfied that both ends of the circuit are safe.
The Megger is programmed to apply 5KV for one minute and then discharge the cable. The
insulation resistance as shown on the display is recorded on the test form.
When the measurement of Red Phase cable is completed the termination conductor contact
is confirmed as discharged by moving the grounding jumper from Yellow Phase termination to
the Red Phase termination before handling the Megger connector. The Megger connector is
transferred to the Yellow Phase termination conductor contact and the cable insulation
resistance measured by the same procedure as for Red Phase cable.
The insulation resistance of Blue Phase cable is measured by repetition of the foregoing
procedure. Where more than one cable is used per phase, each run of cables is tested
individually.

4. CAPACITANCE TEST

a) Test device

Megger with 5kV DC

b) Test acceptance criteria

Measured capacitance value shall not be greater than the theoretical value

c) Safety and precaution

Test is conducted by the operation manager in communication with a person posted at the
opposite end. After test the cable will be discharged and earthed. Test operator. Test operation
 SCAN ELECTROMECHANICAL CONT.CO.LLC

manager and consultant will have exclusive access to the cable test part to witness. Others
people will be kept away from the live conductor parts

d) Test procedure
The capacitance of every complete cable circuit including the termination will be measured
between phase and metallic sheath for each core. Value of capacitance will be then calculated
per meter of the cable, C=0.284 pf/km.

5. CONDUCTOR RESISTANCE
a) Test device

Digital resistance tester

b) Test acceptance criteria

The measured DC resistance value corrected at 20 degree Celsius must be equal or less than
the specified resistance in accordance with IEC 60287:

R dc = 0.036 ohm/km

c) Safety and precaution

Test is conducted by the operation manager in communication with a person posted at the
opposite end.
After testing the cable will be automatically discharged by the tester.
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d) Theory

The D.C resistance Rm of the complete cable circuit will be measured at ambient temperature
using an instrument with a four-wire coupling. The resistance value at ambient temperature
will be corrected to the value at 20C and compared with the specified value. The test will be
performed with two cables connected in series, R+Y, Y+B. B+R The resistance of the
connecting leads used to connect the testing equipment, and to link the two cables at the other
side, is measured and recorded.

Then, the actual resistance calculated at 20C will be deducted:

With Skin effect factor and proximity factor

e) Measurement
Resistance of the connecting lead to be measured and recorded Rcl
Resistance of two cables, connected in series by the connecting lead, to be measured
and recorded, Rm
Resistance of two cables, at ambient temperature to be calculated: R= Rm - RcI and
then resistance to be corrected to the value of 20 C (R20).
Resistance per phase at 20 C to be calculated.
Resistance per meter at 20 C for each phase to be calculated
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6. ZERO PHASE SEQUENCE IMPEDANCE

a) Test device

Single phase AC power generator and digital power meter to measure AC electrical parameters
such as voltage, current, reactive power, active power, angle and frequency.

b) Safety and precaution

Test is conducted by the operation manager In communication with a person posted at the
opposite end. After testing the cable will be discharged by switching off the AC generator.
Test operator, test operation manager and consultant will have exclusive access to the test
equipment part to witness

c) Theory

The calculations are performed with the assumption that all currents return by the metallic
screens and that resistance of earthing points are negligible. The zero sequence impedance is
given by:
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d) Measurement and procedures

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e) Acceptance criteria

Measured value shall be found after correction close to theoretical value given in the cable
specifications.
However it is worth mentioning that the theoretical values are obtained based on ideal
conditions for the cable laying.
Z0=0.088+J0.053

7. POSITIVE/ NEGATIVE SEQUENCE

a) Test device

Three phases AC power generator and digital power meter to measure AC electrical
parameters such as voltage, current, reactive power, active power, angle and frequency

b) Safety and precaution

 SCAN ELECTROMECHANICAL CONT.CO.LLC

Test is conducted by the operation manager in communication with a person posted at the
opposite end. After testing the cable will be discharged by switching off the AC generator.
Test operator, test operation I manager and consultant will have exclusive access to the test
equipment part to witness.

c) Theory

The calculations are performed with the assumption that the currents are symmetrical and they
only flow in the phase conductor. The positive or negative sequence impedance is then given
by Z+ = Z

d) Measurement and procedures

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e) Acceptance criteria
Measured value shall be found dose to the theoretical value given in the cable specification.
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However it is worth mentioning that the theoretical values are obtained based on ideal
conditions for the cable laying.
Since in some particular points the arrangement of cables is to be adapted to site condition
(Extra depth with increased cable spacing for instance) theoretical and actual values may vary
slightly.
The actual value of the Positive negative sequence impedance

Z+=0.048+J0.108

8. HV TEST
a) General

As agreed and instructed by FEWA engineers in previous projects, the high voltage test of the
complete 54kV cable installation (Complete circuit) will be applied between conductor and
metallic screen/ sheath, for 30 min. without any breakdown, supplied an AC low frequency
(0.2Hz). Insulation resistance measurement shall be performed before and after high voltage
test.

b) Safety
Test is conducted by a competent person, responsible for safety and in communication with a
person posted at the opposite end. The person at the remote end must be fully aware of the
dangers involved and be briefed on his responsibilities. Prior to the test the testing perimeter
must be isolated and cordoned with appropriate waning tapes.
A barrier / warning tapes should also be erected at the remote end as well as a special warning
light system surrounding the test area equipped with remote emergency switches to shut down
the test. No personnel shall be permitted to work in the vicinity of the cable during test. After
testing the cable will be completely discharged and earthed.

c) General test procedure

Prior to this test, a 10kV DC test for one minute on outer sheath shall be performed
GIS supplier has to confirm before the HVAC test that its equipment can withstand test
voltage
Test equipment will be connected to the cable through an outer termination or a test
bushing
Cable sheaths are earthed at both ends of the cable.
Insulation resistance measurement prior to the high voltage test
The high voltage test is performed with an AC voltage of applied between the
conductor and the metallic sheath. An AC 20-300Hz resonance test set is utilized. The
test voltage is gradually increased at a preset rate and kept for 60 min at the voltage test
level.
Once the test will have been carried out, the cable shall be discharged and short-
circuited Insulation resistance measurement subsequent to the high voltage test.
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 SCAN ELECTROMECHANICAL CONT.CO.LLC

EQUIPMENTS/ TOOLS
1. MEGGER WITH 5kv DC
2. AC POWER GENERATOR
3. DC POWER GENERATOR
4. DIGITAL POWER METER
5. DIGITEL RESISTANCE TESTER

SUPERVISORY REQUIREMENTS
Work shall be supervised at all times by SCAN competent person (Salman/Sudhakar), who
will be the document holder and will be on site during the work period.

PROGRAM
Site activities arc coordinated via regular consultation with POYRY/REL/FOT and substation
contractor.

WASTE MANAGEMENT AND HOUSEKEEPING

It is general responsibility for everyone on site to keep the work area tidy. Any general rubbish
shall he disposed of into a general waste skip located on site and any waste classed as
hazardous shall be disposed of into a separate skip. Daily housekeeping shall be carried out to
ensure a good healthy working environment.

ENVIRONMENTAL ISSUES
No envisage environmental issues are predicted.

ANNEXURE
1. Risk assessment.