CABLE PULLING SAFETY PRESENTATION

This presentation raises awareness uploaded y HSE Documents on safe pulling of electrical power and control cables in buried trenches. It identifies key hazards like falls, trips, and manual handling injuries, while outlining best practices, job planning, PPE requirements, and safe installation procedures to prevent incidents.

PURPOSE

The Purpose of this presentation is:

• To bring awareness in relation to safe pulling of electrical power & control cables laid in the buried trench;
• To identify the hazards associated with these activities;
• To familiar with good working practice to be followed during cable pulling.

Hazards of Cable Pulling

• Falls
• Dropped objects
• Tripping hazards
• Sharp edges, cuts & pinch points
• Caught between or struck by cable drums
• Personal injuries resulted in improper manual handling techniques

Tripping over the cables

• Poor cable management

Sharp edges, cuts & pinch points

Caught between or struck by cable drums

• Unsecured cable drums

Improper Manual Handling

• Musculoskeletal Injuries
• Ligaments & Tendon Injuries
• Nerve Injuries
• Hernias

Job Planning

• Site preparation, permit & safety requirements.
• Determine the methods to be used in placing each type of cable.
• Identify and obtain appropriate cable pulling tools, equipment and supplies
• Identify working surface hazards, especially for outdoor work and ensure adequate hazard controls are used to prevent slips, trips or falls.
• Identify safe locations for accessing and pulling the cable.
• Determine the staffing required and assign tasks to team members.
• Provide proper communication as needed
• Storage, handling and transportation.

Site Preparation

• The area in which the cable drums are to be placed shall be identified and the ground surface to be prepared to have an evenly leveled and hard surfaced without any loose soil.
• The cable drum stands intended to support the cable drums shall be shifted to the location and positioned on the ground surface
• The solid mild steel bars shall be arranged to be used as a shaft to support the cable drum.
• The concrete trench shall be inspected for depth, width & proper sand cushioning in line with the cable layout and standard drawing

PTW Requirements

• Remember If It’s more than 1.2 meters deep, you need a confined space entry permit
• TRENCH
• Verify whether the confined space entry is applicable to the nature of the work and arrange the permit accordingly
• Ensure that Method Statement, JSA, HIP are prepared and approved
• Ensure the tool box talk is given about the work prior to commencement of the activity
• All cable-pulling personnel shall be trained and competent

Safe Working Environment

• All unprotected areas must be barricaded to prevent fall risk
• Warning signs must be posted to prevent tripping hazard
• Use installed scaffolding bridges to cross trenches safely

Tools & Equipment

• Use right tool for cable pulling
• Examine all work tools to ensure they are in safe condition
• Carefully follow all manufactures’ instructions when mounting, securing & using potentially dangerous mechanical equipment for cable pulling such as winches, cable wheels and cable brakes
• Adequate PPE must be worn
• Never use homemade tools

Pre-task discussions

• Everyone must attend a pre-task talk (Toolbox Talk) before starting work
• The talk should be led by the supervisor
• Discussion should concern hazards of the work about to be performed
• Please share any concerns or lessons learned from previous jobs to increase awareness with regard to safe task performance and prevent incidents in the future
• Report to your supervisor all unsafe conditions and acts

Personnel Protective Equipment

• Hard hats shall be worn for work that has serious potential for falling or flying objects and striking of the head
• Wear adequate safety glasses to protect your eyes
• Wear protective foot ware such as steel-toe slip resistant sneakers or shoes
• Wear protective gloves when performing any work that has potential for hand or forearm injuries
• Wear well-fitting clothes to protect against minor cuts, scratches and abrasions.
• Do not wear loose fitting cloths that could get caught on tools or surroundings

Task Specific PPE

• Use safety harnesses while working at unsecured and exposed edges / comply with 100 % tied off requirements
• Hearing protection is required in high noise areas
• Wear extra eye protection PPE if there is possibility of any foreign body to embedded into the eyes

Preparation for cable installation

Prior to commencement ensure that:

• The cable-pulling job underwent proper work planning.
• Use drinking water frequently in hot environments.
• Before work begins, clearly mark the work areas to restrict area for authorized personnel only.
• Never leave work areas unattended or without barrier and warning signs if they present a hazard.
• Examine all work tools to ensure that they are in safe working condition.
• Carefully follow all manufactures’ instructions when mounting, securing & using potential dangerous mechanical equipment such as winches, cable wheel and cable brakes.

Cables Installation

• The cable drums shall be positioned in the cable stands as per manufacture direction of rotation of the cable.
• The cables shall be uncoiled from the drum and be placed in the rollers by means of pulling rope to be followed by pulling of the cable with the electrical personnel.
• The cable ends on the drums shall be sealed properly once the cable installation is completed or by the end of the day.
• Cable pulling during high temperature weather conditions shall be avoided.
• Whenever the electrical or Diesel operated winch is used to pull a long distance cable, ensure that the winch operators and the supervisors involved in the signaling for the operation of winch is properly coordinated by the use of communication equipment, colored flags & whistle.

Manual Handling

To prevent pain, injuries and damage:

• Examine & test… Weight, sharp edges, awkward shapes, stability of the load,
• Plan the job… Safe system of work, route free of hazards, no where the load is going, plan rest stops!!
• Get a good grip… How you are going to hold it, protect hands and feet by grasping the load firmly, wear good fitting gloves.
• Get help… Use of mechanical aids, avoid manual handling.
• Wear… the required PPE
• Rest frequently… avoid becoming over tired
• Talk… discuss problems
• Lift… Get comfortable, lift smoothly keeping the load close to the body, avoid twisting, move your feet.
• Always seek for assistance from co-workers

Lifting & Rigging

• Personnel involved in lifting shall be trained & certified.
• Ensure proper maintenance and inspections of cranes and rigging devices.
• Ensure that color coding requirement are complied.
• Barricade areas within swing radius and post warning signs.
• Provide adequate communication.

Transportation

• Cable drums shall shifted to the working site by using long vehicles, trailers and forklifts.
• Operators / drivers shall be certified and competent.
• Ensure that cable drums to be delivered on the site are secured in proper manner!

Storage

• Cable drums shall be handled with care and be stored at the project site warehouse in a separate location.
• Cable drums shall be stored away from each other
• Barricades and warning signs shall be installed.
• Cable drums shall be secured by chocks

Safety Inspections

• It shall be the responsibility of assigned competent person to routinely inspect physical areas under their control in a cable pulling.
• The inspections shall include determining the following:
• If trenches are in safe conditions (free from fall, slipping, tripping, dropped objects etc. hazards)
• If the personnel are trained and competent
• If adequate tools and equipment are in place
• If the job site is clean up.
• Unsafe conditions must be reported

Clean up the job sites

• Prevent development of hazards and risks.
• Pick up pull strings and pull ropes immediately after use.
• Collect and dispose of removed sheath, wire scrap, pieces of cable ties and waste wood with protruding nails.
• Store significant amount of cable and cable reels in a secure area when pulling is complete.
• Dispose of all personal items.
• Remove unnecessary tape barricades and warning signs.
• Store tools, equipment and unused materials properly at the end of working day.

Cable Pulling Safety Quiz

True / False

1. Hazards identification and personnel training contributes to reduce at-risk behaviours
2. A responsible person shall conduct weekly inspections of the trenches
3. Maintain proper housekeeping and cable management at site
4. Cable pulling in 140cm deep trench only needs approved Method Statement, JSA, HIP Form
5. Keep materials and tools at least 60cm from the edge of trenches
6. Pre-task discussions are considered less effective if involved personnel are trained and competent
7. Proper job planning ensure to reduce task-related risks, avoid injuries and loss
8. Cable drums shall be secured by chocks at 2 points in storage areas
9. The trench 30cm deep or more needs safety hard barriers
10. You may cross the trench anywhere whether safe scaffolding crossovers are not installed

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PERMIT TO WORK

Table of Content

• Basic Permit Details.
• Hazards of Non-Compliance to PTW/ LOTO.
• Scope of Permit.
• Definitions.
• Competent Person responsibilities.
• Senior Authorized Person responsibilities.
• Authorized Person responsibilities.
• Control Person responsibilities.
• Types of Permits.
• Types of Certificates.
• LOTO 6 Steps.
• LOTO System at…..
• LOTO Sequence at…..
• Risk Assessment Technique.
• Risk Assessment at……..

Basic Permit Details

• What is a permit?
  It’s a part of a safe system of work to control high-risk activities, such as hot work, confined spaces, excavation, and work on electrical equipment.
  It ensures that all risks have been identified, precautions are in place before, during, and after work, and appropriate information is communicated to all relevant parties.
• Permit to Work (PTW):
  A formal document specifying the work to be done, hazards, and precautions. It provides a clear written record signed by a responsible person/supervisor that all foreseeable hazards have been considered and necessary actions taken. Must be in possession of the person in charge before work commences.
• Common Sections of PTW:
  Issue, Acceptance, Clearance, Cancellation.

Hazards of Non-Compliance to PTW/ LOTO

• Puts team at fatal risk due to:
  Hazardous substances, hot/cold temperatures, electrical hazards, mechanical energy hazards, hazardous areas, height dangers, radioactive substances, dangerous fumes.
• Puts equipment and business at risk.
• Puts environment at risk.
• Leads to direct costs (first-aid, hospital treatment, equipment replacement, overtime).
• Leads to indirect costs (loss of competent staff, morale, investigation costs, loss of customer goodwill, overtime to meet deadlines, recruitment/training costs).

Scope of Permit

• This contains Procedure, Definition, and Guidelines. It is only applicable to commissioning activities at the PROJECT SITE.

Definitions

(Multiple slides titled "Definitions" with placeholder content – specific definitions not detailed in provided text.)

Competent Person Responsibilities

• Shall comply with Safety Rules stated in [].
• Works within the limit of the work scope of the permit.
• Retains Safety Document and Keys in safe custody and displays at job location.
• Provides immediate/personal supervision as required.
• Warns and withdraws personnel if hazards arise.
• Reports hazards to Senior Authorized Person.
• Signs clearance only when site is safe.
• Ensures tools/gear removed, guards replaced, housekeeping done.
• Manages permit transfer/suspension with Senior Authorized Person.
• Provides personal supervision for restoration of power (PFW) or tests (SFT).

HEI-Contractor’s Competent Person Authorization:
Nominated by Department Manager/Lead via email to Project & Commissioning Manager. Approved after interview on PTW, LOTO & Risk Assessment.

Competent Person = KATE:
K = Knowledge, A = Ability, T = Training, E = Experience.

Senior Authorized Person Responsibilities

• Complies with Safety Rules stated in [].
• Implements procedures for releasing Plant/Apparatus for work/testing.
• Ensures all safety precautions are completed.
• Obtains agreement from Control Person for release.
• Confirms safety precautions with Control Person for HV systems.
• Ensures feedback is considered.
• Decides on drain earths, venting, purging, and stored energy.
• Specifies conditions for removing/reapplying safety precautions.
• Issues Safety Document, keys, and decides supervision level.
• Manages transfer/suspension of Safety Documents.
• Informs Control Person upon completion.
• Cancels Safety Document and ensures Plant/Apparatus is ready for service.
• Decides work/testing limits and issues Limited Work Permit if needed.
• Determines LV work method (routine, Safety Document, or Personal Supervision).

Authorized Person Responsibilities

• Carries out work area inspection and follows SAP instructions.
• Receives Isolation Certificate, locks, and tags from SAP to effect isolation.
• Records name, date, time, and signs Isolation Certificate.
• Hands over keys to SAP for permit issuance.
• Removes isolations upon SAP’s request after permit cancellation.
• Performs switching operations up to 6.6kV; above that is Control Person’s responsibility.
• For Sanction for Test: removes isolations as requested, signs, and hands permit to Competent Person.
• May be required to be present during testing.
• Reinstates safety precautions after testing.
• Ensures security of isolations, guards, safety devices, and stored energy dissipation.

Control Person Responsibilities

• Agrees to release of Plant/Apparatus for work/testing.
• Acknowledges completion of work/testing and any restrictions on returning to service.
• Takes over plant/apparatus after permit cancellation and isolations removed by Authorized Person.

Types of Permits

1. Permit for Work:
   Used when precautions are needed to achieve safety for work on apparatus. Protects employees in hazardous situations.
2. Limited Work Permit:
   Used when limiting work/access alone ensures safety. No isolation required.
3. Sanction for Test:
   Used for testing with adequate precautions. Requires surrender of other permits; only one safety document issued.

Types of Certificates

1. Isolated:
   Disconnected by isolating device, physical separation, or sufficient gap.
2. Hot Work:
   Work involving burning, welding, cutting, grinding, or spark-producing tools.
3. Confined Space:
   Not designed for permanent occupancy, limited access/egress, large enough for one person to enter.
4. Excavation:
   Moving earth/rock with tools, equipment, or explosives for construction.
5. Radiation:
   Emission of energy as waves/particles (e.g., radio waves, X-rays, gamma radiation).
6. Diving:
   Descending in water for inspection, maintenance, filming, or recording.

General Instructions

• Duration of permit & certificates: 1 whole shift, then reissued.
• Permit transferable up to 2 weeks from issue, then cleared/cancelled.
• Possible attachments: Required Certificates, Key Safe Key, Daily TBT, Risk Assessment, Confined Space Log, Rescue Plan, and Hot Work Monitoring Sheet.
• Suspended during plant emergency; reissued after SAP approval.
• Transfer required if SAP or CP changes.
• Isolations in Isolation Certificate must be reviewed before permit issuance.

LOTO 6 Steps

1. Preparation: SAP & AP investigate hazardous energy. CP can request isolations.
2. Shut Down: Control Person initiates shutdown. AP may do so if nominated by SAP.
3. Isolation: Isolate from energy sources (electrical, hydraulic, pneumatic, etc.) as per Isolation Certificate.
4. Lockout/Tagout: Attach locks/tags to energy-isolating devices. Fill tags with name, sign, and contact number.
5. Stored Energy Check: Release residual/stored energy (e.g., venting, purging).
6. Isolation Verification: Authorized Person verifies isolation. CP checks isolations before work begins.

LOTO System at ….

(Placeholder content – system description not detailed in provided text.)

LOTO Sequence at …..

1. SAP designates person to apply isolation locks/tags at equipment.
2. Isolation keys placed in Key Safe box.
3. Control Lock Key moved to Key Safe Cabinet and secured by SAP.
4. Key Safe box key handed to Competent Person upon permit acceptance.
5. Multiple work sections: multiple Key Safe locks applied.
6. After job completion, CP returns Key Safe keys to SAP.
7. SAP removes Key Safe locks and opens Key Safe.
8. Isolation keys released for de-isolation after control lock removal.

Risk Assessment Technique

• Risk: Likelihood of harm combined with severity.
• Hazard: Something that can cause harm (e.g., electricity, chemicals).
• Risk Assessment: Formal process to identify hazards, assess risk, and eliminate/control it.

Objectives:

• Prevent death, injury, loss incidents.
• Avoid legal breaches and prosecution.
• Reduce direct/indirect costs after accidents.

Five Steps of Risk Assessment:

1. Identify hazards.
2. Identify people at risk and how.
3. Evaluate risk and decide precautions.
4. Record findings and implement.
5. Review and update.

Hazard Identification Methods:

• Inspection.
• Task Analysis (SREDIM):
• Select task
• Record steps
• Evaluate risks
• Develop safe method
• Implement method
• Monitor effectiveness
• Legislation
• Manufacturer Information
• Incident Data

Identifying Population at Risk:

• Workers/operators
• Maintenance staff
• Cleaners
• Contractors
• Visitors
• Public

Risk Assessment at …..

(Placeholder content ...)

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