SC.

PRYSMIAN CABLURI SI SISTEME SA SLATINA ROMANIA

Document: OP-SL-RQMS-7.5.1
Cables & Accessories Delivery and Installation Version: 1
Data: 29/10/2015

Prepared: Verified: Approved & Authorized:

C. Nistor C. Badea V. Badalica
C. Gheorghe

<Original Copy Signed> <Original Copy Signed> <Original Copy Signed>

CCO RQMS & CI Plant Quality Manager

DISTRIBUTION LIST (electronic version: OP-SL-RQMS-7.5.1.pdf):

 CCO RO & Telecom
 SC. PRYSMIAN CABLURI SI SISTEME SA SLATINA ROMANIA:
Industrial Plant Slatina
Human Resources
Purchasing
R&D Department
Sales Energy Cables
Sales Telecom Cables
Quality Department
Manufacturing Energy & Cordon
Manufacturing Telecom
Maintenance Department
Finance, Administration and Control
Logistic Department

It is the responsibility of the above mentioned persons to transfer its content, as part of QMS’s
documents managed, to their subordinated personnel

The electronic version of OP-SL-RQMS-7.5.1.pdf is available in the followings locations:

SL @ \\Srv243-01ro\SistMngmCalitate

MOFIDICATION CONTROL of OP-SL-RQMS-7.5.1

1-10/2015 - First Edition:

Edition Chapter Major Modifications
Para/Pg.

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Document: OP-SL-RQMS-7.5.1
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Data: 29/10/2015

CONTENT

1 PURPOSE 3

2 SCOPE 3

3 DEFINITIONS 3

4 RESPONSABILITIES 3

5 PROCEDURE 4
5.1 On site receipt of Cable Drums/Accessory Boxes 4
5.2 Handling & Storage 5
5.3 Cable Installation 7
5.3.1 Precautions Prior to Cable Pulling and Laying 7
5.3.2 Procedure for Cable Pulling & Laying 8
5.4 Joints & Terminations Installation 9
5.4.1 Precautions Prior to Joints & Terminations Installation 9
5.4.2 Procedures for Joints & Terminations Installation 9
5.5 Installation Activity Verification 10
5.6 Management of Nonconformities 10

6 RECORDS 12

7 ANNEXES 12

8 REFERENCES 15

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1 PURPOSE
This procedure defines rules and recommendations for the correct handling and laying of Prysmian
Cables and Accessories. However the information reported in the present procedure do not represent
the full set of requirements which are needed for the correct management of this process and shall be
integrated by local (BU/Country) procedure/instruction including all necessary operating details

2 SCOPE
This procedure provides guidelines applicable to delivery and installation of EHV and HV Terrestrial
Cables and relevant Accessories; In particular it details roles and responsibilities for those projects
where Prysmian Group is directly managing also the installation (turn key projects). The same principles
can be applied to all other cable families

3 DEFINITIONS
Project Manager
Responsible for the coordination and control of all project activities (planning, execution, and
closing) according to agreed cost, time, and quality targets

Installation Manager
Responsible for the management of installation activities, including:
 resources and equipment management and certification
 compliance with Quality and Safety standards
 compliance with Installation best practices
 compliance with Group policies

Site Manager
Responsible for all operating activities for a specific installation site, including:
 site preparation and safety (including risk assessment)
 interface management (coordination with third parties)
 reporting
 assurance of direct labor and subcontractors adequate training and competence for
undertaking their assigned duties
 implementation of the Project Plan and issue of work method statements

Delivery
Transportation of a finish good product to the Customer

4 RESPONSABILITIES
The overall responsibility of the process is in charge to the Project Manager, who is responsible for the
coordination and control of all project activities (planning, execution and closing) according to agreed
cost, time and quality targets. In this process also Installation Manager and Site Manager are involved; in
particular:
Installation Manager is responsible for the management of installation activities, including:
Resources and equipment management and certification
Compliance with Quality and Safety standards

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Compliance with Installation best practices

Compliance with Group policies
Site Manager is responsible for all operating activities for specific installation site, including:
Site preparation and safety (including risk assessment)
Interface management (coordination with third parties)
Reporting
Assurance of direct labor and subcontractor adequate training and competence for
undertaking their assigned duties
Implementation of the Project Plan and issue of work method statements
Other responsibilities are described within the document
Countries/BU are required to define dedicated procedures/instructions which provide all necessary
details for carrying out the delivery and installation activity within their organization

5 PROCEDURE
The delivery and installation process includes:
Acceptance of cables/accessories shipment at installation site
Handling and storage of drums and boxes
Laying and jointing activity
The commissioning test is not part of this procedure

In particular, for “turn-key” projects all installation activities are to be carried out only by qualified
personnel with adequate experience and skill relevant to the specific System to be installed. The
responsibility for ensuring the proper installation condition is allocated to the Installation Manager. For
jointing activities, it is mandatory to utilize only Prysmian Qualified Jointers, certified at Jointing Training
School

In case of “supply only” (where the installation is not under direct Prysmian responsibility), the activities
should be carried out using the same criteria reported in the present procedure and general
handling/storage recommendations relevant to the supplied products (cables and/or accessories) shall
be clearly provided in writing to the Customer/Installer

5.1 On site acceptance of Cable Drums/Accessory Boxes

All delivered drums/boxes shall be provided with:
A synthetic card/tag reporting handling, storage and laying recommendations (annex 1)
Packaging list
Upon receiving the Cable/Accessory shipment, an acceptance inspection shall be carried out by Site
Manager which consists of:
Visual inspection in order to identify any damage eventually occurred during transport and
product compliance to the packing list and specifications (e.g. accessories Kit completeness and
presence of relevant work instructions)
Check of tags and labels to ensure their consistency with product order
Presence of all accompanying documentation (e.g. test report)

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5.2 Handling & Storage

Necessary precaution shall be taken, when moving cable drums, to ensure that material handling
equipment does not come in contact with cable surfaces or with protective covering on the drum.
Example of correct/incorrect Cable Drums handling and storage are reported below; similar
precaution shall be adopted for Accessories boxes
YES NO

drop drums from

be
hydraulic gate, hoist or
LOWER

Forks shall be long enough to Do not allow forks to touch

support the full drum width cable drum

Drums be lifted with a Drums shall not be lifted with

extending the cords that interfere with
both the flanges

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Drums shall be stored with Do not store Drums so that they

safety chock can freely rotate

Inspect all drums. Drums

laying flat should be refused. Do
Drums shall be stored not storage drums laying flat.
with the flanges aligned

Where possible, cable drums are to be stored indoors on a hard, dry surface to prevent their
deterioration and possible ingress of moisture into the cables. Cable drums stored outdoors must be
supported off the ground and covered with a suitable weatherproof material (e.g. avoiding direct
exposure to sunlight in case of jacket material not UV resistant). Cable drums are to be stored in such
a manner allowing easy access for lifting and moving, away from construction activities, falling or
lying objects, sources of high heat, open flames, chemicals or petroleum products, etc. that may
come in contact with the cable and cause damage. The use of fencing or other barriers to protect
cables and drums against damage by vehicles or other equipment moving about the storage area is
highly recommended. If the cable is to be stored on drums for future use after the factory applied
end-caps are removed, the exposed cable ends MUST be re-sealed using properly applied
weatherproof end-caps aimed at preventing the entrance of moisture into the cable. An example of
suitable end-cap is reported in Annex 2
Tapes are not suitable for preventing the entrance of moisture
Loose cable ends on the drums must be securely re-fastened to the drum flange and are not allowed
to lie on the ground. For prolonged storage of drums, especially in outdoor environment, drums and
end-caps shall be inspected periodically

5.3 Cable Installation

The information reported below are general guidelines for the installation of all terrestrial cable
families and specific requirements for EHV/HV shielded, jacketed cables up to 500kV, laid in conduit,
underground ducts, racks, trays or direct buried; they are aimed at avoiding the main causes of
damage during installation such as:
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Excessive pulling tension

Excessive bending
Accidental damage to the cable screen and metallic sheath due to mechanical forces

5.3.1 Precautions Prior to Cable Pulling and Laying

Temperature
Low temperatures create handling and pulling difficulties depending on cable construction and
installation location. Situation like this requires special consideration of the cold induced stiffness of
the cable when choosing radii and number of bends in the proposed installation. If temperatures are
expected to fall below the specification values (as defined by R&D) during the preceding 24 hour
period, provisions shall be made to move the cable to a warm storage area or provide localized
shelter and heating. The cable shall be exposed to a suitable temperature (e.g. 15°C for 24 hours) to
ensure its complete warm-up. Pulling eyes, if necessary, shall be installed at this time. During cold
weather installations, cable shall be pulled more slowly and trained in place the same day it is
removed from the warm storage area. The cable shall not be impacted, dropped, kinked or bent
sharply in cold temperatures

Materials
All materials used for the Installation activities shall be present on site, properly maintained and
regularly verified to confirm their adequacy

Cable route condition

Before starting the cable pulling work, the whole trench/pit/tunnel is to be inspected; in case of
pipe/ducts they have to be checked to ensure they are correctly aligned and cleaned: the cleaning
brush must have a suitable size and should be passed through the pipe ducts in order to remove any
obstacles eventually present. Smooth, burr-free pipe duct interiors are important in preventing
abrasion damage to the cable jacket during pulling
In case of trench for Direct Burial, it shall be cleared of all sharp stone, glass, metal or wood debris,
which could damage cable jacket during or after cable installation. The trench bottom shall be
uniformly covered (where required by specifications) by a special thermal backfill, to provide smooth,
soft bedding for the cable
In case of Rack/Trays, the entire pulling path shall be checked to make sure that the cable will ride
free and clear of all obstructions, sharp edges or projections which might cause it to jam or be
damaged
To avoid abrasion and damage of the cable jacket when guiding the cable from the drum to the duct
mouth or trench, all guides shall have large diameter, smooth surfaces, free-turning sheaves or rollers
In direct-burial installations, the cable may be paid off the drum and laid into the trench as the drum
is moved along the length of the trench. In such cases, the cable is simply laid on the bed of screened
soil or sand. Where the cable must be pulled through the trench, the preferred method is to support
the cable on temporary rollers so that the cable does not drag over the soil or sand bed. If rollers are
not available, sacks filled with very fine sand or other fine powdery material may be used as “pillows”
to support the cable and keep it from dragging on the trench bed during pulling

5.3.2 Procedure for Cable Pulling & Laying

The key parameters to be considered for cable pulling are:
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Maximum Permissible Pulling Tension (Conductor / Pulling Eye cable pulling)

Minimum Bending Radius
Maximum Permissible Cable Sidewall Pressure

Maximum Permissible Pulling Tension (Conductor / Pulling Eye cable pulling)

Pulling tensions for installing electrical cables shall be maintained as low as possible to prevent
damage to the cable. This may be accomplished through use of proper size ducts or conduits,
avoiding long pulls, and avoiding runs containing sharp bends or an excessive number of changes in
elevation. The maximum permissible pulling tension differs from cable to cable and depends upon
conductor size & material

Minimum Bending Radius

The minimum values for radii to which any cable may be bent differs from cable to cable based on
specific geometry (conductor diameter and/or outside diameter)

Maximum Permissible Cable Sidewall Pressure

Sidewall pressure applied on cables at bends shall be less than the calculated maximum permissible
side wall pressure for the specific cable
To preclude damage to the cable from the dynamic radial pressure, which develops when a cable is
pulled around a bend under pulling tension, this pressure must be kept as low as possible

The maximum (minimum for Bending radius) allowable values relevant to these three key parameters
shall be part of the requirements to be provided to the Installation Team by R&D. An example of
requirements for these three parameters is reported in annex 3

There are several methods for cable pulling whereas the main utilized are:
Nose / End Pulling
Continuous Bond pulling
Manually Assisted Method

Detailed information about pulling method to be applied on each specific Installation project shall be
provided to the Installation Team by R&D-Engineering department
During cable pulling, outer surface of the cable must be visually inspected for detecting any eventual
damage
After cable pulling and laying, all equipment are to be dismantled and put out of the trench.
Particular care is to be taken for avoiding cable damage and preventing workers from stepping on the
cables

5.4 Joints & Terminations Installation

The information reported below is general guidelines for the installation of HV terrestrial
joints/terminations up to 500kV. The complete set of information concerning joint/termination
handling and assembly are contained in the relevant instructions that must be available for jointer
during operations: 41.148.6.1019_C TES 1123-1145 AL (MIG)_FILI+PY (isol. xlpe ridotto).pdf &
41.297.6.1066_A GMS 1170 CR AL (MIG)_FILI-PY.pdf
The jointing shall be carried out only by Prysmian Qualified Jointers

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5.4.1 Precautions Prior to Joints & Terminations Installation

Environmental condition
Jointing operations shall be carried out in cleaned and controlled environment. A jointing area shall
be protected by standard supporting structures and tarpaulins, when the installation area is not
interested by strong wind, rain or other critical polluted elements (e.g. sand)
When the local environmental conditions (windy or sandy) are very critical, the jointing area shall be
double protected. In any case it is mandatory an accurate cleanliness of the jointing area with a
vacuum cleaner before starting the molding positioning on the cable insulation. Good electric lighting
must be maintained at all time during jointing and shall be kept in good working order
In severe hot conditions, air conditioning and airflow are necessary to prevent jointers perspiring.
However air conditioning and/or air fans shall be switched off before starting the molding positioning
until the removal of the PVC carrier tube, to limit air movements

Tools
All necessary tools and equipment must be carefully checked in due advance before commencing any
jointing operations, to ascertain that they are present and serviceable

Storage
Storage area is laid out in a confined, protected and tidy environment
In case of damage, the non-conforming items shall be clearly marked and segregated, and remedial
actions taken
Materials shall be stored in a clean environment and, where practicable, on racks that bear the item
description. Labels shall be affixed showing limited shelf life.
Before joints commences, the jointers must examine the wooden boxes in which the accessories
components are dispatched
Once taken from the boxes, all materials must be stored in clean and protected area (i.e., dedicated
container/s) to avoid mechanical damages and to preserve them from humidity, oxidization and
other contaminated agents. It is therefore advisable to keep the store temperature variation
between 0° C and 40 °C

5.4.2 Procedures for Joints & Terminations Installation

All the activity relevant to handling and installation of joints and terminations is described in detail by
the Jointing Training School documentation

5.5 Installation Activity Verification

Each Installation project is the responsibility of the Site Manager using a dedicated check list, aimed
at controlling and recording the compliance to requirements (both Prysmian and Customer) of
delivery and Installation activity. Special focus shall be given to those aspects which can impact on
the conformity of the installed system
An example of suitable check-list with the minimum set of controls to be carried out is reported in
Annex 4

5.6 Management of Non Conformities

In case of issues identified during the installation activities, it is responsibility of everyone involved
into the process to highlight the deviation and promptly inform the Site Manager for the definition of
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the appropriate containment actions (e.g. replacement of cables/accessories, repair)

Detailed information about the issue shall be provided in writing (formal non conformity notification)
by the Site Manager to the Project Manager who has the responsibility to fix the problem, involving
the appropriate functions as reported into the following chart:

Installation Issue

Containment actions
Site Manager and NC notification

Project Manager Issue Management

Evident Installation Fault Product/System

Installation Manager Country/BU Quality Manager

Issue Investigation

Network Components Cable Manufacturing Plant

System R&D (Group) Jointing
Business Unit School
Engineering

Root cause identification

Country/BU Quality Manager
and corrective action plan

Evaluation of potential
Project Manager impact on the project

In particular:
The Site Manager is responsible to immediately involve the Project manager for guaranteeing
an adequate evaluation of potential impact on the project (timing, costs, etc.) and for addressing
the investigation to the appropriate function
In case of fault clearly addressable to an installation error, it is responsibility of the Installation
Manager to define all appropriate actions for preventing any recurrence of the problem
In case of product related issue, it is responsibility of the Quality Manager of the
Country/Business Unit (contact owner) to coordinate the investigation activity involving all
entities/departments necessary for identifying the root cause of the problem

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Group R&D (Training School) can be involved (on demand) for participating to the
investigation activities and/or for specific training which may be needed for the local installation
team. In case of EHV/HV applications (≥ 132 kV) the involvement of the Jointing School is
mandatory

NOTE: in case of disputes about the responsibility attribution (and relevant costs) of non-conformity,
Group Quality is entitled to decide

Appropriate records of all installation issues shall be guaranteed by the involved Country/Business
Unit Quality Manager and regular feed-back shall be provided to Group Quality

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6 RECORDS
None

7 ANNEXES
Annex 1: example of handling, storage and laying recommendations cards for Drums (a) and Boxes (b)
a)

b)

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Annex 2: example of suitable cable end-cap and application on cable end

Annex 3: example of Key parameters for Installation

Minimum Bending Radius for single core Cables

Std sheathed design* Special Sheathed Design**
Static Condition 15 De 20 De
Dynamic Condition 25 De 30 De
** Metal laminated or lead sheathed
De is the external cable diameter * Cu wire screen only and/or with integrated fiber optics

2
Maximum pulling force : Alluminium conductors...... ≤ 30 N/mm
2
Copper conductors............ ≤ 50 N/mm

Maximum side wall pressure : SWP (N/m) = Te/Br

Where : Te = Pulling force (N), Br = Bend Radius (m)

Te

Br

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Annex 4: example of check list for cable laying (FO-SL-RQMS-037)

CHECK LIST FOR CABLE LAYING

Location: Project Name:

______________________
Product Code/description:
___________________________________
Installation Manager Name: Joint supervisor name:
_______________________________________
Not
N° ITEM YES NO Evaluat COMMENT/REMARKS
ed

1 DOCUMENTATION

Is all the documentation relevant to cable installation available (technical

specifications, drawings, cables certificates etc.)?

2 DRUMS PACKAGING, HANDLING AND STORAGE CONDITION

Are drums rotated according to the arrow mark direction if the drum
required to be rolled on the ground ?
Is the ground leveled and with steel plate for laying the cable drum on it
?
Are all wooden battens (or other protective system) totally removed
without any nuts, nails or bolt left that could damage the cable surface
?

Are the jack stands suitable (approved) for supporting the cable drum ?

3 VISUAL EXAMINATION OF THE CABLE

Is the surface of the cable smooth and free of damages ?

Is the cable correctly marked and identified?

4 CABLE ROUTE INSPECTION & PRELIMINARY PREPARATION

Trench

Is trench floor prepared as per requirements (e.g. Sand bed) and free
from sharp objects ?
Are trench bends in accordance with the minimum cable bending radius
required ?

Pipe

Is the internal surface of Pipes thoroughly brushed and clean ?

Are pipes mouths sealed with watertight caps before cable laying ?

Did you perform a trial pulling with an appropriate dimension test piece
?
After the trial pulling was the external surface of test piece in good
condition ?

5 MEASUREMENT EQUIPMENT AND TOOLS VERIFICATION

Is the measurement equipment complete and adequate (range,

calibration, accuracy, etc)?
Are tools and machinery available and adequate (Compliance to
requirements, range, accuracy etc)

6 WINCH SETTING

Are the winches anchored in order to sustain the force during cable
laying?

Are winches equipped with measuring pulling force ?

Are test certificates for winches and measuring pulling force device
available?

7 ROLLER POSITIONING

Is the distance between each roller aligned to requirements (about 2 m

on straight line and 0.5m along curve)?

Are rollers in good condition, freely rotating and with a smooth surface ?

8 LAYING OF WIRE ROPE

Are wire ropes in twist or kink condition ?

Are available wire ropes suitable for pulling the cable (with admissible
strength 5 or 6 times the max expected pulling tension)?

Is wire rope connected to pulling eye through a swivel shackle?

Does the swivel freely rotate to absorb the torsion force of the wire
rope?

9 CABLE LAYING

Is the rolling direction of cable drum opposite to the arrow mark

direction printed on the drum?
Is drum rotation speed in accordance to requirement and controlled by
means of a brake (of any kind)?
Are the bell mouths attached to the pipe mouths to prevent the abrasion
of cable outersheath?
Is the cable lubricated with approved lubricant to facilitate scrolling into
the pipes during pulling?

Is the maximum pulling force during cable laying recorded ?

Wich is the maximum pulling force recorded during cable laying (write
the value)?

10 AFTER CABLE LAYING

Are all openings of installed cable pipes completely filled with bentonite
mixture after cable installation?
Are cable ends (both of installed and remaining length on the drum)
sealed with approved end caps?

Are spare pipes capped after cable installation?

11 JOINT/TERMINATION INSTALLATION

Did you check if Joint team/supervisor are qualified and with a valid
certificate?

Are the Assembly Drawing and Jointing Instruction available ?

Did you check the expiry date of the Joint/terminal?

Are the tools listed in the Jointing Instruction available and in a good
condition?

Is the nose cone of the correct size for the PVC tube to be used?

Are all components present, thoroughly examined, with no dameges and

cleaned?
Is the joint bay adequately protected from an environment point of view
?

Did you take note of the sleeve(s) part number/code?

Did you check the temperature of the sleeve before assembly?

Did you check that after removing the semiconducting cable screen the
insulation is not marked or damaged?
Did you check that the cable insulation is undamaged and has a
perfectly smooth surface?

Did you check that the casing is correctly positioned?

Did you check that the heat shrinkable tubes have been correctly shrunk
down?

Date: _________________ Signature:__________________________

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8 REFERENCES
PQMS Prysmian Quality Management System

QM-SL-RQMS-4.2.2 Quality Management System Manual of PRYSL.

OP-Sl-RQMS-4.2.3/4.2.4 Documents & Record Management

OI-R&D-ELAB-ET-805 Management Training School

XLPE 500 kV Jointing Training Handbook

OP-DQ-QS-024 Cables and Accessories Delivery and Installation - ver 2

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