STTS WIDEBODY AIRCRAFT FACILITY

METHOD STATEMENT FOR CABLE TERMINATION & JOINT FOR HV SYSTEM

METHOD STATEMENT FOR CABLE TERMINATION & JOINT FOR HV SYSTEM

Document No: P103-STTS-GEC-ASI-MS-ELE-005

REV. DATE DESCRIPTION GENFOCUS ASI/WSP

PREPARED APPROVED

00 27-05-18 Issued for Approval QA/QC PM

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METHOD STATEMENT FOR CABLE TERMINATION & JOINT FOR HV SYSTEM

1.0 PURPOSE

1.1 The purpose of this Method Statement is to define the procedure to be adopted for HV
cable jointing and termination

2.0 SCOPE

2.1 The purpose of this method statement is to define the sequence and methodology for
the Cable Splicing/Joining and Termination with the requirements specified in the
relevant specifications.

3.0 TOOLS AND RESOURCES

3.1 Gas Torch

3.2 Hydraulic Cable cutter
3.3 Coring knifE
3.4 Hydraulic crimping tool
3.5 Meggar
3.6 Isopropyl alchol
3.7 Cotton waste
3.8 Torque wrench
3.9 Set of metric spanners
3.10 Vacuum cleaner / dry, oil free compressed air
3.11 Aluminium stepladder
3.12 Hand tools

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METHOD STATEMENT FOR CABLE TERMINATION & JOINT FOR HV SYSTEM

4.0 RESPONSIBILITIES

4.1 PROJECT MANAGER

4.1.1 Is responsible for ensuring that all works are carried out as per the specifications,
drawing/shop drawings and method statement as per the manufacturer instructions,
coordinated with other works and will plan for the required manpower and tools for
all activities.

4.2 SITE ENGINEERS/ SUPERVISOR

4.2.1 Coordinate all the site activities required according to the project specification,
manufacturer data sheet and approved shop drawings.

4.2.2 Ensure that the installation complies with the approved shop drawings/specifications.

4.2.3 Coordinate and explain the work to be carried out to the certified cable jointer.

4.2.4 Maintain records of work done and submit the progress report to the authorities
concerned.

4.2.5 Ensure the compliance of works with the related approved quality control procedure
and co-ordinate with the QA/QC Engineer to advise for the areas to be raised for
inspection

4.4 QA/QC ENGINEERS

4.4.1 Carry out the material inspection to ensure that materials received on site are approved
materials.

4.4.2 Monitoring the installation works according to the approved drawings and method
statement.

4.4.3 Coordinate with the ENGINEERS and EMPLOYERS REPRESENTATIVE to carry out
inspection/testing of the completed works

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METHOD STATEMENT FOR CABLE TERMINATION & JOINT FOR HV SYSTEM

4.5 HSE OFFICER

4.5.1 Ensure that all installation or construction works will be carried out in accordance
with the Health Safety & Environmental (HSE) Plan and standard regulations and
practices.

4.5.2 Ensure that all necessary permits shall be obtained from Employer Representative and
the concerned authorities wherever necessary.

4.5.3 Ensure that good housekeeping at work site is implemented.

4.5.4 Ensure that all necessary personnel protective equipment will be provided as per the
requirement of the job.

4.5.5 Ensure that usage of cranes, lifting items and working platforms will be used in
accordance with the Health Safety & Environmental (HSE) Plan.

5.0 PROCEDURE
5.1 CABLE TERMINATION

5.1.1 PRE INSTALLATION PROCEDURES

5.1.1.1 Ensure all relevant permits are obtained for the jointing/terminations

5.1.1.2 Check to ensure that the kit going to be used fits the cable and is approed.

5.1.1.3 Ensure the availability of Gas torch.

5.1.1.4 Ensure the torch is always used in a well ventilated environment.

5.1.1.5 Ensure all safty measures like portable fire extingushers/fire blankets/documets
available at site

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METHOD STATEMENT FOR CABLE TERMINATION & JOINT FOR HV SYSTEM

5.1.1.6 Adjust the torch to obtain a soft blue flame with a yellow tip.

5.1.1.7 All the pre installation checks shall be done by qualified cable jointer as per the
manufacturer installation guide line

5.1.2 METHOD OF INSTALLATION

5.1.2.1 Cable preparation (Using Cleat) shall be done as per manufacturer’s

recommendations.

5.1.2.2 Making hole on the glanding plate as per the required dimension.

5.1.2.3 Cable to be cut to the required length and remove the over sheath.

5.1.2.4 Leave enough length to sent the cores into final position.

5.1.2.5 Clean and degrease the end of over sheath for about 100mm.

5.1.2.6 The minimum termination length shall be 300mm for indoor straight connection.

5.1.2.7 Separate the core and wrap an earth lead round each core and solder tack it to the
metal tape shield.

5.1.2.8 Fill the earth lead with solder to form a 30mm moisture block 30mm from the over
sheath end.

5.1.2.9 Remove the release paper and wrap one layer of sealant tape (red) round the over
sheath end for 80mm underneath the earth lead .

5.1.2.10 For cables with tape armour earth lead shall also be connected to armour.

5.1.2.11 Bend and shape the cores into their final position and then cut the cores to the
required length.

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METHOD STATEMENT FOR CABLE TERMINATION & JOINT FOR HV SYSTEM

5.1.2.12 Place a temporary wire binder around the cores and tear off the tape shield against
wire binder.

5.1.2.13 Remove the core screen to 20mm above the metal tape shield and see that the
surface of insulation should be free all traces of conductive material. Smooth out all
irregularities.

5.1.2.14 Remove the wire binder from the end of the metal tape shield and remove the
release paper and wrap the void filling strap for 5mm on to the metal tape shield,
continuing over the core screen and 10mm on to the insulation.

5.1.2.15 Stretch the strip to half of its original width to achieve a fine, thin edge on to the
insulation.

5.1.2.16 Place the stress control tubing over the cores and position them to 70mm above the
end of the over sheath cut and shrink down the tubing starting at the bottom and
working upwards.

5.1.2.17 Remove the release paper and slide the break out over the cores. Shrink the turrets
on to the cores. The shrinking sequence to be followed as per manufacturer guide
lines which are attached herewith.

5.1.2.18 Cut back the insulation according to depth of cable lug barrel hole plus 5mm install
the cable lugs then clean the insulation and cable lugs.

5.1.2.19 Remove the release paper and wrap the sealant tape around barrel of the cable lug
with a small overlap and tension. Wrap the sealant tape around the turrets of the
cable breakout.

5.1.2.20 Place the tubing over the cores and push the tubing over the turrets as far as
possible and shrink it down. Tie the shielding wires or the earth lead with a wire
binder to the over sheath below the break out. Gather the shielding wire together to
form an earth lead as depicted in manufacturer’s catalogue.

5.1.2.21 Cut the tubing back onto the connector barrel if necessary. Post heat palm of the lug
until a bead of mastic appears around the top of the tubing.

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METHOD STATEMENT FOR CABLE TERMINATION & JOINT FOR HV SYSTEM

5.2 CABLE JOINT PROCEDURE

5.2.1 PRE INSTALLATION PROCEDURES

5.2.1.1 Ensure the torch is always used in a well ventilated environment.

5.2.1.2 Ensure all relevant permits are obtained for the work.

5.2.1.3 Ensure safty measures

5.2.1.4 Adjust the torch to obtain a soft blue flame with a yellow tip.

5.2.1.5 All the pre installation checks shall be done by qualified cable jointer as per the
manufacturer installation guide line.

5.2.1.6 Check to ensure that the kit fits the cables and is approved.

5.2.1.7 Refer to the kit label and the title of the installation instruction.

5.2.2 CABLE PREPARATION

5.2.2.1 Overlap the cables to be jointed by about 100mm. Mark the reference line (the
middle of the overlap). Slide the shortest of the three sealing sleeves over the short
side of the joint. Fold and tape it down temporarily so that the next sealing sleeve
can be slide over it. Tape down the second sealing sleeve over the first one.
Position the remaining sealing sleeve over the two sealing sleeves.

5.2.2.2 Remove the oversheath, armour and bedding according to the dimensions given in
the Manufacturer Installation Instruction.

5.2.2.3 Do not cut the earth conductor (if any). Slide the screw clips over the cables ends.
Lift the armour wires and slide the support rings underneath as per the Manufacturer
Installation Instruction. Build up the bedding under the support ring with a piece of

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METHOD STATEMENT FOR CABLE TERMINATION & JOINT FOR HV SYSTEM

oversheath. Secure the ends of the armour wires with a wire binder. Shape and
position the cores as shown in the Manufacturer Installation Instruction and cut them
at the reference line.

5.2.2.4 Cables with metal tape shields -Twist the shielding wires together to form an earth
conductor.

5.2.2.5 Cables with extruded core screens -Remove the extruded semi-conducting screen
Note: Do not nick the insulation! Clean and decrease the insulation.

Wrap plastic tape round the insulation 10mm above the end of the core screen. Cover
the 10mm of the insulation and about 5mm of the core screen with conductive paint.
Wait until the paint has dried and then remove the plastic tape.

5.2.2.6 Cables with tape screens and conducting layers - Remove the semi-conducting tape
screen

Cover the end of the conducting layers with plastic tape (adhesive side upwards).
Completely remove every trace of the conducting layer. Use a solvent recommended
by the cable manufacturer. Remove the plastic tape. Cover the 10 mm of conducting
layer and about 5mm of the semi-conducting tape screen with conductive paint.

5.2.3 COMPLETION OF JOINT

5.2.3.1 Slide one combined tubing set over each long core end.

5.2.3.1.1 Stress control tubing (black)

5.2.3.1.2 Insulating tubing (red)

5.2.3.1.3 Screened insulating sleeve (black and red)

5.2.3.2 Joint the conductors by crimping, soldering or any other equivalent method. Remove
any sharp edges. Clean and degrease the insulation.

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METHOD STATEMENT FOR CABLE TERMINATION & JOINT FOR HV SYSTEM

5.2.3.3 Remove one paper from the void filling compound (yellow) and roll it up.Wrap it
around the connector with a 50% overlap stretching it to about half of its original
width.Fill up the connector area continuing onto the insulation for not more than
5mm Note: Do not use too much void filling compound.The final diameter,
whichever is larger. Smooth out the surface of the insulation with a thin film of
silicone grease. Slide the stress control tubing (black) over the completed connector
area taping the other cores.

5.2.3.4 Position the stress control tubing centrally over the connectors .Start shrinking in the
centre working towards the ends. The tubing should be fully shrunk and wrinkle
freeNote: Take care not to accidentally shrink the other tubing at this stage.Pull the
insulating tubing (red) from the inside of the screened tubing (black and red) and
position it centrally over the stress control tubing.

5.2.3.5 Start shrinking in the centre working towards the ends.

5.2.3.6 Position all three screened insulating sleeves (black and red) centrally over the
previously installed tubing.

5.2.3.6.1 Start shrinking the sleeves in the centre.

5.2.3.6.2 Continue shrinking by working towards one side stopping 50mm from the end.

5.2.3.6.3 Shrink the other half in the same way.

5.2.3.6.4 Shrink down the first end and finally the second, The sleeves should be fully shrunk
without leaving ridges.

5.2.3.7 Cables with wire shields-Relay the cores as far as possible. Wrap all the copper
braid round the cores with a 50% overlaps so that the whole joint area is covered.
Joint the earth conductor by crimping or any other equivalent method.

5.2.3.8 Cables with metal tape shields - Wrap two layers of copper braid with a 50%
overlap round each joint area, continuing for 20mm onto the metal tape shield.

5.2.3.9 Attach the copper braid to the metal tape shield on both sides of the connector area
by soldering or any other equivalent method to maintain shield continuity. Relay the
cores as far as possible.

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METHOD STATEMENT FOR CABLE TERMINATION & JOINT FOR HV SYSTEM

5.2.3.10 Wrap the joint case round the joint and secure with about two layers of cloth tape as
shown in the picture.

5.2.3.11 Clamp the ends of the joint case onto the steel wire armour using the screw clips.

5.2.3.12 Cover the sharp edge of the screw clips by fastening a piece of cable oversheath over
the screw with the remaining cloth tape.

5.2.3.13 Slide the first long sealing sleeve over the long side of the joint. Position the sleeve
so that it overlaps for 150mm on to the oversheath. Shrink it into place starting from
the joint area and working towards the oversheath.

5.2.3.14 Position the second long sealing sleeve over the centre of the joint.

5.2.3.15 Overlap the previously installed sealing sleeve by 150mm. Start shrinking in the
centre working towards the ends.

5.2.3.16 Position the short sealing sleeve over the short side of the joint. Overlap the
oversheath by approximately 150mm. Start shrinking at the joint area working
towards the oversheath.

5.2.3.17 Allow the joint to cool before applying any mechanical stain.

5.2.3.18 Testing will carry out as per the approval itp prayer to termination.

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