SECTION 16120

CONDUCTORS AND CABLES

TABLE OF CONTENTS

Item No Title Page No

PART 1 GENERAL 1

1.01 DESCRIPTION OF WORK .................................................................................. 1

1.02 SECTION INCLUDES .......................................................................................... 1

1.03 RELATED SECTIONS ......................................................................................... 1

1.04 REFERENCES..................................................................................................... 2

1.05 DEFINITIONS ...................................................................................................... 4

1.06 SUBMITTALS....................................................................................................... 5

1.07 QUALITY CONTROL ........................................................................................... 6

1.08 HEALTH AND SAFETY CONSIDERATIONS...................................................... 6

1.09 FACTORY TESTING ........................................................................................... 6

1.10 SERVICE CONDITIONS...................................................................................... 7

1.11 DELIVERY, HANDLING AND STORAGE ........................................................... 7

PART 2 PRODUCTS 9

2.01 GENERAL ............................................................................................................ 9

2.02 1000 V AND BELOW POWER CABLE................................................................ 9

2.03 15 kV AND 34.5 kV SINGLE CORE CABLES ................................................... 12

2.04 115 kV SINGLE CORE CABLE ......................................................................... 15

2.05 CABLE MARKING AND IDENTIFICATION ....................................................... 17

2.06 SPLICES, TERMINATIONS AND ACCESSORIES........................................... 18

PART 3 EXECUTION 24

3.01 GENERAL .......................................................................................................... 24

3.02 INSTALLATION OF CABLES IN DUCT............................................................. 24

3.03 INSTALLATION OF DIRECT BURIED CABLES .............................................. 31

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TABLE OF CONTENTS (Contd.)

Item No Title Page No

3.04 TESTING AND COMMISSIONING.................................................................... 32

3.05 FIGURES AND TEST DATA SHEET................................................................. 34

Rev 0 ii Contract No:

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PART 1 GENERAL

1.01 DESCRIPTION OF WORK

A. This Section specifies the minimum technical requirements for design engineering,
furnishing, manpower, installing and supervision, of Conductors and Cables as per
the Contract Documents.

B. The Contractor shall, as part of his full responsibility scope, check the conductors
and cables as specified in the Contract Drawings/Documents. When this check
indicates that the specified conductors and cables are not adequate, the Contractor
shall notify the Royal Commission and take the necessary action/changes with
approval by the Royal Commission.

C. The Contractor shall also check and verify every requirements, aspect and detail
necessary for coordinating with new or existing systems of conductors and cables.

D. These Specifications define the minimum requirements for conductors and cables
with either IEC/SASO or North American based standards, as specified in par. 1.04.

E. Where works interface with Saudi Electricity Company (SEC), the

equipment/materials and installation system shall comply with latest revision of SEC
standards and shall be reviewed and approved by SEC.

1.02 SECTION INCLUDES

A. This Section specifies furnishing, installing and testing of insulated cables,

conductors and all conductor accessories. This will include 600/1000 V, 15 kV,
35 kV, and 115 kV Cables.

1.03 RELATED SECTIONS

A. Section 01320 Construction Progress Documentation

B. Section 01330 Submittal Procedures

C. Section 01410 Regulatory Requirements

D. Section 01450 Quality Control

E. Section 01650 Product Delivery Requirements

F. Section 01660 Product Storage and Handling Requirements

G. Section 02315 Excavation and Fill

H. Section 02580 Electrical and Communication Structures

A. Section 16055 General Provisions for Low Voltage Electrical Works

B. Section 16075 Electrical Identification

Rev 0 1 of 46 Contract No:

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CONDUCTORS AND CABLES

1.04 REFERENCES

A. The referred codes and standards are intended to provide an acceptable level of
quality for materials and products. In case of conflict between these standards and
the text of this Specification, the Specification text shall govern.

B. The latest revision of the referred codes and standards shall be used wherever
applicable. In case of conflict, the Contractor shall propose equipment conforming to
one group of codes and standards.

C. SASO Saudi Arabian Standard Organization

1. SASO 55 PVC Insulated Cables with Circular Copper

Conductors

2. SASO 56 Methods of Test for PVC Insulated Cables and Cords

with Circular Copper Conductors

3. SASO SSA 751 Conductors of Insulated Cables

4. SASO 1054 Power Cable with Extruded Insulation and their

Accessories for Rated Voltages from 1 kV (Um =
1.2 kV) up to 30 kV (Um = 36 kV) - Part 2. Cables
for Rated Voltages from 6 kV (Um = 7.2 kV) up to 30
(Um = 36 kV)

D. SEC-ERB Saudi Electricity Company-Eastern Region Branch

1. SES-P-104. 02 Cable Construction

2. SES-P-104. 03 Cable Sizing and Selection

3. SES-P-104. 04 Splice and Termination

4. SES-P-104. 05 Cable Installations Engineering Requirements

5. SES-P-104. 07 Refer to SES-P-104.04

6. SES-P-119. 29 LV Cable Selection and Sizing

7. 11-SMSS-3 Power Cable, XLPE Insulated, Copper or Aluminum

Conductor, Single Core, 34.5 kV Rating

8. 11-SMSS-5 Specifications for Power Cable, XLPE Insulated

Copper Conductor, Single Core, 115 kV or 230 kV
Rating

9. 11-SMSS-12 Specifications for Power and/or Control Cable

Copper or Aluminum Conductor 600/1000 V Rating

10. 12-SMSS-2 Specifications for Splice and Termination Kits, Heat

Shrinkable, for Cables Rated 34.5 kV and Below

Rev 0 2 of 46 Contract No:

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E. AEIC Association of Edison Illuminating Companies

1. AEIC CS4 Specifications for Impregnated-Paper-Insulated Low

and Medium Pressure Self Contain Filled Liquid
Cable

2. AEIC CS5 Cross-Linked Polyethylene Insulated Shielded Power

Cable Rated 5 through 46 kV

3. AEIC CS6 Ethylene Propylene Rubber Insulated Shielded

Cables Rated 5 Through 69 kV

4. AEIC CS7 Specifications for Cross-Linked Polyethylene

Insulated Shielded Power Cables Rated 69 kV
Through 138 kV

F. ASTM American Society for Testing and Materials

1. ASTM B3 Standard Specifications for Soft or Annealed Wire

2. ASTM D1248 Standard Specifications for Polyethylene Plastic

Extrusion Materials for Wire and Cable

3. ASTM D3485 Standard Specifications for Smooth Wall Coil-able

Polyethylene (PE) Conduit (DUCT) for Pre-
assembled Wire and Cable

4. ASTM E28 Test Method for Softening Point by Ring and Bell
Apparatus

G. ICEA/NEMA Insulation Cable Engineers Association/National Electrical

Manufacturer Association

1. ICEA P-45-482 Circuit Performance of Metallic Shields and Sheaths

on Insulated Cable

2. ICEA S-66-524/NEMA WC 7 Cross-Linked Thermosetting Polyethylene

Insulated Wire and Cable

3. ICEA S-68-516/NEMA WC 8 Ethylene Propylene Rubber Insulated Wire

and Cable

H. IEC International Electro-Technical Commission

1. IEC 60227 Polyvinyl Chloride Insulated Cables of Rated Voltage

up to and Including 450/750 V

2. IEC 60228 Conductors of Insulated Cables

3. IEC 60446 Basic and Safety Principle for Machine Interface,

Marking and Identification of Conductors by Colors or
Numeral

4. IEC 60502 -1 Power Cables with Extruded Insulation and Their

Rev 0 3 of 46 Contract No:

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Accessories for Rated Voltages From 1 kV (Um =

1.2 kV) up to 30 kV (Um = 36 kV) – Part 1: Cables for
Rated Voltages of 1 kV (Um = 1,2 kV) up to 3 kV
(Um = 3.6 kV)

5. IEC 60840 Tests for Power Cables with Extruded Insulation for
Rated Voltage Above 30 kV (Um = 36 kV) up to
150 kV (Um = 170 kV)

I. IEEE Institute of Electrical and Electronic Engineers

1. IEEE 48 Test Procedures and Requirements for Alternating

Current Cable Terminations 2.5 kV through 765 kV

2. IEEE 404 Test Procedures and Requirements for High Voltage

Alternating Current Cable Splices

J. NEMA National Electrical Manufacturer Association

1. NEMA CC1 Electric Power Connectors for Substations

K. NFPA National Fire Protection Association

1. NFPA 70 National Electrical Code

L. UL Underwriters Laboratories Inc.

1. UL 62 Flexible Cord and Fixture Wire

2. UL 486 A Wire Connectors and Soldering Lugs for Use with

Copper Conductors

1.05 DEFINITIONS

A. ampacity: The current in amperes that a conductor can carry continuously under the
conditions of use without exceeding its temperature rating.

B. cable: Conductor with insulation or a stranded conductor with or without insulation

covering (single conductor cable), or a combination of conductors insulated from one
another conductor cable).

C. conductor: Any carrier of electric current. In practical terms, a wire or cable

designed to carry electric current. A conductor can be insulated or un-insulated
depending on application. Examples include wire, cable and bus bar.

D. concentric neutral cable: A two conductor cable consisting of an insulated wrapped

in a copper neutral conductor.

E. duct bank: A group of ducts or conduit usually encased in concrete in a trench.

F. direct buried: Also referred to a URD or underground distribution. Cable is laid in a

trench and directed to specific locations through the use of pad-mount transformers,

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switch gear, to centers, riser poles.

G. heat shrink: A material used to connect two pieces of conductor together. The
material shrinks to fit when heat is applied.

H. insulation: Non-conductive material that is applied over a conductor (e.g. cable,

wire) to insulate a conductor from other conductors or ground.

I. jacket (the outer covering of a cable): A tough plastic material that provides
physical protection for the cable. Jacketed cable protects against physical damage
and corrosion, thus reducing the risk of damage to the primary neutral.

J. manhole: A subsurface enclosure which personnel may enter, manholes are for
installing, operating and maintaining underground cable systems.

K. splice: The joining of two or more cables by connecting the conductors pair to pair.

L. shield (screen): A metallic layer usually in the form of a braid of foil surrounding one
or more electrical conductors to insulate them from electromagnetic interference.

M. overcurrent: Any current in excess of the rated current of equipment or the ampacity
of a conductor. It may result from overload, short circuit, or ground fault.

N. overload: Operation of equipment in excess of normal, full-load rating, or of a

conductor in excess of rated ampacity that, when it persists for a sufficient length of
time, would cause damage or dangerous overheating. A fault, such as a short circuit
or ground fault, is not an overload.

1.06 SUBMITTALS

A. The Contractor shall submit to the Royal Commission, under the provision of
SECTION 01330, the following items for review and approval before commencing
work:

1. Vendor Drawings and original Product Data as listed below:

a) List of manufacturers.

b) Drawings and original technical catalog to indicate numbers of

conductors and accessories and lengths of insulated cable required.

c) Supplier’s installation instructions for cable and accessories.

d) Quality Control Program as outlined in SECTION 01450.

e) Factory test reports.

f) Samples of cables and accessories.

g) Certificate of compliance.

h) Calculations for cable sizing to justify the proposed cables.

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B. The Contractor shall submit field test reports after the completion of Testing and
Commissioning.

1.07 QUALITY CONTROL

A. The Contractor shall be responsible for the quality of work and shall develop and
propose programs and methods of construction and testing such as to achieve the
specific quality to the approval of the Royal Commission in accordance with
SECTION 01450.

1.08 HEALTH AND SAFETY CONSIDERATIONS

A. All works undertaken in relation to this Specification are to be completed in full

accordance with the respective health and safety requirements established by the
following:

1. Kingdom of Saudi Arabia

a) Legislation, Regulation, Standards and Codes.

2. Royal Commission Regulations

a) Standards, Contractual Conditions, and Health and Safety Systems.

3. Contractor

a) Health and Safety Standards and Systems as accepted by the Royal

Commission.

B. In the absence of any of the above, best accepted industry practice shall be
employed throughout.

1.09 FACTORY TESTING

A. General

1. All conductors and cables and their accessories shall be tested at the factory
in accordance with the latest approved manufacturing codes and standards.
The Contractor shall notify the Royal Commission in writing not less than
30 days prior to the scheduled starting date of the factory tests.

2. The Royal Commission reserves the right of deputing their representative for
witnessing the factory testing.

3. Upon completion of factory tests, and before shipment of the conductors and
cables and their accessories, the Contractor shall submit 5 certified copies of
test reports not later than 10 days after the completion of all factory tests for
review and approval by the Royal Commission.

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1.10 SERVICE CONDITIONS

A. All the cables and accessories installed indoor shall be suitable for continuous
operation under the following service conditions:

1. Ambient Air Temperature

a) A maximum of 40°C.

b) A minimum of 0°C.

c) Average temperature, measured over a period of 1 month, of a

maximum of 35°C.

2. Relative Humidity (Average Value)

a) For a period of 24 hours, does not exceed 95%.

b) For a period of 1 month, not exceeding 90%.

B. All the cables and accessories installed outdoor shall be suitable for continuous
operation under the following service conditions:

1. Ambient Air Temperature

a) A maximum of 50°C.

b) A minimum of 0°C, unless a lower temperature is specified on the

Contract Drawings.

c) Average temperature, measured over a period of 1 month, of a

maximum of 45°C.

2. Altitude

a) Less than 1000 m, unless a higher altitude is specified on the Contract

Drawings.

3. Relative Humidity (Average Value)

a) For a period of 24 hours, not exceeding 95%.

b) For a period of 1 month, not exceeding 90%.

c) Relative humidity may be temporarily 100%.

C. All the cables and accessories to be installed in classified areas, as indicated on the
Contract Drawings, shall be suitable for such installation as per NEC Article 500.

1.11 DELIVERY, HANDLING AND STORAGE

A. The Contractor shall deliver, handle and store material and product units in

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accordance with SECTIONS 01650 and 01660, as well as the following

requirements:

1. Ensure cable ends are sealed with waterproof, heat-shrinkable plastic or

elastomeric end cap with adhesive type sealing compound. Cable ends shall
be properly secured to the reel.

2. Provide marking on each item in accordance with the manufacturer’s

instruction. Ship each unit securely wrapped, crated or packaged and labeled
for safe handling in shipment and to avoid damage or distortion.

3. Ensure equipment and materials are delivered to site originally packed,

securely wrapped and labeled by manufacturer in unopened containers.
Protect materials during delivery to comply with manufacturer’s direction.

4. Store cables and accessories in secure and dry storage facility.

5. Store materials at building site strictly according to manufacturer’s instruction.

Store products or equipment in dry and ventilated place.

6. Store cables and accessories in environmental (service) conditions close to

operating conditions.

7. The Contractor shall be held responsible for damage of the cables and
accessories during storage or transportation.

Rev 0 8 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

PART 2 PRODUCTS

2.01 GENERAL

A. All goods and products covered in these Specifications shall be procured, when
available, from an in-Kingdom manufacturer. However, procurement of all goods and
products manufactured out-of-Kingdom or in-Kingdom must be approved by the
Royal Commission.

B. Where Royal Commission utilities interface with power company (SEC) the cables
and related materials shall be approved by SEC.

2.02 1000 V AND BELOW POWER CABLE

A. General

1. The cable shall meet or exceed the requirement of this Specification in all
respects.

2. The cables shall be manufactured in accordance with SASO, AEIC, ICEA, IEC
or equivalent standards.

3. The cable shall be designed for use in all low voltage power circuits and for
installation in conduits, underground ducts, cable trays, raceways or for directly
buried installations.

4. Cables shall be suitable for all service conditions as specified in par. 1.10
that occur in the areas where they are installed.

5. Cables shall be suitable for operation in wet or dry locations with alternately
wet and dry conditions. If exposed cable tray installations are used, cables
shall be suitable for operation in a sandy and salty atmosphere without
affecting its physical and electrical characteristics.

6. The cables shall be thermally stable, moisture resistant (non-hygroscopic),

chemical resistant, immune to fire propagation and mechanically strong.

B. Conductor Design Requirements

1. Conductors shall be concentric lay uncoated annealed stranded or solid

copper conductors, covered with insulation suitable for Class B. Maximum
operating temperature is 90°C in accordance with ICEA-S-66-524/NEMA WC-
7 or IEC 60228.

2. Single core cables shall not be larger than 300 mm2. Conductors 4 mm2 and
larger shall be stranded, while conductors below 4 mm2 may be stranded or
solid, as specified on the Contract Drawings.

C. Insulation Design Requirements

1. The insulation material shall be PVC or XLPE in accordance with ICEA-S-66-

524 or IEC 60502-1, as indicated on the Contract Drawings.

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2. The insulation shall be heat and moisture resistant, flame retardant and ozone
resisting compound suitable for 85/90°C maximum conductor temperature
under normal operating conditions.

3. For multi-conductor cables, filler shall be of non-hygroscopic material

compatible with the insulation and suitable for the operating temperature of the
cables.

4. The maximum outside diameter of 600 V cable shall be 22 mm2.

5. Cable details describe only cable construction containing conductors of the

sizes listed below and the nominal conductor insulation thickness for single
core, 3/C, and 4/C shall be as specified in Tables given below, conforming to
the ICEA-S-66-524 or IEC 60502-1.

a) Single conductor cable details given in Table 2A.

TABLE 2A: CONDUCTOR INSULATION THICKNESS FOR SINGLE CONDUCTOR

CABLES

Conductor Insulation
Conductor Size
Thickness (mm2)
No. of Strands
mm2 AWG or MCM PVC XLPE

70 2/0 19 1.4 1.1

95 3/0 19 1.6 1.1

120 4/0 37 1.6 1.2

150 300 37 1.8 1.4

185 350 37 2.0 1.6

240 500 61 2.2 1.7

300 600 61 2.4 1.8

400 800 61 2.6 2.0

500 1000 61 2.8 2.2

b) Three Conductor-3/C (2 Phase and 1 Neutral) Cable details given in

Table 2B.

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TABLE 2B: 3-CONDUCTOR-3/C CABLE DETAILS

Phase Conductor Size Neutral Conductor Size

Insulation Insulation
AWG Thickness AWG Thickness
No. of No. of
mm2 or in mm mm2 or in mm
Strands Strands
MCM MCM
PVC XLPE PVC XLPE
35 2 6 1.2 0.9 35 2 7 1.0 0.7
50 1 6 1.4 1.0 50 1 7 1.2 0.9
70 2/0 12 1.4 1.1 70 2/0 7 1.2 0.9
95 3/0 15 1.6 1.1 95 3/0 19 1.4 1.0
120 4/0 18 1.6 1.2 120 4/0 19 1.4 1.1
150 300 18 1.8 1.4 150 300 19 1.4 1.1
185 350 30 2.0 1.6 185 350 19 1.6 1.1
240 500 34 2.2 1,7 240 500 37 1.6 1.2
300 600 34 2.4 1.8 300 600 37 1,8 1.4
400 800 53 2.6 2.0 400 800 37 2.0 1.6
500 1000 53 2.8 2.2 500 1000 61 2.2 1.7

c) Four Conductor-4/C (3 Phase and 1 Neutral) Cable details given in

Table 2C.

TABLE 2C: 4-CONDUCTOR-4/C CABLE DETAILS

Phase Conductor Size Neutral Conductor Size

Insulation Insulation
AWG Thickness in AWG Thickness in
No. of No. of
mm2 or mm mm2 or mm
Strands Strands
MCM MCM
PVC XLPE PVC XLPE
35 2 6 1.2 0.9 35 2 6 1.2 0.9
50 1 6 1.4 1.0 50 1 6 1.4 1.0
70 2/0 12 1.4 1.1 70 2/0 12 1.4 1.1
95 3/0 15 1.6 1.1 95 3/0 15 1.6 1.1
120 4/0 18 1.6 1.2 120 4/0 18 1.6 1.2
150 300 18 1.8 1.4 150 300 18 1.8 1.4
185 350 30 2.0 1.6 185 350 30 2.0 1.6
240 500 34 2.2 1.7 240 500 34 2.2 1.7
300 600 34 2.4 1.8 300 600 34 2.4 1.8
400 800 53 2.6 2.0 400 800 53 2.6 2.0
500 1000 53 2.8 2.2 500 1000 53 2.8 2.2

D. Jacket

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1. The jacket shall be black, ST 2 type, extruded PVC per IEC 60502-1 or ICEA-
S-66-524 with heat, moisture, oil, sunlight, acid, alkali and flame resistant
properties.

2.03 15 kV AND 34.5 kV SINGLE CORE CABLES

A. General

1. The insulated cables are to be furnished in accordance with the cable

specification sheets covered under this clause, and the other codes and
standards mentioned therein.

2. Cable material and construction shall be suitable for storage, installation and
operation in service conditions stated in par. 1.10. The impact of the higher
ambient temperature on ampacity will be factored in cable selection and
application during system design.

3. Cable shall be suitable for installation in wet and dry locations.

B. Conductor Design Requirements

1. Unless otherwise specified, the cable shall be manufactured and tested in

accordance with AEIC CS5.

2. Cables shall be designed to withstand a conductor temperature of 130°C

without any detrimental effects on any of its components. However, the cable
sizing shall be based on a maximum permissible continuous temperature of
90°C and emergency loading temperature of 105°C.

3. Conductor

a) Conductors shall be concentric-lay, uncoated, annealed copper; strand

Class B insulation complying with IEC 60228.

b) The conductor size and material shall be as specified in Table 2D.

TABLE 2D: CONDUCTOR MATERIAL

Conductor Size (mm2) Material

70, 95, 185, 240, 500 Copper
120, 400 Aluminum

4. Conductor Shield

a) The conductor shield shall consist of an extruded black thermosetting

semi-conducting material compatible with the conductor and the
insulation. A suitable semi-conducting tape may be applied between the
conductor and the specified extruded semi-conducting layer.

b) The minimum thickness of the conductor shield shall not be less than
80% of the average thickness.

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C. Insulation Design Requirements

1. Insulation shall consist of cross-linked thermosetting polyethylene (XLPE) in

accordance with AEIC CS5 or ICEA S-66-524, containing no carbon black.
The insulation shall consist of semi-conducting paint, semi-conducting tape
and uncoated copper tape or wire.

2. The minimum thickness of the insulation shall not be less than 90% of the
average thickness.

3. Cable insulation materials shall be in accordance with Table 2E.

TABLE 2E: CABLE INSULATION MATERIAL

Insulation Voltage Temperature Emergency Short Circuit

Material Rating Rating Operating Operating
Temperature Temperature
(kV) (°C) (°C) (°C)
XLPE 0.6 to 34.5 90 105 250
Super clean
69, 115 90 105 250
XLPE

4. Insulation Shield

a) The insulation shield shall consist of an extruded black thermosetting

semi-conducting material compatible with XPLE insulation.

b) The average thickness of the insulation shield shall not be less than
125% of the minimum point thickness.

5. Metallic Shield

a) Helically applied soft drawn copper wires or tapes may be used as

metallic shield, with prior approval from the Royal Commission, and as
well as SEC when required to interface with the Royal Commission
facilities.

b) When copper tape is used as a metallic shield, the tape shall have a
minimum thickness of 0.178 mm applied at 25% overlap.

c) ICEA P-45-482 shall be used by the manufacturer to determine the

effective cross-sectional area of the metallic shield and its short circuit
current carrying capability.

6. Moisture Impervious Layer

a) The moisture impervious layer shall be applied over the metallic shield
to prevent top ingress of moisture.

b) Aluminum coated with ethylene acrylic acid copolymer, copper coated

with chlorinated polyethylene and cross-linked synthetic super
absorbent polymer water blocking tapes are acceptable materials for the
moisture impervious layer.

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7. Jacket

a) The jacket material shall be black polyvinyl chloride (PVC), type ST 2

per IEC 60502. A suitable binder tape may be applied between the
moisture impervious layer and the outer jacket.

b) For services wherein the power cable will be continuously exposed to

saline water, the jacket material shall be linear low density polyethylene
(LLDPE) or linear medium density polyethylene (LMDPE).

c) The jacket thickness of multi-conductor cables (for all voltages and

uses) shall be in accordance with applicable ICEA S-66-524, par. 4.3.1.
or IEC 60502 standards.

8. Overall Diameter

a) The power cable shall have a maximum overall diameter as provided

below in the Table 2F and 2G. For power cables with copper tape
metallic shield refer to Table 2F. For power cables with copper wire
metallic shield refer to Table 2G.
TABLE 2F: POWER CABLES WITH COPPER TAPE METALLIC SHIELD
(APPLICABLE TO BOTH ALUMINUM AND COPPER
CONDUCTORS)

Conductor Size (mm2) Overall Diameter (mm)

70 40
95 41
120 43
185 47
240 49
400 56
500 59
TABLE 2G: FOR POWER CABLES WITH COPPER WIRE METALLIC SHIELD

Conductor Size (mm2) Overall Diameter (mm)

70 Cu 43
95 Cu 45
120 Al 47
185 Cu 51
240 Cu 54
400 Al 59
500 Cu 66

9. Fabrication

a) The conductor shield, cross-linked polyethylene insulation and insulation

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shield shall be extruded by the double tandem or triple extrusion method

to assure homogeneity between the insulation and the semi-conducting
shields.

b) The insulation shield shall be strippable type.

c) The cross-linking process shall be by the dry-cure method.

d) The power cable shall be free of material and manufacturing defects that
would prevent it from meeting the requirement of this Specification.

2.04 115 kV SINGLE CORE CABLE

A. General

1. The XLPE insulated power cable rated 115 kV shall meet or exceed the
requirements of this Specification in all respects.

2. For service conditions and other details, refer to par. 2.03 above.

B. Conductor Design Requirements

1. The power cable rated 115 kV shall be manufactured in accordance with AEIC
CS7 and tested in accordance with AEIC CS7 or IEC 60840.

2. The cable shall be designed to withstand a conductor temperature of

130°C without any detrimental effects on any of its components. However, the
cable sizing shall be based on a maximum permissible continuous temperature
of 90°C and emergency loading temperature of 105°C.

3. Conductor

a) The conductor shall be segmental or non-segmental, round, compacted

and compressed concentric stranded copper Class 2 per IEC 60228.

b) For 115 kV power cable, conductor sizes shall be 400, 630, 800, 1000,
and 1200 mm2.

c) The conductor construction shall be as specified in Table 2H.

TABLE 2H: CONDUCTOR SIZE

Conductor Size (mm2) Conductor Construction

400, 630, 800, 1000 Segmental or non-segmental

1000, 1200, 1500, 2000, 2500 Segmental

4. Conductor Shield

a) The conductor shield of cable, rated 115 kV shall consist of an extruded

black thermosetting semi-conducting material compatible with the
conductor and the XLPE insulation.

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b) A conductor moisture impervious layer (longitudinal water barrier) shall

be applied between the conductor and the specified extruded semi-
conducting layer.

c) The outer surface of the conductor shield shall be cylindrical and shall
be firmly bonded to the overlying insulation. The extruded shield shall be
easily removable from the conductor.

C. Insulation Design Requirements

1. The insulation shall be super clean cross-linked polyethylene (XLPE).

2. The cable insulation shall be in accordance with the Table 2E as indicated

above.

3. Insulation Shield

a) The insulation shield shall consist of an extruded black thermosetting

semi-conducting material compatible with the XLPE insulation.

4. Metallic Sheath

a) The metallic sheath shall consist of a seamless tube of corrugated

aluminum or extruded lead alloy.

b) For power cables to be installed below water table level, an extruded

lead alloy sheath shall be provided over the insulation shield.

c) For power cables to be installed above water table level, the sheath
shall be extruded lead alloy or seamless tube of corrugated aluminum.

d) ICEA P-45-482 shall be used by the manufacturer to determine the

effective cross-sectional area of the metallic sheath and its short circuit
current carrying capability.

e) When lead is used as sheath, the material and mechanical properties

shall conform to applicable clauses of AEIC CS4.

5. Moisture Impervious Layers

a) The moisture impervious layers shall consist of the following:

1) First Layer (Longitudinal Water Barrier)

(a) A layer of semi-conductive water blocking tape or powder

between the insulation shield and the metallic sheath.

(b) The thickness of this first moisture impervious layer shall be

independent of that of the extruded insulation shield.

2) Second Layer (Longitudinal Water Barrier)

(a) A layer of semi-conductive water blocking tape or powder

Rev 0 16 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

between the metallic sheath and the jacket.

6. Jacket

a) The jacket material shall be black Linear low-density polyethylene

(LLDPE) or linear medium-density polyethylene (LMDPE) tested per
IEC 60502. The LLDPE or LMDPE jacket shall be ultra-violet ray
resistant. A suitable binder tape may be applied between the moisture
impervious layer and the jacket.

7. Conductive Layer

a) A conductive layer shall be applied over the jacket to serve as an

electrode for testing the integrity of the jacket.

8. Fabrication

a) The conductor shield, cross-linked polyethylene insulation and insulation

shield shall be extruded by the triple extrusion method to assure
homogeneity between the insulation and the semi-conducting shields.

b) The insulation shield shall be bonded firmly and continuously to the

insulation.

c) The cross-linking process shall be by the dry-cure, dry-cooling method.

d) The power cable shall be free of material and manufacturing defects that
would prevent it from meeting the requirements of this Specification.

2.05 CABLE MARKING AND IDENTIFICATION

A. The jacket for all the cables shall be marked by embossing in English at intervals not
exceeding 1 m with the following minimum information:

1. Electric Cable.

2. Voltage designation, 600/1000 V, 15 kV, 34.5 kV, and 115 kV.

3. Type of insulation, PVC, XLPE.

4. Insulation thickness (in mm).

5. Conductor cross sectional area in mm2 and material.

6. The manufacturer’s name or trademark and country of origin.

7. Year of manufacture.

8. Cumulative length at every 1 m with the highest length mark on the outer end
of the cable.

B. Marking by matrix print is not acceptable.

Rev 0 17 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

C. The conductor insulation shall be colored as follows:

1. Single Core: Black

2. 3-Core: Red, Yellow, Blue

3. 4-Core: Red, Yellow, Blue, Black

2.06 SPLICES, TERMINATIONS AND ACCESSORIES

A. Low Voltage Splice and Termination

1. Connectors and splice caps shall be tin-plated copper (compression type only)
and shall meet the requirements specified in par. 1.04.

2. Terminal lugs required for termination on bolt or screw terminals shall be tin-
plated copper (compression type only).

B. Medium Voltage Splice and Termination

1. General

a) The splice or termination kits shall meet or exceed the requirements of

this Specification in all respects.

b) System neutral shall be solidly grounded.

c) Manufacturer's drawings shall show the outline of the splice or

termination, together with all pertinent dimensions. Any variations in
these dimensions due to manufacturing tolerances shall be indicated.

2. Design Criteria

a) Splices

1) Splices may be installed underground wherein the maximum

thermal resistivity of the ground may reach 240°C.cm/W.

2) The splice system shall meet all requirements of IEEE 404, and
shall be designed such that no insulating or semi-conducting
tapes are required. Only heat-shrinkable polyolefin material shall
be acceptable.

3) Splices shall provide waterproofing, mechanical and electrical

protection; and be completely sealed from cable jacket to cable
jacket.

4) The diameter of heat-shrinkable materials shall reduce to a

predetermined size upon application of heat in excess of
120°C yielding a minimum shrink ratio of 3 to 1, and maximum
longitudinal shrinkage of 5%.

Rev 0 18 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

5) The recovered wall thickness of insulation tubing over the

connector shall be uniform and equal to, or greater than, the cable
insulation thickness as given in IEC 60502 or in the
manufacturer’s data schedule.

6) The adhesive shall have a softening temperature not less than

90°C in accordance with ASTM E28, be compatible with other
components of joint and cables and shall not flow after curing at
normal service temperature.

7) The insulation tubing shall be generally suitable for indoor and

outdoor installation, be ultra-violet and chemical resistant and with
or without adhesive coating. It shall be capable of being stored
without damage at temperatures not exceeding 50°C.

3. Termination

a) In addition to criteria stated in par. 2.06 B.2.a.2 to 7, the terminations

shall be designed to provide a complete moisture seal, including the
crotch area of multi-core cables and complete re-jacketing of the
individual cores, conforming to Class 1 terminations as per IEEE 48.

b) Creepage distance for outdoor termination shall be minimum 690 and

1725 mm for 13.8 and 34.5 kV terminations, respectively.

4. Fabrication

a) Splices

1) Splices shall be supplied in complete kit form with all materials

and components required to complete the installation. Connectors
will not be included in the kits.

2) Components shall not be adversely affected in any manner by

contact with other materials normally used in the construction of
cable joints and shall not increase the rate of corrosion of any
metal with which they may come into contact.

3) All components of a splice shall perform without distress under

the normal conditions, cyclic loading and fault conditions.

4) Components supplied with adhesive coating shall have means to

prevent the coated surfaces from adhering to each other.

5) In case of tape armored and shielded cable, all items needed for
wire or tapes clamping shall also be included. Ratings shall be
provided for such applications.

6) Reinstatement of mechanical protection for armored cables shall

be in form of galvanized steel wrap-around and not steel tubing.
The steel wrap-around shall be protected with heat-shrinkable
wrap-around tube.

b) Termination

Rev 0 19 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

1) Terminations shall be supplied in complete kit form with all

materials and components required to complete the installation,
Fabrication shall be as stipulated in par. 2.06 B.4.a.1 to 5.

c) Marking

1) All components of splices and terminations shall be clearly

marked with the supplier’s name and reference numbers.

2) Electrically conducting components shall be marked “conducting”

clearly and permanently.

3) All components shall be capable of being stored without

deterioration within the temperature range - 10°C to + 50°C.
Components or materials, if subject to a shelf life limitation, shall
have the final date of use prominently and permanently shown on
all packages.

C. High Voltage Splice and Termination

1. General

a) General notes shall be as specified in par. 2.06 B.1.a, b and c above.

2. Design Criteria

a) The splice design shall also prevent the presence of air especially at
stress points.

b) When required, splice shall be provided with a shield interruption or

break.

c) The jacket tubing, if needed, shall be generally suitable for indoor and
outdoor installation, be ultraviolet and chemical resistant and with or
without adhesive coatings. It shall also be capable of being stored
without damage at temperatures not exceeding 50°C. Shelf life of the
jacket tubing shall be at least 5 years.

d) The details specified in 2.06 B.2.a.3, 2.06 B.4.a.2 and 3 shall also be
applicable.

e) The termination shall be Class 1 as defined in IEEE 48.

3. Materials (Connector if provided)

a) The connector material shall be suitable for copper conductors. Copper-

to-copper cable connections shall use copper connectors. Copper-to-
aluminum cable connections shall use suitable bi-metallic connectors.
For outdoor and indoor terminations, all connectors shall be tin-plated.

b) For connections wherein the conductor of the cable and the connector
are of the same material, the effective cross-sectional area of the
connector shall at least equal the size of conductor of the cable.

Rev 0 20 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

c) Both compression and mechanical type connectors are acceptable.

However, mechanical type connector shall be subject to initial approval
by the Royal Commission (and Section, where required).

d) Terminal lug-hole size and spacing shall be as per NEMA CC1

requirements. The number of holes shall be as follows:

CABLE SIZE NO. OF HOLES

2
For 400 to 500 mm 2 or 4
2
For 630 mm and above 4

4. Splice Insulation

a) The splice insulation material can be heat shrinkable, pre-molded or

laminated type. It shall equal or exceed the electrical and physical
properties of the cable insulation.

b) For heat-shrinkable materials, the diameter shall reduce to a

predetermined size upon application of heat in excess of 120°C, yielding
a maximum longitudinal shrinkage of 5%.

c) Details specified in 2.06 B.2.a. 5 and 6 shall also be applicable.

5. Splice Jacket (if required)

a) The splice jacket shall be a heat-shrinkable tube made of material

compatible with the cable jacket. Power cables with black PVC (type
ST 2), linear low-density polyethylene (LLDPE) ST 7 and linear medium-
density polyethylene (LMDPE) ST 7 jackets as per IEC 60840. The
splice jacket shall be ultraviolet resistant.

b) The recovered wall thickness of splice jacket shall match or exceed the
thickness of the cable jacket.

c) The splice jacket shall be able to withstand an acceptance voltage test

of 10 kV DC for 1 minute after installation.

6. Splice and Termination Stress Control

a) The stress control material can be a heat-shrinkable, pre-molded or

laminated type.

7. Termination Porcelain Insulator or Outer Tubing

a) The porcelain insulator shall be brown with standard glaze.

b) The heat-shrinkable outer tube shall be ultraviolet resistant.

8. Grounding

a) Necessary grounding materials shall also be included in the kit.

9. Fabrication

Rev 0 21 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

a) Connectors may be included in the kit, fabrication of splices and

terminations shall also be applicable as specified in 2.06 B.4.a.1.

b) Components supplied with adhesive coatings shall have means to

prevent the coated surfaces from adhering to other non-coated
components.

c) In case of shielded cable, all items needed for wire or tape clamping
shall also be included. Roll springs shall be provided for such
application.

10. Marking

a) Splice Kits

1) A suitable nameplate shall be provided in the kit giving the

following information:

(a) Manufacturer’s name/logo, part identification and date of

manufacture.

(b) Maximum voltage rating.

(c) Cable insulation diameter range, for pre-molded splice only.

(d) Conductor size in mm2.

b) Termination Kits

1) A suitable nameplate shall be provided in the kit giving the

following information:

(a) Manufacturer’s name.

(b) Type of termination.

(c) Designation number.

(d) IEEE terminator class number.

(e) Insulation class.

(f) Maximum design voltage to ground.

(g) Maximum/Minimum cable conductor size.

(h) Maximum/Minimum cable insulation diameter.

(i) Basic Insulation Level (BIL)

(j) Rated internal pressure, MPa (psi).

(k) Date of manufacture.

Rev 0 22 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

c) Connector Kits
1) For compressor type connectors, the surface shall be marked with
crimp position knurls, die index number and manufacturer’s code
number.

Rev 0 23 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

PART 3 EXECUTION

3.01 GENERAL

A. The Contractor shall provide all equipment and labor as deemed necessary to show
proper execution of the work.

B. Except as may be described otherwise in Part 3 below, refer to SECTION 16055.

C. All SEC direct interface work shall be done with prior SEC approval and in strict
accordance with SEC standards.

3.02 INSTALLATION OF CABLES IN DUCT

A. General

1. The duct for underground cables shall not be located in the main (busy lane) of
the street or road and should be at least 1.5 m from the median bay.

2. The location of all underground ducts shall be selected with consideration for
future structural installations in the area.

3. All the duct banks shall be constructed with the use of concrete forms or by the
use of pre-cast duct banks.

4. Duct banks shall be constructed of either hot-dipped galvanized rigid steel

conduit encased in concrete or PVC conduit encased in reinforced concrete.

5. Duct bank shall be provided with a minimum of 20% spare conduits of each
size required.

6. The ends of ducts and conduit terminating below grade or in open air shall be
sealed with duct sealing putty or an equivalent compound.

7. All cables shall be routed as required by the Drawings. If at any time during the
progress of the work the Contractor finds raceways which appear inadequate
to accommodate the assigned cable, he shall notify the Royal Commission at
once and shall discontinue any further work on the questionable raceway until
advised by the Royal Commission on how to proceed.

8. Immediately prior to the placement of each cable or cable group, the raceway
route shall be inspected and ascertained to be complete in installation and free
of all materials detrimental to the cables or their placement.

9. All cables assigned to a particular duct or conduit shall be grouped and pulled
in simultaneously, using cable grips or pulling eyes and acceptable lubricants.

10. Maximum percent of cross section of conduit or duct fill for all types of
conductor shall be as specified in Chapter 9 of NEC.

11. All cables shall be carefully checked, both, with regards to size and length,
before being pulled into conduits or ducts. Cables pulled into the wrong conduit

Rev 0 24 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

or duct or cut too short to rack, train, and splice as specified herein, shall be
removed and replaced. Cable removed from one conduit or duct shall not be
pulled into another conduit or duct.

12. Figures 3A, 3B, 3C, 3D, and 3E, indicate standard Duct Bank Design
Parameters for the required width, depth, backfill and circuit separation. For
duct bank and manholes, refer to SECTION 02580.

B. Cables In Manholes

1. The maximum straight run spacing of manholes shall be based on the

maximum cable pull length for minimum cable size installed in the duct bank,
based on pulling calculations for the cables.

2. Manholes shall have minimum inside dimensions of 2500 x 2500 mm (98 x

98 in.), by 2000 mm (79 in.) deep.

3. Adequate space shall be allowed for making splices, supporting cable

clearances between low voltage control, power and medium voltage cables,
bending and training cables for offsets and changes in horizontal and vertical
direction, providing adequate working clearance as required per NEC
Article 210, for pulling, terminating and splicing cables.

4. Manholes shall be provided with a minimum of one 760 mm (30 in.) man-way
cast into the top cover.

5. The design of manholes shall be approved by the Royal Commission. When

manufactured manholes are used, they shall be approved by the Royal
Commission.

6. Cables shall be supported at all times without short bends or excessive sags
and shall not be permitted to lie on the manhole floor. Cable ends must not be
submerged. Cable racks, saddle supports or trays shall be provided for
permanent support. Temporary support required during placement shall be
with rope slings, timbers or an alternate method acceptable to the Royal
Commission.

7. Cables shall be located in manholes to provide minimum interference with

other cables to be installed or installation of future cables in spare conduit.

C. Cable Pulling

1. Finishing and pulling shall be done with flexible round metal tape, CO2
propelled polyethylene cord, nylon rope or manila rope.

D. Cable Grips

1. Factory installed pulling eyes shall be used for pulling cable where they are
available. The area of the cable covered by the grip or seal plus 150 mm shall
be cut off and discarded when the pull is completed.

2. Woven wire cable grips shall be used to pull all multi-conductor cables, as well
as single conductor cable 70 mm2 (2/0 AWG) and larger, where pulling eyes
are not available.

Rev 0 25 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

3. Pulling loops shall be used to pull single conductor cable smaller than 70 mm2
(2/0 AWG). When pulling loops are used, the entire loop shall be cut off and
discarded when the pull is completed. As soon as the cable is pulled into
place, the pulling eyes, cable grips, or pulling loops shall be removed and any
cable that was sealed shall be resealed.

E. Swivels

1. A reliable non-freezing type of swivel, or swivel connection, shall be inserted

between the pulling eye, grip, or loop to prevent cable twisting under strain.

F. Feeding Tubes

1. A 100 mm or larger flexible feeding tube, with a removable nozzle sized to fit
the ducts, shall be used in pulling all underground cable. The feeding tube
shall be long enough to extend from the duct entrance to the outside of the
manhole and shall be so arranged that it will be impossible for the cable to
drag across the edge of the manhole ring or any other damaging surface.

G. Lubricant

1. Only lubricants recommended by the cable manufacturer and acceptable to

the Royal Commission shall be used.

H. Inspection

1. Inspection shall be performed at the field before installation of the cable, the
outside of each cable reel shall be carefully inspected and protruding nails,
fastenings, or other objects which might damage the cable shall be removed. A
thorough visual inspection for flaws, breaks or abrasions in the cable sheath
shall be made as the cable leaves the reel, and the pulling speed shall be slow
enough to permit this inspection. Damage to the sheath or finish of the cable
shall be sufficient cause for rejecting the cable. Cable damaged in any way
during installation shall be replaced.

I. Pulling Tension

1. The axial and tangential forces applied during pulling process shall not
damage any component of the cable assembly during the installation of
cables.

2. Cable pulling calculations shall be submitted to the Royal Commission for

approval and review prior to all cable pulling operations.

3. Pulling calculations and drawings which indicate the maximum allowable

pulling tension shall be provided to pulling crews prior to all cable pulls.

4. The placement of all rollers that conforms to the radii bends and degree angle
curves shall be verified prior to commencing the cable pull.

5. The maximum pulling tension placed on a cable shall not exceed the following:

a) For cable equipped with a pulling eye or bolt attached to the conductor:

Rev 0 26 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

1) For copper of any temper and hard drawn aluminum, maximum

tension in Newtons is equal to 70.216 times the cross-sectional
area in square millimeters.

6. Whenever the capacity of the pulling mechanism exceeds the recommended

pulling tension of the cable as given by the cable manufacturer, a
dynamometer shall be used to show the tension on the cable and the indicator
shall be constantly watched. If any excessive strain develops, the pulling
operation shall be stopped at once and the difficulty determined and corrected.

7. A dynamometer shall be installed to monitor the cable pulling tension.

J. Sidewall Pressure

1. To avoid insulation damage from excessive sidewall pressure at bends in duct

and conduit runs, the maximum sidewall pressure shall not exceed
4,371 kN/m, i.e. the tension in the cable in kiloNewton as it leaves the bend
shall exceed 4.371 times the radius of the bend in meters.

2. Detailed maximum pulling tension and sidewall pressure calculations with the
route drawings showing bending radius, roller placement and dimensions shall
be developed and submitted to the Royal Commission for each specific cable
pull within the cable route.

K. Cable Bends

1. Extreme care shall be exercised during the placement of all cables to prevent
tension and bending conditions in excess of the manufacturer's
recommendations. The permanent radius of bend after cable installation shall
be in accordance with the cable manufacturer's recommendations.

L. Supports

1. All cable supports and securing devices shall have bearing surfaces located
parallel to the surfaces of the cable sheath and shall be installed to provide
adequate support without deformation of the cable jackets or insulation.
Adequate cable end lengths shall be provided and properly placed in
manholes to avoid longitudinal strains and distorting pressures on the cable at
conduit bushings and duct end bells.

2. Final inspection shall be made after all cables are in place and where
supports, bushings, and end bells deform the cable jacket, additional supports
shall be provided. Additional cable protection such as a wrapping of light
rubber belting, friction tape, or similar material shall be provided when
required. Cables in vertical runs shall be supported by woven wire grips in
accordance with the NEC requirements.

M. Cable Racks

1. Where cable trays are not specified in manholes, cable racks shall be
furnished and installed according to the drawings and as required to provide
the proper cable support. Cable racks shall be installed at spacing not greater
than 1000 mm and shall be securely bolted to permanent wall surfaces with
self-drilling anchors or continuous slot concrete inserts.

Rev 0 27 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

N. Requirements by Other Utilities

1. The following requirements are meant to be used with facilities such as water,
sewer, gas, telephone, or any other than power cable.
TABLE 3A: CLEARANCES BETWEEN ROYAL COMMISSION (OR SEC) CABLES AND OTHER
UTILITY LINES

Royal Commission (or SEC) Cable

Low Voltage 0.6/1 kV 13.8 or 34.5 kV 69 to 380 kV
Utility
Horizontal Vertical Horizontal Vertical Horizontal Vertical
Clearance Clearance Clearance Clearance Clearance Clearance
(mm) (mm) (mm) (mm) (mm) (mm)

Water &
500 500 500 500 1000 500
Sewer
300 for 300 for
service service
telephone telephone
cable cable
Telephone 300 1000 5000 1000
or 500 for or 500 for
main main
telephone telephone
cable cable
Gas - 500 - 500 1000 500

O. Cable Identification

1. For Cable Identification, refer to SECTION 16075.

2. The primary purpose for identification of the circuit conductors and grounded
conductor terminals are for safety of person during maintenance and for the
ease of installations during new construction and installation.

3. The Contractor shall identify the ends of all power circuits and also identify all
circuits in manholes. At terminations, the Contractor shall identify each
conductor of power circuits. Each cable marker shall bear the number of the
corresponding circuit according to the drawings.

4. Markers shall be attached where the first individual conductor is routed away
from the assembly. Each phase of multi-phase power circuits shall be
individually identified. In manholes, each cable shall be identified. Each marker
shall bear the number of the circuit according to the Contract Drawings.

5. Each marker shall be so attached that it is readily visible for circuit

identification.

P. Moisture Seals

1. Each cable shall be kept sealed except when termination and splicing work is
being performed. The ends of all cables shall be sealed with heat-shrinkable
caps. Cap sizes shall be as recommended by the cap manufacturer for the

Rev 0 28 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

cable outside diameter and insulation.

2. Caps shall contain sufficient adhesive so that shrinkage of the cap during
application results in formation of a positive watertight seal capable of
withstanding complete immersion or total exposure without permitting the
entrance of moisture.

3. Before and after pulling, the leading end seal of each length of cable shall be
examined and repaired if necessary. All cut cable ends shall be promptly
sealed after cutting except those to be spliced or terminated immediately.

Q. Cable Arc-Proofing

1. All cable shall be arc-proofed where it occupies an enclosure such as a

manhole, building basement or a room in a building.

2. The separate conductors of a single circuit may be grouped together under the
arc-proof covering if they are pulled into a single duct. Single conductors pulled
into single ducts shall be individually arc-proofed.

3. Arc-proofing in a manhole shall extend in one helically wound half-lapped layer

from one duct end in the manhole over the cable to the other duct end. The
arc-proofing shall be secured in position with glass tape random wrapped
according to the instructions of the arc-proofing tape manufacturer.

R. Splices

1. General

a) Power cable circuits may be spliced only by methods and at locations

specified, or as acceptable to the Royal Commission.

b) Splices shall not be made to utilize short lengths of cable nor shall they
be made to provide correct lengths on cable initially cut too short for a
particular circuit.

c) Splices, joints and connections in cables shall be made only in

manholes or be buried for direct cables, unless otherwise indicated on
the Contract Drawings, and shall be made in accordance with the
instructions of the cable and splice manufacturer.

2. Splicing and Joints for 1000 V and Below

a) Splices or joints are not allowed in low voltage feeders or branch circuits
except at accessible splice or junction boxes and accessible raceway
fittings.

b) Secure joints in circuit wiring mechanically and electrically. Conductors

6 mm2 or smaller may be joined with splice caps applied with the correct
indent tool, which provides deformation of the cap in 2 directions at right
angles to each other simultaneously. Conductors larger than 6 mm2
shall be joined by compression splicing sleeves.

c) Split bolt type connectors, all joints shall be insulated to a voltage level

Rev 0 29 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

at least equal to the insulation of the conductors. Splices and joints in

wet locations shall provide a moisture seal equal to the cable insulation.

3. Splicing and Joints for Above 1000 V

a) Splices shall have ratings that are at least equal to those of the cable.

b) All splicing operations shall be conducted in a double walled tent

equipped with a positive pressure type air conditioning unit. The air
conditioning unit shall be capable of maintaining the relative humidity
below 40%.

c) Splicing and termination operation shall not be performed when the

relative humidity exceeds 40%.

d) The splices and terminations shall be prefabricated, factory-made (no

field tapes), pre-molded or heat-shrinkable type. Pre-molded
terminations (elbow) shall be load-break type. Elbows shall not be used
for terminations rated more than 200 A. Pre-molded splices shall be
separable bolted connectors.

e) All splices and terminations can be insulated, suitable for indoor,

outdoor, or submersible applications.

4. Splicing Personnel Qualification Requirements

a) All workmen who install terminations or splices greater than 600 V shall
be certified by the Contractor or relevant authorities.

b) This certification shall be current and approved by the Royal

Commission or their appointed representatives.

S. Terminations

1. General

a) All conductor terminations for 1000 V power cable shall be made using
compression type connectors. Conductors in size 1.5 mm2 through and
including 25 mm2 shall be terminated with crimp type, full ring (or
rectangular) tongue terminal connectors having conductor insulation
gripping sleeves or nylon.

b) Diamond grip type or approved equal shall be used for conductor sizes
1.5 mm2 through and including 6 mm2, pre-insulated. Conductors in
sizes larger than 25 mm2 shall be terminated with 2-hole, long barrel,
double indent, crimp type lugs, or approved equal. Suitable crimping
tools shall be provided for the connectors used, in accordance with
recommendations of manufacturer of connector.

c) All conductor termination above 1000 V power cable shall be terminated

in the switchgear and transformers. After permanent connections have
been made to substation switchgear, they shall be insulated with
materials to cover exposed bus conductors and exposed portions of
cable terminators.

Rev 0 30 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

d) The Contractor shall provide all the necessary cable termination kits as
per the Contract Drawings to complete the cable terminations in the
switchgear/transformers. These splicing and termination kits are
required to be approved by the Royal Commission (or SEC where
required) before termination of the cables.

3.03 INSTALLATION OF DIRECT BURIED CABLES

A. General

1. In the event of minor damage to outer jacket during installation, a heat-

shrinkable split sleeve shall be applied to repair the jacket.

2. The route of cable trenches shall avoid above ground and below ground
obstructions so as to maintain a reasonable access to the buried cables.
Trenches in unpaved areas are preferred. A minimum clearance shall be
maintained between underground runs and parallel runs of underground
piping. Recommended clearances are show on Figures 3A to 3L.

3. Power and associated control circuits can be laid adjacent. 3 single conductor
cables comprising one 3-phase circuit (trefoil) shall be laid without spacing. In
order to achieve a reasonable derating factor, a minimum spacing shall be
determined between all 3-phase power circuits.

4. Where cables cross under main road, concrete slabs, paved areas, railroad, or
any areas that would require extensive or impractical excavations to replace,
then they shall be run in duct. Where such duct runs exceed 3 m, overall cable
ampacity shall be based on the duct portion of the run. Bell end or protective
bushing shall be provided on each duct where it terminates.

5. Direct buried cable coming up and through a concrete slab shall be encased in
type DB PVC conduits or PVC coated, tape wrapped, or fully concrete
encased hot-dip galvanized rigid steel conduits. The conduits shall start 90 mm
away from the bottom of the slab and extend above grade.

6. The conduits shall be sealed 30 mm above grade with extensions beyond this
depending on the area of classification and cable type in use. All conduits shall
have bell ends or protective bushings where the conduits terminate
underground.

7. Cables can be unreeled directly into the trench by means of a side boom and
large sheave mounted on a vehicle carrying the reel or a reel on a side-hoist
crawler crane. Caution shall be taken in using the roller system by checking
the pulling tension and sidewall pressure during direct buried cable
installations.

8. Cable shall not be laid on top of other cables.

9. Figures 3F to 3J indicate Standard Direct Buried Design Parameters for the

required width, depth, backfill and circuit separation.

10. All direct buried conduits shall be rigid hot-dip galvanized steel or polyvinyl
chloride (PVC). For excavation and fill, refer to SECTION 02315.

Rev 0 31 of 46 Contract No:

 SECTION 16120
CONDUCTORS AND CABLES

B. Conduit

1. Unless otherwise required at greater depths by Agency/Ministry having right-

of way jurisdiction, the burial depths for conduit and cable shall be as shown
in Table 3B.

TABLE 3B: MINIMUM COVER REQUIREMENTS IN MM FROM GRADE LEVEL TO THE

TOP SURFACE OF A CABLE OR DUCT

Direct Buried PVC Direct Buried Rigid

Voltage Direct Buried Cables
Conduit Steel Conduit
(kV)
Type A* Type B** Type A* Type B** Type A* Type B**
0.6/1 560 610 560 610 310 460
13.8 610 760 560 610 310 460
34.5 760 760 610 610 310 460
69 to 380 920 920 610 610 310 460

* Type A: Light Traffic Areas

** Type B: Heavy Traffic Areas

2. For paved roads, the grade level is the surface immediately below the
concrete or asphalt pavement. Subgrade is another term for this surface. For
unpaved roads or areas, the grade level is the road surface or natural ground
level.

3. On street railway crossings, the minimum cover between the conduit system
top and rail top shall be 900 mm. On an isolated railroad crossing, the
minimum cover between the conduit system top and rail top shall be
1300 mm.

4. Under airport runways, including adjacent defined areas where trespass is

prohibited, cable shall be permitted to be buried not less than 460 mm deep
and without raceways, concrete encasement or equivalent.

C. Marking of Direct Buried Cables

1. All direct buried cables shall be installed with warning signs, markers and
cable identification in accordance with SECTION 16075.

3.04 TESTING AND COMMISSIONING

A. General

1. The Contractor shall carry out all site tests in accordance with approved test
procedures to ensure that the cable and accessories comply with the
specifications and operational requirements. All tests are subject to witnessing
by the Royal Commission’s representatives.

2. At least 4 weeks prior to schedule tests, the Contractor shall submit to the

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Royal Commission an outline of the plan and procedures to be used in

performing the site inspection and site tests. This outline shall include a brief
description of the test equipment, connection diagrams, proposed tests and
procedure, test sheets, calculations, reference drawings, minimum and
maximum test and performance values in conformance with the Specification
and acceptability of the cables and equipment and acceptability of the
installation.

3. Upon completion of installation and prior to final acceptance, each component

of each system shall be tested to the complete satisfaction of the Royal
Commission. The Contractor shall provide all test instrumentation, equipment
and accessories necessary for demonstration and putting the equipment into
operation before commissioning.

4. Upon completion of all testing, the Contractor shall submit 5 copies of a

certified reports attesting that each test has been performed in accordance
with the approved test procedures. The report for each test shall include the
name of the person in-charge of the test and the date of performance. All
factory and field test reports shall be included in Operation and Maintenance
Manuals.

5. Care shall be taken that the test apparatus does not damage the cables and
accessories during the testing.

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3.05 FIGURES AND TEST DATA SHEET

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CABLE TEST DATA FORM

Project and Location _______________________________ Project No. ____________________
Circuit Description _________________________________ Date _________________________

DC TEST DATA DC Test Voltage_____________________

Time in Minutes Current ȝ A
Cable Installation New____Used___ Years
After 100% Test
Phase Phase Phase
Voltage is Cable Size_______Length________Meter
A B C
applied
Oper. kV____Grd.______ Ungrd._______
1
2 Rated Cable Voltage_________________
3 Insulation Wall______________________
4
5 (Type & Thickness)
6 Conductor Jacket Wall _______________
7
8 (Type & Thickness)
9 Shield_____________________________
10
11 (Type)
12 Cable Manufacturer __________________
13
14 Temperature_____ Humidity___________
15 Type Terminations___________________
KVDC 1 Min.
Decay Type Splice & Location _______________
Remarks & Fault Location _____________
100 Microamperes (ȝA) = Milliamp
APPLICATION OF TEST VOLTAGE
The initially applied direct-current voltage shall be not greater than 3.0 times the rated
alternating current voltage. The rate of increase from the initially applied voltage to the
specified test voltage shall be approximately uniform and shall be not over 100 percent in 10
seconds nor less than 100 per cent in 60 seconds. The Duration of the direct-current voltage
test shall be 15 minutes for shield cables and 5 minutes for non-shield cables.
TEST CURVE
Notes
Current in Microamperes

1. Plot tests on all

three phases on
this graph.
2. Assign and
indicate values for
each division on
the microampere
scales as required
for the circuit
being tested.
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Time in Minutes After 100% Test Voltage is applied

END OF SECTION

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