CA04!04!33-P-SP-008 - X2 Power & Control Cables

SINCOR
Sincor Document No: CA04-04-33-P-SP-008

Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 1/CA040433PSP008
Rev./Date: X2/ 23 Junio 2006
SINCOR, C.A.
UPSTREAM SURFACE FACILITIES PROJECT
POWER AND CONTROL CABLES
REVISION INDEX:
This Document Consists of 16 Pages
NOTE: Any technical change from the original Sincor document is indicated by | in the right hand
margin.
APPROVAL REGISTER
Prepared By/ Checked By/ Project SINCOR

No. Date Date Approved By/ Approved By/ Reason for Revision
Date Date
A0 J. Cabrera D. Baillie Issued for IDC
99.05.18 99.05.18
0 J. Cabrera D. Baillie R. Caldwell Issued for Quote
99.05.25 99.05.25 99.05.25
1 P. Quintero D. Baillie B. Docherty Issued for Purchase
99.08.31 99.09.01 99.09.02
X0 J. Menendez/A. A. Avila S. Cuesta J. Riera Update As Built by SINCOR
Avila 16/09/04 16/09/04 16/09/04 16/09/04 Rev 2004
X1 J. Menendez A. Avila S. Cuesta J. Riera Update As Built by SINCOR
26/09/05 26/09/05 26/09/05 26/09/05 Rev 2005
X2 M. Bazaco A. Avila J. Riera Update As Built by SINCOR
23/06/06 23/06/06 23/06/06 Rev 2006
CA04-04-33-P-SP-008_X2.DOC
SINCOR
Contents
SECTION N
1. SCOPE 3
2. CODES AND STANDARDS 3
3. CABLE CONSTRUCTION 5
4. CABLE SPECIFICATION 8
5. REQUIRED INFORMATION TO BE SUPPLIED FOR CABLE DERATING AND

STANDARD CALCULATIONS 11
6. CABLE IDENTIFICATION 12
7. TEMPERATURE RATINGS 13
8. TESTING AND INSPECTION 13
9. REELS AND SHIPMENT 15
10. DOCUMENTS BE SUPPLIED WITH QUOTATION 16
CA04-04-33-P-SP-008_X2.DOC
SINCOR
1. SCOPE
A. This specification covers the basic requirements, features, general construction, design
and fabrication and testing of 600V-35 kV cable suitable for operation in dry or wet
locations.
B. This specification is to be used jointly with the Material Requisition (MR). Unless
otherwise specified in the MR, the Seller shall comply with the requirements of this
specification. Should any conflict arise between this specification and the MR, the MR
shall take precedence. In the event of ambiguity of any portion of the subject
documents, it shall be the responsibility of the Seller to contact the Buyer for
clarification.
2. CODES AND STANDARDS

Unless otherwise noted, the fabrication and testing of the power and control cable shall be in
accordance with the latest edition of the applicable specifications and codes of the following
organizations:
A. International Electrotechnical Commission (IEC)
In Particular:
IEC 600183 Guide to the selection of High-Voltages Cables
IEC 600227 Polyvinyl Chloride Insulated cables of rated Voltages up to

including 450/750V
IEC 60228 Conductors of Insulated Cables. Guide to dimensional limits

of circular conductors.
IEC 60230 Impulse test on cables and their accessories
IEC 60287 Calculation of the continuous current rating of cables (100%

load factor)
IEC 60331 Test for electric cables under fire conditions (all applicable
parts)
CA04-04-33-P-SP-008_X2.DOC
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IEC 60332 Tests on Electric cables under fire conditions
IEC 60502 Extruded solid dielectric insulated power cables for rated
voltages from 1 kV up to 30 kV
IEC 60811 Common test methods for insulating and sheathing materials
of electric cable.
IEC 60840 Testing For 34.5 kV Cables
IEC 60949 Calculation of Thermally permissible short-circuit currents,

taking into account non-adiabatic heating effects
B. Venezuelan Cdigo Elctrico Nacional, Covenin 200 latest Edition.
C. The cables may conform to the standards of the country and the countrys approval
authority as follows:
European Committee for Electrotechinical Standardization (CENELEC).
France, Union Technique de lElectricite (UTE)
United Kingdom, British Approval Service for Electric Cables (BASEC)
Norway, Norges Elektriske Materiell/Kontroll/ (NEMKO)
Germany, Verband Deutscher Electrotechniker (VDE).
Bidders shall identify any deviations or discrepancies between the country

standard and IEC Standards.
D. Alternative Standards
The offered power cables may conform to the standards of the country of manufacture,
provided these standards are based on, or comparable to the above-preferred standards.
Each bidder proposing other standards must specifically indicate from the above codes.
CA04-04-33-P-SP-008_X2.DOC
SINCOR
3. CABLE CONSTRUCTION
A. The cables shall in all respects be suitable for operation under the service conditions
stated in the attachments to the Material Requisition. They shall have a design life of at
least twenty years.
B. All armored cables shall be suitable for operation when installed:
a) Direct buried in the ground (Note: Cables shall be suitable for direct burial in
water-logged ground.)
b) In underground ducts
c) Below ground in enclosed sand filled trenches.
d) Aboveground, fastened to cable ladder rack or tray in the open air exposed to
direct sunlight (UV).
C. Cable fillers shall be solid, non hygroscopic and fill the cross section such that the
transmission of gas and hydrocarbons along the length of the cable, under normal
pressure, is not possible.
D. When specified, cables shall be flame retardant to reduce risk of fire spread. Cable flame
retardancy shall comply with the applicable IEC publications.
E. When specified, cables shall be fire resistant in accordance with the applicable IEC
publications.
F. Power Cables shall have insulation level adequate for the system category A per IEC
60183, sub-clause 4.2 (where earth faults are cleared as rapidly as possible but in any
case within 1 minute).
G. Cables shall have uniformity in insulation and outer sheath color and be resistant to
hydrocarbons in the soil. The overall jacket shall be PVC.
H. The cable outer protective sheath shall be color-coded depending on the system voltage
as follows:
CA04-04-33-P-SP-008_X2.DOC
SINCOR
System Voltage Color
Up to 480 Volts -Black
6.9 kV -Red
13.8 kV -Red
34.5 kV -Red
125VDC -Black
I. Color Coding
The color coding for multiwire cables shall be as follows:
a) Power phase leads shall be black
b) Multiwire lighting circuits and wire branch circuits connected to the same system
shall conform to the following:
480-277 V 208-120 V
Phase A - Brown Phase A-Black
Phase B - Orange Phase B- Red
Phase C - Yellow Phase C- Blue
Neutral - Gray Neutral - White
Earth - Green Earth - Green
(or green with one or more yellow stripes)
c) All control leads, including those for push-button stations, interlock circuits,
instrument control circuits, current and potential transformer circuits, etc., and
shall be red.
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d) Power supplies to/from instruments shall be yellow (live line) and white for the
neutral.
e) All earthing or grounding conductors shall be either bare or have a green or

yellow/green covering.
J. Cable cross sectional area, conductor material, number of cores, rated voltage and type
shall be as stated in the Material Requisition.
K. The type of armoring which encases the cable core(s) shall be as follows and shall be as
specified in the MR:
a) Round or flat wire (steel galvanized) helically applied.
b) Interlock steel armor corrugated.
c) Continuously corrugated welded sheath made of steel
L. The cable insulation voltage in relation to the system voltage shall be as follows:
System Voltages: Cable rated Voltages in kV (Uo/U(UM) :
125VDC, 120/208/230V 0.6/0.75kV
480 Volts 0.6/1(1.2) kV
6.9 kV 0.6/10/ (12) kV
13.8 kV 8.7/15/ (17.5) kV
34.5 kV 26/45/ (52) kV
Uo= Phase to Ground Voltage
U= Phase to Phase Voltage
UM = Maximum value of the Highest System Voltage
For which the equipment may be used.
M. Insulation shall be extruded solid dielectric of one of the types listed below and good for
90 OC rating.
CA04-04-33-P-SP-008_X2.DOC
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a) XLPE Cross-linked Polyethylene
b) EPR Ethylene Propylene Rubber
c) PVC Polyvinyl Chloride (for 1 kV cables only).
4. CABLE SPECIFICATION
A. In general cables shall be as specified below.
B. Cables for High Voltage Above 1 kV
1. Single conductor, XLPE or EPR insulated, armored power cable for cables above
1 kV.
a) Stranded annealed copper conductor (Class 2 per IEC 60228),

semiconducting strand shield, 90 0C XLPE or EPR insulation,
semiconducting insulation shield, copper shielding tape, inner PVC
Sheath, helically applied flat or round aluminum wire armoring or double
aluminum tape armoring and with outer PVC Jacket of the color specified
in the MR.
b) The copper tape shield shall be sized based on the fault current
magnitude & duration (refer to IEC 60183 and/or Covenin 200) as
specified in the MR.
2. There conductor, XLPE or EPR insulated, armored power cable for cables above
1 kV.
a) Stranded annealed copper conductors (Class 2 per IEC 60228), extruded

semiconducting material, 90 0C XLPE or EPR insulation, additional
semiconductor material, over which the copper tape insulation screening
shall be laid up in triplex formation. An uninsulated stranded soft draw
copper ground conductor shall be laid up with the insulated conductors
separately with each main run.
b) Suitable approved filler shall be utilized to from basis for the inner binder
material. A PVC jacket intermediate sheath shall then be applied with.
wire or double galvanized steel tape armoring, and with an outer PVC
jacket of the color specified in the MR. The ground conductor shall be
CA04-04-33-P-SP-008_X2.DOC
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sized based on the fault current magnitude & duration (refer to IEC 60183
and/or Covenin 200) as specified in the MR.
C. CABLES FOR LOW VOLTAGE UP TO 1 kV
1. ARMORED
a) Three conductor XLPE or EPR insulated, armored power cables for 1 kV.
b) Stranded copper conductors (Class 2 per IEC 60228) with 90 0C XLPE or

PVC insulation, intermediate protective covering, inner PVC jacket,
armored and with an outer PVC jacket.
c) Three conductor with neutral and ground, XLPE or EPR insulated,

armored power cables for 1 kV.
d) Stranded copper conductors (Class 2 per IEC 60228) with 90 0C XLPE or

PVC insulation, immediate protective covering, inner PVC jacket, armored
and with an outer PVC jacket.
e) Multi conductor control cable, with ground, XLPE or EPR or PVC

insulated, armored, for 1 kV.
f) Stranded copper conductors (Class 2 per IEC 60228) with 90 0C XLPE

insulation, inner PVC jacket, armored and with an outer PVC jacket.
2. NON-ARMORED
a) Three conductor XLPE or EPR insulated, non-armored power cables for 1

kV.
b) Stranded annealed copper conductor (Class 2 per IEC-60228), 90 0C,

XLPE or EPR or PVC insulation. Intermediate protective covering of
extruded semiconducting tape between the insulation screen and copper
tape screen. The copper tape shield shall be sized based on the fault
current magnitude and duration (refer to IEC-60183 and/or COVENIN
200) as specified. Protective sheath of fire retardant PVC to IEC-60332-3
or equivalent.
c) Three conductor with neutral and ground, XLPE or EPR insulated, non-
armored power cables for 1 kV.
CA04-04-33-P-SP-008_X2.DOC
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d) Stranded annealed copper conductor (Class 2 per IEC-60228) 90 0C,

XLPE or EPR or PVC insulation. Intermediate protective covering of
extruded semiconducting tape screen. The copper tape shield shall be
sized based on the fault current magnitude and duration (refer to IEC
60183 and/or COVENIN 200) as specified in the MR. Protective sheath of
fire retardant PVC to IEC-60332-3 or equivalent.
e) Multi-conductor control cable, with ground, XLPE or EPR or PVC

insulated, PVC sheathed, non-armored for 1 kV.
f) Stranded or solid annealed copper conductor (Class 2 per IEC-60228),

twisted, with 90 oC XLPE or EPR or PVC insulation. Extruded intermediate
protective covering made of an inner sheath acting as filler and non-
hygroscope tape and overall protective inner PVC sheath. PVC of outer
sheath shall resistant to aliphatic hydrocarbons and fire retardant to IEC-
60332-3 or equivalent.
D. CABLES FOR 600V OR 750V
1. NON-ARMORED
a) One or three phase conductor, with neutral and ground, XLPE or EPR or
PVC insulated, non-armored cables for 600V or 750V for lighting and
small power.
b) Stranded (or solid for lighting circuit up to 4mm2) annealed copper

conductor (Class 2 per IEC 60228) with 90 0C, XLPE or EPR or PVC
insulation, inner protective covering, and PVC protective outer sheath.
PVC shall be resistant to aliphatic hydrocarbons and fire retardant to IEC-
60332-3 or equivalent.
2. ARMORED
a) One or three phase conductor, with neutral and ground XLPE or EPR or
PVC insulated, armored cables for 600V or 750V for lighting (external)
and small power.
CA04-04-33-P-SP-008_X2.DOC
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b) Stranded (or solid for lighting circuit up to 4 mm2) annealed copper

conductor (class 2 per IEC 60228) with 90 0C XLPE, EPR or PVC
insulation. Extruded intermediate protective covering made of an inner
hydrocarbon elastic material. Armoring shall be galvanized aluminum
tape. PVC outersheath shall be fire retardant to IEC-60332-3 or equivalent
5. REQUIRED INFORMATION TO BE SUPPLIED FOR CABLE DERATING AND

STANDARD CALCULATIONS
A. The Seller shall supply the following information on all cables supplied:
a) Cable Derating
Cable Rated Voltage kV
Conductor size and type mm2 (AWG or kcmil)
Cable Ampacity :
Cable Ampacity for direct buried A.
Cable Ampacity for single way ducts A.
Cable Ampacity in Free Air A.
Short Circuit rating tables (KA vs. seconds)
Group rating factors for depth of laying (triad and flat formation)
Rating : factors for variation of thermal resistivity of soil.

O
Cable insulation rated temperature C
DC Resistance microhm/meter at 25 OC
Outside diameter mm
Thermal resistance ohm-meter
Dielectric losses watts/meter
Yc [ AC/DC losses of the conductor (per unit) ]
CA04-04-33-P-SP-008_X2.DOC
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Yc = Ycs (skin effect) + Ycp (proximity effect) = .
Ys [ratio of shield losses to DC losses (per unit) ]
Ys = Ysc (circulating current) + Yse (eddy currents) = .
Note : Rac/Rdc = 1 + Yc + Ys
Capacitance n F/meter
b) Cable Pulling
Cable weight Kg/1000 meter
Maximum allowable tension kg/mm2
Minimum cable bending radius mm.
c) Short circuit and load flow/voltage drop calculations for each cable size at rated
insulation level (75 OC or 90 OC)
d) Positive sequence Reactance X = ohms/1000 meter
Resistance R = ohms/1000 meter
Negative sequence Reactance X = ohms/1000 meter
Resistance R= ohms/1000 meter.
6. CABLE IDENTIFICATION
A. The outer surface of each cable shall be durably marked throughout its length with the
manufacturers identification, type of insulation (e.g., XLPE, EPR, PVC etc., in addition to
the manufacturers trade name), size of copper conductor in mm2 (AWG or kcmil), rated
voltage, year of manufacture, insulation thickness, number of cores, nominal cross
sectional area of conductors and progressive length of cable at every meter.
B. Auxiliary insulation shielding and conducting jackets shall be conspicuously identified as

conducting.
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C. The proceeding identifications shall be repeated along the cable at regular intervals. The
cable size mm2 shall be repeated at intervals not exceeding 600 mm. All other markings
shall be repeated at intervals not exceeding one meter.
7. TEMPERATURE RATINGS
A. Highest rated temperatures for the different types of insulating compound shall comply
with IEC 60502, paragraph 1.4.
8. TESTING AND INSPECTION

A. General
a) The Seller shall provide certificates for routine tests, type tests and special tests
carried out on cables. Tests shall be those listed in the relevant IEC Publications,
this specification and any additionally specified requirements within the material
requisition.
b) The Buyer reserves the right to witness all tests specified on completed cables.
c) The Seller shall give two weeks notice of test prior to commencement
d) The Buyer reserves the right to inspect all cables at the Sellers works at any time
prior to shipment to prove compliance with the specifications.
e) Cables shall not be shipped unless the test certificates have been approved by
the Buyer
B. Tests on Samples (One per Each Voltage).
a) Samples of cables shall be checked by the following tests and shall comply with
IEC-60332 requirements:
Electrical moisture absorption test.
Ozone resistance test.
Mechanical water absorption test.
C. Electrical Tests on Entire Lengths of Completed Cables
CA04-04-33-P-SP-008_X2.DOC
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a) Alternating-Current Voltage Test
AC voltage test shall be conducted in accordance with IEC-60332 and/or 60502

Publications.
b) Insulation Resistance Tests
The insulation resistance in megohms per 300 meter at temperature of 15.6

Cshall not be less than the value of R calculated as follows:
R= K log 10 D
d
Where R= Insulation resistance in megohm per 300 meter.
K= 20,000
D= Diameter over insulation
d= Diameter under insulation
If temperature at the time of measurement differs from 15.6C, the resistance shall
be corrected to that at 15.6O C, by multiplying the measured value by the proper
correction factor per IEC 60502.
c) Direct-Current Voltage Test
Upon completion of the insulation resistance test, the DC voltage test shall be
made. The test voltage shall be per IEC 60502.
d) Type Tests and Special Tests
The completed cable shall be tested for type tests and special tests in accordance
with IEC 60502 requirements if specified in the MR.
D. Dimensional Verification
a) Each length of insulated conductor shall be examined to verify that the conductor
is of correct size.
CA04-04-33-P-SP-008_X2.DOC
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b) Each length of insulated conductor shall be measured to verify that the insulation
wall thickness is of the correct dimension.
c) Each length of completed cable shall be measured to verify that the protective
covering or jacket wall thickness is of the correct dimension.
9. REELS AND SHIPMENT

A. The cable shall be placed in the reels in such a manner that it will be protected from
injury during shipment. Each end of the cable shall be firmly and properly secured to the
reel.
B. Each end of each length of cable shall be durably sealed before shipment to prevent
entrance of moisture.
C. Reels shall be securely blocked in position so that they will not shift during transit.
D. The Seller shall be responsible for corrosion and any damage to the cable during transit
which in the result of the cable reels not having been properly fastened, sealed, packed
or blocked.
E. The reels shall be lagged or covered with suitable material to provide physical protection
for the cables during transit and during ordinary storage and handling operations.
F. Identification labels shall be attached to the outside of each cable reel flanges. Labels
shall be protected by transparent plastic envelopes or other weather resistant material
and give the following information:
Reel identification number
Cable voltage grade
Cable construction (e.g. XLPE, EPR, and PVC)
Number of cores and cross sectional area
Cable quantity (meters)
Purchase order number and item number
Total weight, of cable and drum (kg)
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Manufacturers name
Year of manufacture
Stock code number
11. DOCUMENTS TO BE SUPPLIED WITH QUOTATION

A. The Seller shall submit with his proposal the following information and data:
Full technical description and performance details of the equipment and

components offered.
Overall dimensions and shipping dimensions and weights.
B. For the required quantity of drawings, test reports, instruction manuals and spare parts
requirements refer to MR.
C. All electrical symbols on the drawings and diagrams furnished by vendor shall be in
accordance with IEC 60617.
CA04-04-33-P-SP-008_X2.DOC

CA04!04!33-P-SP-008 - X2 Power & Control Cables

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SINCOR

Sincor Document No: CA04-04-33-P-SP-008

Prepared By/ Checked By/ Project SINCOR

2. CODES AND STANDARDS 3

5. REQUIRED INFORMATION TO BE SUPPLIED FOR CABLE DERATING AND

8. TESTING AND INSPECTION 13

9. REELS AND SHIPMENT 15

10. DOCUMENTS BE SUPPLIED WITH QUOTATION 16

2. CODES AND STANDARDS

A. International Electrotechnical Commission (IEC)

IEC 600183 Guide to the selection of High-Voltages Cables

IEC 600227 Polyvinyl Chloride Insulated cables of rated Voltages up to

IEC 60228 Conductors of Insulated Cables. Guide to dimensional limits

IEC 60230 Impulse test on cables and their accessories

IEC 60287 Calculation of the continuous current rating of cables (100%

IEC 60332 Tests on Electric cables under fire conditions

IEC 60949 Calculation of Thermally permissible short-circuit currents,

B. Venezuelan Cdigo Elctrico Nacional, Covenin 200 latest Edition.

European Committee for Electrotechinical Standardization (CENELEC).

France, Union Technique de lElectricite (UTE)

United Kingdom, British Approval Service for Electric Cables (BASEC)

Norway, Norges Elektriske Materiell/Kontroll/ (NEMKO)

Germany, Verband Deutscher Electrotechniker (VDE).

Bidders shall identify any deviations or discrepancies between the country

B. All armored cables shall be suitable for operation when installed:

c) Below ground in enclosed sand filled trenches.

System Voltage Color

Up to 480 Volts -Black

The color coding for multiwire cables shall be as follows:

a) Power phase leads shall be black

Phase A - Brown Phase A-Black

Phase B - Orange Phase B- Red

Phase C - Yellow Phase C- Blue

Neutral - Gray Neutral - White

Earth - Green Earth - Green

(or green with one or more yellow stripes)

e) All earthing or grounding conductors shall be either bare or have a green or

a) Round or flat wire (steel galvanized) helically applied.

b) Interlock steel armor corrugated.

c) Continuously corrugated welded sheath made of steel

System Voltages: Cable rated Voltages in kV (Uo/U(UM) :

125VDC, 120/208/230V 0.6/0.75kV

480 Volts 0.6/1(1.2) kV

6.9 kV 0.6/10/ (12) kV

13.8 kV 8.7/15/ (17.5) kV

34.5 kV 26/45/ (52) kV

Uo= Phase to Ground Voltage

U= Phase to Phase Voltage

UM = Maximum value of the Highest System Voltage

For which the equipment may be used.

a) XLPE Cross-linked Polyethylene

b) EPR Ethylene Propylene Rubber

c) PVC Polyvinyl Chloride (for 1 kV cables only).

B. Cables for High Voltage Above 1 kV

a) Stranded annealed copper conductor (Class 2 per IEC 60228),

a) Stranded annealed copper conductors (Class 2 per IEC 60228), extruded

C. CABLES FOR LOW VOLTAGE UP TO 1 kV

b) Stranded copper conductors (Class 2 per IEC 60228) with 90 0C XLPE or

c) Three conductor with neutral and ground, XLPE or EPR insulated,

d) Stranded copper conductors (Class 2 per IEC 60228) with 90 0C XLPE or

e) Multi conductor control cable, with ground, XLPE or EPR or PVC

f) Stranded copper conductors (Class 2 per IEC 60228) with 90 0C XLPE

a) Three conductor XLPE or EPR insulated, non-armored power cables for 1