08/09/99

Saudi Consolidated Electric Company ≠B@IZ¢y{{ ©X@R•}{A ™¶X•@@la{A ™yZ@c{A

in the Eastern Province
™@@¶@vZ@c{A ™@@@wi
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

CABLE INSTALLATION,
FIELD HANDLING PROCEDURES

[SC10406/AAG:as] 0799 PAGE NO. 06 : 1 of 19

 08/09/99
Saudi Consolidated Electric Company ≠B@IZ¢y{{ ©X@R•}{A ™¶X•@@la{A ™yZ@c{A
in the Eastern Province
™@@¶@vZ@c{A ™@@@wi
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

TABLE OF CONTENTS

1.0 SCOPE

2.0 GENERAL REQUIREMENTS

3.0 LPOF CABLE HANDLING DURING INSTALLATION

4.0 CABLE PULLING

5.0 OIL FEED SUPPLIES

6.0 LAYING OF CABLES

LIST OF DRAWINGS

06-01 Drum Handling Caution

06-02 Rolling Direction of Drum

06-03 Laying of Cable

06-04 Typical Laying of Cables

06-05 Typical Installation - Cable Pulling Procedure

06-06 Exchange of Pressure Tanks

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 08/09/99
Saudi Consolidated Electric Company ≠B@IZ¢y{{ ©X@R•}{A ™¶X•@@la{A ™yZ@c{A
in the Eastern Province
™@@¶@vZ@c{A ™@@@wi
}{A ßs

SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

1.0 SCOPE

The purpose of this standard is to describe the techniques and procedure for installation
of XLPE and LPOF cables in a manner that will not damage them.

2.0 GENERAL REQUIREMENTS

2.1 An overall project schedule shall be developed to include the sequence of

installation, mobilization of work force and equipment, placement of cable
drums, required pulling equipment and tools and procedure for pulling cables.

2.2. All equipment required for proper installation shall be certified as operational
and strategically placed to avoid interruption of the installation process.

2.3 Prior to commencing the cable pull, all cable drums shall be set in place and all
necessary equipment, tools and hardware set up to start the cable pull.

Cable pulling shall not be started if it appears that climatic conditions will
deteriorate and cause the cable pulling sequence to be interrupted or delayed.

2.4 Safety Precautions

2.4.1 Barricades, warning signs and warning lights shall be provided to comply
with the requirements of the municipality and traffic police. Warning
signs both in Arabic and English, shall be displayed to caution
pedestrians and traffic. Warning list and signs shall be provided along
the trench on both sides. Steel plates or wooden planks shall be provided
across the trench at entrances to residences.

Warning signs of minimum (100 x 60 cms) size shall be displayed at

approximately every 50 meters length along the trench and wherever
practical the barricades shall be located on both sides of the trench edges
and at one (1) meter from the nearest trench edge and in a continuous
manner. In addition, the requirements of SCECO-East Construction
Safety Manual and SCECO-East Accident Prevention Manual shall also
be followed.

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Saudi Consolidated Electric Company ≠B@IZ¢y{{ ©X@R•}{A ™¶X•@@la{A ™yZ@c{A
in the Eastern Province
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

2.5 Cable storage

2.5.1 Cables can be seriously damaged if proper care is not exercised in its
storage in warehouse or contractors’ yards. Following factors shall be
considered for cable storage:

a. Cable drums shall be stored on firm and flat surfaces only so that
flanges of the drum do not sink in the ground.

b. Water shall not accumulate at the storage location.

c. Storage location shall be away form any ongoing construction,

chemical or petroleum sources, open fires, heat sources or heavy
vibration areas.

d. Cable drums shall be supported on flanges only. Drums shall

never be kept flat.

j. Loose cable coils shall be stored on wooden pallets. Coiled cable

shall be properly tied with rope or wire at four (4) or more points
round the coil. The coil radius shall not be less than the
minimum bending radius of the cable.

f. During storage, cable ends must remain capped with appropriate

heatshrink caps to prevent moisture from entering the cable.

3.0 LPOF Cable Handling During Installation

3.1 The trenches and ducts into which the cable is to be installed must be clean and
free of projections. Stones, sharp edges, etc. that may damage the jacket either
during the installing operation or after the cable is placed in its final position.

3.2 Locating the Cable Drum

3.2.1 All part of the cable shall be maintained under a positive oil pressure
because LPOF cables undergoes changes of hydraulic pressure due to
differences in elevation.

The route profile shall be verified and studied before deciding at which
end of the cable route to place the drum.

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in the Eastern Province
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

3.2.2 A flat profile with differences in elevation not exceeding the maximum
oil pressure of the cable drum oil reservoir will normally present little
problem.

On a hilly route, the difference in elevation approaches or exceeds the

maximum oil pressure of the cable reel oil reservoir.

To avoid damage to the reservoir and prevent negative pressure

conditions within the cable, the drum must be placed at the higher end of
the cable route. However, consideration shall be given to bends in the
route before deciding the direction of pull.

3.2.3 To avoid excessive mechanical sidewall pressure on the cable as it is

pulled around severe bends in ducts or on rollers, the cable pulling
direction shall be arranged if possible such that these bends are
negotiated at the start of the pull rather than at the end.

3.2.4 A convenient approximation for calculating static oil pressure is to allow

9kPa pressure for every meter of elevation.

3.2.5 Where more than one cable section is involved, the sequence of cable
pulling may require some study. Once a cable has been pulled before the
end is removed from its cable drum, a temporary oil supply is required
either from an oil reservoir or by cross-connection with an adjacent cable
section.

Prior to commencing the work, therefore, it is necessary to take into

account secure locations for temporary oil feed points, cross-connection
of oil feeds between cable sections, the jointing sequence and elevation
differences as they affect the static pressure of oil.

4.0 CABLE PULLING

4.1 Prior to cable pulling into ducts, the duct must be cleaned with suitable brushes
and swabs followed by a mandrel test. A 300mm long wooden mandrel having a
diameter 20% less than the inside diameter of the duct shall be pulled through
each duct run. The mandrel must pass through freely and upon leaving the duct
shall not show evidence of scoring. To prevent injury to the cable by scraping
on the manhole frame or at the duct opening or in passing over other cables, a
suitable flexible feeding tube shall be used.

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Saudi Consolidated Electric Company ≠B@IZ¢y{{ ©X@R•}{A ™¶X•@@la{A ™yZ@c{A
in the Eastern Province
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

4.2 Before pulling cable into open trenches, the trench shall be graded and
compacted with a minimum of 150mm of the specified backfill material. The
compacted backfill materials shall be smooth and free of stones and projections
which might damage the cable. An adequate number of cable rollers shall be
placed in the trench, spaced at intervals of 1.5 to 2 meters depending on the
stiffness of the cable, sufficient to prevent the cable dragging on the ground
between rollers. Where the cable passes around bends, rollers must be arranged
to provide smooth passage and maintain correct installation bending radii.

4.3 The cable drum is normally set up with the leading end of the cable coming from
the top of the drum. A tendency for turns of cable to become loose and
unmanageable results from pulling the cable from the bottom of the drum. A
ramp of two or more long rollers will assist the cable from the top of the drum
into the trench or manhole. Care must be taken so that minimum installation
bending radii are not exceeded when setting up the rollers leading the cable into
the trench or manhole.

Several methods of cable pulling may be used:

a. Hand pulling
b. Direct wind line pulling
c. Carrier wind line or “Bond Pulling”
d. Motorized rollers and puller drives

The selected method will depend on manpower and equipment available and
upon other considerations of pulling tension, sidewall pressure, route
configuration and cable characteristics.

4.4 Where direct wind line pulling is used, the cable end shall be fitted with a
properly designed pulling eye which transfers the winch line tension to the cable
conductor. Cable stockings or Kellems grips must not be used.

A dynamometer fitted to the cable winch is required so that the pulling tension
on the cable may be checked and that safe pulling tensions are not exceeded. To
reduce tension when pulling cable into ducts, a suitable lubricant shall be
applied to the cable. A recommended lubricant is 80% glycerin and 20% water
by weight with a thickening agent added of 1½% to 2½% hydroxyethyl-
cellulose. The lubricant recommended by the cable manufacturer can be used.

For convenience and cleanliness in splicing, the first and last 1.5m of the cable
shall not be lubricated.

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in the Eastern Province
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

5.0 OIL FEED SUPPLIES

Before completing the pulling-in operation and removing the cable end from the drum, a
temporary oil feed must be connected to the leading end of the cable. A source of
degassed cable oil, either a reservoir or an adjacent cable, must be ready and equipped
with a suitable length of treated and filled copper tubing.

The connection is made to the flared fitting on the end of the cable. Ensure that oil is
flowing from both cable and oil source while making the connection to avoid the ingress
of air. Once this connection has been made, the cable drum reservoir may be shutoff
and the cable removed from the drum.

If there is an excess of cable and it has to be cut and capped, this may only be done with
the cable end elevated to form a ‘U’ or oil trap below the point of cutting and with a
positive flow of oil applied to the remote end of the cable.

In all the operations of oil-filled cable installation, cable pulling, connection and
disconnection of oil supplies, cutting and capping, jointing, terminating, etc., the
following points must be observed:

5.1 No parts of the cable system shall be left without a positive oil pressure.

5.2 A source of pressurized degassed cable oil must be available at all times.

5.3 Consideration must be given to static hydraulic pressures when selecting the
pressure of the oil supply to be applied for temporary oil feeds.

5.4 All connectors must be made with a positive oil flow from both ends to be
connected.

5.5 After cutting and capping cable ends and after disconnecting any oil feed line, a
flush of oil shall be made through the fitting to ensure any trapped air is flushed
out.

5.6 All oil feed points and accessible connections shall be secured from
unauthorized tampering or vandalism.

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 08/09/99
Saudi Consolidated Electric Company ≠B@IZ¢y{{ ©X@R•}{A ™¶X•@@la{A ™yZ@c{A
in the Eastern Province
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

6.0 LAYING OF CABLES

The laying shall be carried out in the following order:

6.1 Preparatory work for laying

After the excavation of cable trench, the following works shall be done:

6.1.1 Pump out the water from the cable trench, if necessary
6.1.2 Remove any obstacles out of the trench
6.1.3 Prepare the laying tools, i.e. drum jacks, shaft tension meter and others
stated in Figure 06-02 and 06-03
6.1.4 Set the cable rollers with spaces of about 1.5m

6.2 Cable Unreeling

Cable drum lagging shall be carefully removed. Cable can be unreeled form
cable drum mounted on the transporting trailer or an axle supported by jacks.
Unreeling of cable must be done so that the cable is reeled off from top of the
drum. The drum shall be turned by hand to reduce tension in the cable. The
drum shall be rotated in a direction opposite to the direction of the arrow marked
on the drum. (Refer Figure 06-02).

6.3 Laying of Cable

6.3.1 It is very important that the cable not be bent to a radius too small nor be
subjected to abnormal tension.

In being ran out, it shall be laid carefully so as not to be dropped on the

ground. Bends of the cable must not be straightened out by standing and
jumping on the cable.

All handling of the cable shall be done smoothly and steadily without any
jerking.

The next preliminary steps shall be taken:

a. Setting of Cable Drum Jacks: The drum shall be raised about

25cm by adjusting the jacks to gain the same level.

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 08/09/99
Saudi Consolidated Electric Company ≠B@IZ¢y{{ ©X@R•}{A ™¶X•@@la{A ™yZ@c{A
in the Eastern Province
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

b. Removal of Battens of Drums: The battens are to be taken off

one by one by rotating the drum, taking care not to damage the
cable. Battens are to be removed only just before the actual time
of pulling.

c. Fastening of Leading Wire: The leading wire rope is to be

fastened to the pulling eye with clevises and through the swivel.
The cable is then to be pulled and introduced into the trench by
leading wire.

d. Setting of Winch: A winch is to be set on the opposite side of the

section and wire is to be wound around it.

e. Preparation of Communication Set: A means of audio

communication between the drum side and the winch side shall
be provided, i.e. walkie-talkie portable telephone, etc.

6.3.2 Manual Cable Laying

If the trench is sufficiently wide, workers can carry the cable and lay it in
the trench or pull the cable over rollers in the trench by hand.

To carry the cable, the workmen are positioned three (3) to four (4)
meters apart in the trench so the weight shared per person does not
exceed 30kg. If the cable length to be laid is short and the cable coiled,
the cable is uncoiled outside the trench and carefully laid in the trench.

For pulling cable over rollers by hand, the workmen are positioned four
(4) to six (6) meters apart in straight sections of the trench and rollers
with skid plates are used at bends (minimum bending radius of the cable
must be maintained).

6.3.3 Temporary Support of Cable Ends

After the cable laid in the trench, the cable ends shall be temporarily
supported so that they will not be on ground or in water.

6.4 Pulling Tension and Speed

Pulling the cross-linked polyethylene insulated power cable can easily be done
by means of pulling eye previously attached to a cable end of each drum.

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 08/09/99
Saudi Consolidated Electric Company ≠B@IZ¢y{{ ©X@R•}{A ™¶X•@@la{A ™yZ@c{A
in the Eastern Province
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}{A ßs

SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

The cables shall not be pulled with an excessive tension or excessive sidewall
pressure at curve of the cable route during laying. The tension and the pressure
depend upon the material and cross-sectional area of the conductors. Allowable
pulling tension and sidewall pressure are as follows:

Allowable Pulling Tension 7.1kg/mm² for copper conductor

3.5kg/mm² for aluminum conductor
Allowable Side wall Pressure 447 kg/m

It must be noted that the cable shall be pulled with an appropriate speed to keep
the movements of cable and drum smooth. The drums must never rotate faster
than the cable run. If it is not braked in time, the cable may be drawn in under
the drum and be damaged. The cable must be laid out smoothly and without
interruption.

6.5 Cable Pulling Procedure (Conductor/Pulling Eye - Cable Pulling)

6.5.1 Description

Typical procedure for the cable pulling work is shown on the following
scheme. Typical positions for cable pulling are shown on Figure 06-02
through 06-05.
UNDERGROUND DUCT
WINCH SIDE BANK, TRENCH/CABLE DUCT CABLE DRUM SIDE

Setting Cable pulling winch Inspection of the trench condition Transportation of cable
and drum of wire rope Cleaning the cable duct1 drum and setting it on
for cable pulling cable drum jack

Setting cable rollers/curve Remove wooden

rollers in trench battens from cable drum

Laying wire rope for cable Inspection of the surface

pulling in trench/cable duct and oil leakage of cable
visually
Setting of match block
on the pulling eye in line Setting portable telephone Setting guide rollers
with the cable to be along the cable trench with supporting facilities
pulled through duct bank
and manhole system Connecting cable to wire
rope for cable pulling

Cable lubrication for duct

bank and manhole system

Note: Pulling Cable

1. Do a mandrel test
Exchanging cable drum
pressure tank to construction
portable pressure tank

Disposition of the ends

of cable

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Saudi Consolidated Electric Company ≠B@IZ¢y{{ ©X@R•}{A ™¶X•@@la{A ™yZ@c{A
in the Eastern Province
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

6.5.2 Procedure of Cable Laying:

a. Pulling Direction: One of the ends of the route is selected for

setting the drums and the other is for the winch.

Pulling direction shall be decided by computation where less

tensile force and sidewall pressure in the cable is met during
laying work.

b. Inspecting the Trench Condition: Before the cable pulling work

commences, the whole trench shall be inspected.

Gravels, sharp edges and any other objects shall be removed on

the bedding sand in the trench.

c. Cleaning the Cable Duct: Prior to the start of cable pulling work,
the cable duct shall be cleaned.

The properly sized cleaning brush shall be passed through all

cable ducts to remove any obstacles in the duct.

d. Setting Cable Pulling Winch and Drum of Wire Rope for Cable
Pulling: The cable pulling winch is to be fixed firmly so that it
can stand against the pulling force.

The winch shall be capable of changing pulling speed in the range

of 0-10 meter per minute.

Rotation of the drum of the winch shall be smooth at the start of

pulling, so the engine winch equipped with a clutch is preferable.

A tension meter or dynamometer shall be incorporated to the

winch.

The wire rope drum for cable pulling shall be settled at the
available position in order to roll up the wire rope easily.

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Saudi Consolidated Electric Company ≠B@IZ¢y{{ ©X@R•}{A ™¶X•@@la{A ™yZ@c{A
in the Eastern Province
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

e. Setting the Cable Drum on Cable Drum Jack: The cable drum
transported to the construction site shall be set on the cable drum
jack.

The cable drum and the cable drum jack shall be settled at proper
position for cable pulling.

f. Inspecting the Surface of Cable and Oil Leakage: The outer

surface of the cable, oil feeding pipe and cable drum pressure
tank shall be visually inspected and checked to detect oil leakage.

g. Setting Cable Rollers/Curve Rollers: Cable rollers shall be

placed in the right position of the cable route.

The intervals of the rollers shall be kept about 1.5 to 2m. The
rollers shall be maintained to enhance smooth rotation. If the
cable is planned to be pulled through a curve, curve rollers shall
be placed at proper positions in order to keep the allowable cable
bending radius.

h. Setting Guide Rollers with Supporting/Facilities: The cable

guide roller shall be placed at the proper position between cable
drum and trench/splice bay in order to pull the cable smoothly.

i. Laying of Wire Rope for Cable Pulling in Trench/Cable Duct:

The wire rope for cable pulling shall have 4 times as much safety
factor for calculated maximum value of pulling tension.

It is important that the wire rope is handled in such a manner that

it is not twisted or kinked.

j. Connecting Cable to Wire Rope for Cable Pulling: The pulling

eye hook that is fixed at the top of the cable shall have the proper
size to be connected to the wire rope for cable pulling through a
swivel and shackles.

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in the Eastern Province
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

k. Pulling Cable: After the facilities and the equipment are properly
set, the portable telephones shall be installed at both ends of the
pull with provision of tapping within the section being pulled.

They are utilized to control the pulling speed and for other
communication.

Cable pulling shall be started gradually.

l. Cable pulling shall start only if all cables required for route’s
section to be pulled are available.

m. After inspection by a COMPANY REPRESENTATIVE, newly

laid cables shall be backfilled immediately. Prolonged open
trench is hazardous to public, traffic and cables.

A watchman shall be stationed to observe the leading end of the

cable. This watchman walks along the cable being pulled.

The rotating speed of the drum shall be compatible to that of the

pulling speed.

If necessary, the rotating speed shall be controlled with a simple

wooden brake.

The pulling speed must be regulated.

When the leading end of the cable approaches the terminating

point at the winch side or the tail end of the cable is just going off
the drum, the pulling work shall be stopped. The oil feeding
copper pipe which is fastened to the pressure tank on the cable
drum and connected to the cable and tank on drum shall be
loosened and extended gradually by exchanging of pressure tanks.

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in the Eastern Province
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

n. Exchanging of Pressure Tanks: The procedure of exchanging the

cable drum pressure tanks to the construction portable pressure
tank is as follows (Refer Figure 06-06).

1. The pulling work shall be stopped.

2. The valve of the cable drum pressure tank (Tank A) on the

drum shall be closed and again opened slightly (about 5%
of a turn).

3. The valve of the construction portable pressure tank (Tank

B) for temporary oil feeding during joint work shall be
opened slightly (same degree as above).

4. The extra connector union or oil feeding pipe that is

connected to Tank A shall be opened.

5. The oil feeding pipe of Tank B shall be connected to the

extra connector union.

At this time, the oil shall be flowing over from both

outlets (oil feeding pipe of Tank B and extra connector
union on oil feeding pipe shall be connected to Tank A) in
order to avoid penetration of the air in to the openings.

6. After the Tank B is connected to the cable, the oil feeding

pipe of the Tank A shall be disconnected.

o. Disposition of Ends of Cable: After the exchanging of the

pressure tanks is finished, the cable pulling work can be started
again until both ends of the cable reach their final proper, position
for either splicing or terminating.

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 08/09/99
Saudi Consolidated Electric Company ≠B@IZ¢y{{ ©X@R•}{A ™¶X•@@la{A ™yZ@c{A
in the Eastern Province
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

DWG# SC-1040601.00.01

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Saudi Consolidated Electric Company ≠B@IZ¢y{{ ©X@R•}{A ™¶X•@@la{A ™yZ@c{A
in the Eastern Province
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

DWG# SC-1040602.00.01

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 08/09/99
Saudi Consolidated Electric Company ≠B@IZ¢y{{ ©X@R•}{A ™¶X•@@la{A ™yZ@c{A
in the Eastern Province
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

DWG# SC-1040603.00.01

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 08/09/99
Saudi Consolidated Electric Company ≠B@IZ¢y{{ ©X@R•}{A ™¶X•@@la{A ™yZ@c{A
in the Eastern Province
™@@¶@vZ@c{A ™@@@wi
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

DWG # SC-1040604.00.01

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 08/09/99
Saudi Consolidated Electric Company ≠B@IZ¢y{{ ©X@R•}{A ™¶X•@@la{A ™yZ@c{A
in the Eastern Province
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SCECO-EAST CONSTRUCTION STANDARDS SCS-P-104.06

DWG # SC-1040604.00.01

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