003-ms for cable joint and termination.pdf

Pearl GTL Project

LINDE ENGINEERING

Shell Project No: HP-3000-QAT Contractor Project No : 5887 Project Document Number: T.4.234.584 Project Rev.: O Page 2 of 17

Purchase Order Number:

2MH127

Tag/Item Number(s): N/A

Unit(s): ASU

PCWBS: Z

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

E O 22.04.2008 Comments Incorporated SM AK AG CCI

D O 16.04.2008 Comments Incorporated SM/HU OE AG CCI

C O 10.04.2008 Issued for Company Comments SM/HU OE AG ICC

B 19.03.2008 Issued for Review SM/HU OE AG IFR

A 16.03.2008 Issued for Internal Review SM/HU OE AG IIR

GAMA Rev.

Project Rev Date Description

Prepared By

Checked By

Approved By Status

No. No. ORIGINATOR

LINDEGINEERING AG

Document Title:

METHOD STATEMENT FOR CABLE JOINT AND TERMINATION

Document No. GAM MTS ELE GTL 003 E

LOC470 Contractor

Gama Qatar Co. W. L. L. Org.

Code Doc. Type

Disc. Code

Geogr. Area

Seq. No

Rev. No Vendor Code

Project Document Number: T.4.234.584

Rev No: O

Doc. Title : Method Statement For Cable Joint and Termination

Date/Rev. No : 22.04.2008 (REV.E)

T.4.234.584 REV-O Page 4 of 17

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TABLE OF CONTENTS

1 PURPOSE ......................................................................................................................5 2 SCOPE............................................................................................................................5 3 REFERENCES ...............................................................................................................5 4 DEFINITIONS .................................................................................................................5 5 EQUIPMENTS ................................................................................................................5 6 MANPOWER ..................................................................................................................6 7 MATERIALS ...................................................................................................................6 8 RESPONSIBILITY ..........................................................................................................6

8.1 EQUIPMENT & MAINTAINENCE MANAGER 6 8.2 HSSE MANAGER 6 8.3 SITE ENGINEER/SUPERVISOR 6 8.4 AUTHORISED ELECTRICAL PERSON (AEP) 6

9 METHOD OF EXECUTION ............................................................................................7 9.1 PRE-COMMENCEMENT WORKS 7 9.1.1 WORK PERMIT 7 9.2 CABLE JOINTS 7 9.2.1 CABLE JOINTS ON LOW VOLTAGE & CONTROL CABLES 7 9.3 CABLE TERMINATIONS 7 9.3.1 PANEL TERMINATION 8 9.3.2 ELECTRICAL EQUIPMENT TERMINATION 8

10 HSSE ..............................................................................................................................9 11 ATTACHMENTS.............................................................................................................9

11.1 JOB SAFETY ANALYSIS 9


Date/Rev. No : 22.04.2008 (REV.E)

T.4.234.584 REV-O Page 5 of 17

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1 PURPOSE

The purpose of this method statement is to clarify cable joint and termination works that will be carried out at the TSF area at Ras Laffan Industrial City in QSGTL Pearl Plant C2 ASU Project by GAMA Qatar.

2 SCOPE

This method statement identifies the basic system and technique used for the successful completion of the works.

3 REFERENCES

T-4.234.542 : Project Quality PlanT-13.377.360 : Flawless Start-up Initiative (FSI)T-4.234.084 : Method Statement for LiftingT-4.129.872 : Heat Stress Disorder Prevention Procedure T-4.095.303 : HSSE Plan ConstructionT-4.129.860 : Manual handlingT-4.129.859 : Lifting OperationsT-4.219.660 : Permit to Work Handover Implementation Plan T-4.129.861 : Working with ElectricityT-4.219.610 : Construction Waste Management Plan

4 DEFINITIONS

Company : QSGTL or its PMC Contractor : LINDE ENGINEERING AG Sub Contractor : GAMA QATAR Contract : QSGTL Pearl Plant C2 ASU Project TSF : Temporary Site Facilities

5 EQUIPMENTS

Hydraulic cable cutter Crimping Tools Set of electrician tools PPE (Long sleeve coverall, safety helmet, safety goggles, hand gloves, steel toe boots) Fire Extinguisher


Date/Rev. No : 22.04.2008 (REV.E)

T.4.234.584 REV-O Page 6 of 17

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6 MANPOWER

Electrical Site Engineer Electrical Supervisor QA/QC Engineer Electrical Foreman Electrical lead man Electric Technician Helper HSSE personnel

All personnel shall be inducted and trained before attempting work on site and have valid certificates. Specific training: Cable preparation, cable splicing and cable terminations.

7 MATERIALS

Cable Termination Kits Cable Joint Kits

8 RESPONSIBILITY

8.1 EQUIPMENT & MAINTAINENCE MANAGER The equipment manager will be responsible for the lifting equipments availability and good order.

8.2 HSSE MANAGER Responsible for the safety control works for all construction sites under the jurisdiction of his department, inform the site of various kinds of safety policies, plans, etc.

8.3 SITE ENGINEER/SUPERVISOR The site engineer/supervisor will perform the necessary studies and calculations and will supervise procedures. He will ensure that the work is being carried out effectively in accordance with the established Work Method Statements and JSAs.

8.4 AUTHORISED ELECTRICAL PERSON (AEP)

The AEP is the Competent Electrical Person, appointed in writing by the SEA by a Certificate of Appointment. He is responsible to supervise or to carry out specified operations on LV electrical power systems and work on electrical equipment. The authorisation includes the authority to receive a sanction for test, issue and cancel limitations of access and perform the necessary safety procedures associated with such work and testing.


Date/Rev. No : 22.04.2008 (REV.E)

T.4.234.584 REV-O Page 7 of 17

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9 METHOD OF EXECUTION

9.1 PRE-COMMENCEMENT WORKS Before the activity the following must be taken into account.

9.1.1 WORK PERMIT Prior to cable joint or cable termination a request for a permit to work is submitted. After issuance of the related permit, the execution of the work will be done.

9.2 CABLE JOINTS

Accessories for jointing of cables shall be selected from the range of MESC68, as appropriate.

9.2.1 CABLE JOINTS ON LOW VOLTAGE & CONTROL CABLES The trench route shall be free from all obstructions, debris, sharp materials, stones etc. Cable joint ends shall be prepared properly before jointing. Sealing shall be checked at end of the cable to prevent ingress of moisture or dust. Cables joints shall be carried out based on supplier documents. Individual test report on cables are required. QC inspection shall be done.

9.3 CABLE TERMINATIONS

Accessories for termination of cables shall be selected from the range of MESC68, as appropriate. Cable glands shall be selected as suitable type of cable termination box/enclosure and shall be appropriate type of protection. Non metallic cable glands should be used with non-metallic termination boxes and the following conductor shall be terminated at the internal earth terminal. Metallic cable glands should be used with metallic termination boxes. QC inspection shall be done.


Date/Rev. No : 22.04.2008 (REV.E)

T.4.234.584 REV-O Page 8 of 17

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9.3.1 PANEL TERMINATION Installation of the panels shall be checked whether it is properly mounted on proper location. Ensure the terminal blocks on the local panels are correct. Check for physical condition, size and type of cable glands, termination kits, lugs and PVC shrouds at receipt. Ensure the cables are properly dressed and sufficient slag is provided. Ensure the adequate sealing, supports and cleating arrangements are provided below the panels and at entry points. The identification tag on cable near the cable gland is provided. The lock nuts of the cable glands are tightened properly. Check for the torque tightness of the cable cores in the terminals. Ensure all spare holes in panels and gland plates are plugged with approved plugs. Ensure correct size spanners used when tension cable glands. Cable core tag must be provided. QC inspection shall be done.

9.3.2 ELECTRICAL EQUIPMENT TERMINATION

Ensure the installation, levelling, alignment of the electrical equipments, machineries whether it is properly mounted on proper location. The orientation of cables to be ensured at terminal end before termination. Ensure the cables are having sufficient clearance before terminal points. The identification tag on cable near the cable terminals of equipments to be provided. The lock nuts of the cable glands are tightened properly. Check for the torque tightness of the cable cores in the terminals if applicable. Ensure the cable glands are in as per approved drawing. Individual test report is required. QC inspection shall be done.


Date/Rev. No : 22.04.2008 (REV.E)

T.4.234.584 REV-O Page 9 of 17

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10 HSSE

All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and International standards, codes, QSGTL requirements and instructions. In addition all employees and GAMA subcontractor employees on site will have through QSGTL Site Safety Induction, Linde Induction and GAMA Qatar Safety induction for site safety, health, environmental and security prior to work activities. Risk Assessment will have been prepared by the Risk Assessment Team (RAT) ranking the hazards associated with project works and control measures to be taken to mitigate the hazards to an acceptable level. Each work scope or task will have a completed and approved Job Safety Analysis (JSA) identifying the potential hazards and control measures that will be implemented to protect people and environment. The JSA will be used by Supervisor as the basis of conducting his daily Total Safety Task Instruction and his weekly Tool Box Talk (TBT). The job will be performed under supervision of a contractors approved Authorised Electrical Person (AEP). In addition to the above, employees conducting the work will wear required PPE and highly visible vest where traffic or other hazards may exist. For additional safety requirements for a particular or specific task please refer to the JSA prepared for that task.

11 ATTACHMENTS

11.1 JOB SAFETY ANALYSIS

JOB SAFETY ANALYSIS / RISK ASSESSMENT

JSA For: T.4.234.584 Page No: 1 of 8 Job being analysed: MS CABLE JOINT AND TERMINATION

JSA Members: Sydney OSBOURNE, Alper KOSE Department/Section doing JSA: HSSE & Electrical works

Job Performers: Alper KOSE Normal Approvals: Name Signature Date JSA by: Alper KOSE 24.04.2008

General job requirements / Personal Protective Equipment.

Job Supervisor: Alper KOSE 24.04.2008 Additional Approvals (Determined by Job Supervisor in correlation with Linde HSSE Manager). Name Signature Date Discipline Superintendent (Linde)

HSSE Representative (Linde)

1. The following Personal Protective Equipment shall be worn: Approved coveralls, safety goggles, safety helmet, safety steel toe shoes. Hearing protection must be worn(whenever required)

2. Permit To Work.

OTHERS (List Below):

Approval required for hazardous work detailed in the Linde Work Permit Procedure. Changing conditions and emergency procedures Stop work. Switch off equipment. Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing employees are reported to Linde HSSE Dept. When all clear is given, check with Linde HSSE before returning to work. LINDE EMERGENCY TELEPHONE NO. HSSE MANAGER: 506 41 20 Pearl HOT LINE : 474 88 88

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JOB SAFETY ANALYSIS / RISK ASSESSMENT FOR T.4.234.584

SCOPE : METHOD STATEMENT CABLE JOINT AND TERMINATION

Initial Risk Residual Risk

HAZARDS / POTENTIAL RISK MAIN ADDITIONAL ITEM ACTIVITY CONSEQUENCES P C RANK CONTROLS CONTROLS P C R

1.1 Hand & finger injury during manual handling. D 2 MED

1.1.1 1.1.2

Wear approved safety gloves. Use the right tools for the job.

C 2 LOW

1.2 Arm, Muscle strains or sprains while overlaping cables prior to cuts. D 2 MED

1.2.1 1.2.2

Use the "Buddy System" get help. Break the job down into manageable portions.

C 2 LOW

1.3 Cuts injury due to cutting of outer, inner sheath using cable splicer.

D 3 MED

1.3.1 1.3.2 1.3.3

Ensure that workers carrying the task is properly trained and competent.. Keep the splicing tools sharp and hands behind the cutting edges when working. Ensure all tools (hydraulic cable cutter) shall be inspected and approved.

1.3.1.1 Supervisor / foreman shall ensure that the TBT is properly executed at the work front and hazards discussed.

C 3 MED

1 1.a 1.b 1.c 1.d

Low Voltage cable jointing preparation. Overlap the cables to be jointed. Removed the outer sheath and armour. Removed inner sheath from the end of armour. Slide one corrosion protection tube over each cable.

1.4 Pinch point.

D 3 MED

1.4.1 1.4.2

Ensure proper positioning of hand & fingers while doing the job. Keep away hand & finger from any pinch point hazard.

1.4.1.1 Supervisor / foreman shall ensure that the TBT is properly executed at the work front and hazards discussed. C 3 MED

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Initial Risk Residual Risk ITEM ACTIVITY HAZARDS / POTENTIAL P C RISK MAIN ADDITIONAL P C R

CONSEQUENCES 2.1 Hand & finger injury. D 2 MED 2.1.1 2.1.2


C 2 LOW

2.2 Incompetent personnel.

D 3 MED

2.2.1 2.2.2

Ensure trained and competent electricians who will carry out cable core jointing preparation. Pre-employment checks of competence.

2.2.1.1 Competent employees readily identifiable.

C 3 MED

2.3 Eye injury.

D 3 MED

2.3.1 2.3.2

Wear approved safety glass. Supervisor / foreman shall ensure that the TBT is properly executed at the work front and hazards discussed.

C 3 MED

2.4 Improper set-up.

C 3 MED

2.4.1 Check for the seal at end of the cable to prevent ingress of moisture or dust. Check the cable joints are prepared properly. Ensure to place tinned copper earth braid across the joint over the armour of both the cables. Refer to vendors manuals.

2.4.1.1 All work shall be as per Work Method Statement.

B 3 LOW

2.5 Pinch point.

D 3 MED

2.5.1 2.5.2

Ensure proper positioning of hand & fingers while doing the job. Keep away hand & finger from any pinch point hazard.

2.5.1.1 Supervisor / foreman shall ensure that the TBT is properly executed at the work front and hazards discussed.

C 3 MED

2 2.a 2.b 2.c 2.d 2.e 2.f

Low Voltage core jointing preparation. Cut the cores off. Insert one set of nested tubes over each core and push down up to the crutch. Crimp the connectors with a suitable tool. File off burrs. Abrade, clean & degrease the connectors. Wipe the insulation clean with cleaning solvent. Apply black mastic around the cores. Place Tinned copper wire mesh, Bare Copper Braid, Roll spring.

2.6 Vapor inhalation.

D 2 MED

2.6.1 2.6.2 2.6.3

Wear approved respirator. Work up wind. MSDS communicated.

C 2 LOW

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HAZARDS / POTENTIAL RISK MAIN ADDITIONAL RISK ITEM ACTIVITY CONSEQUENCES P C RANK CONTROLS CONTROLS P C RANK 3 Place corrosion

protection tubes. 3.1 Improper

installation/overlaps of protection tubes. D 3 MED

3.1.1 3.1.2

Ensure that workers carrying the task is properly trained and competent. All work shall be done as per Work Method Statement.

C 3 MED

4.1 Burn injury.

D 3 MED

4.1.1 4.1.2

Wear appropriate protective clothing, safety jackets, welding apron, gloves and face shield. Ensure work area properly barricaded and secure with displayed warning signs to warn the workers.

C 3 MED

4.2 Fire hazard.

C 5 HIGH

4.2.1 4.2.2 4.2.3

Keep flames, sparks and hot metal from coming in contact with combustible materials. Keep a fire watch. Obtained approved Hot Work Permit.

4.2.1.1 Suitable fire extinguishers at site. Post emergency phone numbers conspicuously throughout the work. B 5 MED

4.3 Unqualified personnel.

D 3 MED

4.3.1 4.3.2

Ensure trained and competent electricians who will carry out the job. Pre-employment checks of competence.


C 3 MED

4 Shrinking the tube sleeves using gas torch from cable end and proceed towards joint.

4.4 Working in manholes or excavations.

C 5 HIGH

4.4.1 4.4.2

A confined space permit shall be initiated for all manholes / excavations 1.5m or deeper. Ensure atmosphere has been properly checked for toxic gases or vapors i.e. oxygen content, explosive atmosphere, carbon monoxide and hydrogen sulfide.

4.4.1.1 Gas test shall be conducted prior to entry by authorized gas tester.

B 5 MED

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HAZARDS / POTENTIAL RISK MAIN ADDITIONAL RISK ITEM ACTIVITY CONSEQUENCES P C RANK CONTROLS CONTROLS P C RANK 5 Power & Control

instrument jointing cables.

5.1 Hand & finger injury.

D 2 MED

5.1.1 5.1.2


C 2 LOW


D 3 MED

5.2.1 5.2.2

Ensure trained and competent electricians who will carry out cable core jointing preparation. Pre-employment checks of competence.


C 3 MED

5.3 Improper used of tools.

D 3 MED

5.3.1 5.3.2 5.3.3 5.3.4

All tools shall be inspected & colour coded. Select a tool that has a non-slip surface for a better grip. Select a tool that can be used with your dominant hand or with either hand. Select a tool without sharp edges or finger grooves on the handle.

5.3.1.1 Choose a tool that requires the least continuous force and can be used without awkward postures.

C 3 MED

5.4 Cuts injury.

D 3 MED

5.4.1 5.4.2

Ensure that workers carrying the task is properly trained and competent. Keep the splicing tools sharp and hands behind the cutting edges when working.

5.4.1.1 Supervisor / foreman shall ensure that the `TBT is properly executed at the work front and hazards discussed. C 3 MED

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HAZARDS / POTENTIAL RISK MAIN ADDITIONAL RISK ITEM ACTIVITY CONSEQUENCES P C RANK CONTROLS CONTROLS P C RANK 6.1.1 All tools shall be inspected &

colour coded.

6.1.2 Select a tool that has a non-slip surface for a better grip.

6.1.3 Select a tool that can be used with your dominant hand or with either hand.

6.1.4 Select a tool without sharp edges or finger grooves on the handle.

6.1 Improper used of tools.

D 3 MED

6.1.5 Ensure to use a tool that is held power grip, when high force is required.

C 3 MED

6.2.1 Used appropriate cable gland (pvc, steel gland) according to cable sizes.

6.2 Improper cable glanding.

D 3 MED 6.2.2 Ensure all enclosure comply the right Ingress Protection.

6.2.2.1 Ensure all armoured cable use steel gland (brass) and connected to grounding system.

C 3 MED

6 Cable termination to junction boxes, panels, electrical equipment & instruments.


D 3 MED

6.3.1 6.3.2 6.3.3

Supervision by Authorized Electrical Person approved by Client. Ensure trained and competent electricians who will carry out the task. Pre-employment checks of competence.


C 3 MED

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HAZARDS / POTENTIAL RISK MAIN ADDITIONAL RISK ITEM ACTIVITY CONSEQUENCES P C RANK CONTROLS CONTROLS P C RANK 6.4 Hand & finger injury due

tightening of screw at terminal blocks.

D 2 MED

6.4.1 6.4.2

Wear approved hand gloves. Select a tool that can be used with your dominant hand or with either hand.

C 2 LOW

7.1

Improper grounding.

C

4

MED

7.1.1 7.1.2 7.1.3 7.1.4

Grounding shall be provided for all electrical equipment. Metallic panel boards shall be grounded using proper grounding wire. Ensure all electrically energized, equipment shall be earthed at all times through a visually identifiable earth connection. Connect earthing to the earth system before securing them to the phase and neutral conductors.

Earth leads must be colored green, should be of strand copper or copper alloys. Every earthing connection and joint must be properly made by means of efficient clamps or coupling. Non-ferrous material should be used.

B

3

LOW

7

Electrical Testing


C

4

MED

7.2.1 7.2..2 7.2.3

Supervision by Authorized Electrical Person approved by Client. Ensure trained and competent electricians who will carry out the task. Ensure to have updated electrical single line diagram during checking/verification.

The subcontractor shall ensure that these persons have sufficient electrical technical knowledge and experience to fulfill all responsibilities and to avoid danger to himself and others when working on electrical system or equipment.

C

2

LOW

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HAZARDS / POTENTIAL RISK MAIN ADDITIONAL RISK ITEM ACTIVITY CONSEQUENCES P C RANK CONTROLS CONTROLS P C RANK 7.3 Improper used of tools

and test devices

D 3 MED

7.3.1 7.3.2 7.3.3 7.3.4

All tools shall be inspected & colour coded. All test device shall be calibrated and label sticked. Select a tool that has a non-slip surface for a better grip. Select a tool that can be used with your dominant hand or with either hand.

Workers trained in proper use of tools and test devices.

D

2

LOW

7.4 Electrical energization hazard.

E

4

HIGH

7.4.1 7.4.2 7.4.3 7.4.4

The cable between the source of power and the distribution box shall be armoured. Prior to energisation of any temporary power system a pre-energisation checklist shall be completed Wear approved electricians hand gloves,shoes and glass. Ensure work area properly barricaded and secure with displayed warning signs to warn the workers.

Obtained Electrical Energizing Clearance Certificate. Permit to Work on Electrical Equipment. LO/TO procedure to be completed during energization.

D

3

MED

7.5

Defective tools.

C

3

MED

7.5.1 7.5.2 7.5.3

Ensure tools shall maintain in good condition to allow safe operation. All equipment shall be properly inspected & color coded. Ensure employees should inspect and test their tools/equipment before and after used.

C

2

LOW

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003-ms for cable joint and termination.pdf

Documents

revo page

termination document

method statement

cable joints

cable terminations

project rev date description

termination daterev

qat contractor project