Equipment Specification - I&C Cables

Projekt / Project:

Budowa dwóch bloków gazowo-parowych w PGE GiEK S.A.

Oddział Zespół Elektrowni Dolna Odra
Nr kontraktu / Contract No.: POST/GEK/GEK/PMR-ELD/04568/2019
Zamawiający / Pracodawca: Generalny Wykonawca / General Contractor:

Górnictwo i Energetyka
Konwencjonalna S.A.

Miejsce na pieczęć (przegląd i walidacja – jeśli wymagane) / Space for stamping (Review and validation status – if needed)

Historia zmian / Revision History

Zm. Data Opracował Sprawdził Zatwierdził Opis
Rev. Date Created by Checked by Approved by Description

Zwięzły opis ostatniej zmiany / Latest revision short description

Wykonawca / Contractor

GE GAS POWER SYSTEM

Zastępuje / Replaces Numer Dokumentu / Project Document No EDO/00/E/------EQ14/ES/001
Kom. /Dept. Opracował / Created by Sprawdził / Checked by Zatwierdził / Approved by Format
PE-AEA A. SINGH S. Baud P. HERTEL DIN A4
Wydawca dokumentu / Doc. Originator Typ dokumentu / Document Type Status dokumentu / Doc. Status
ES Released
Tytuł Dokumentu / Document Title Nr identyfikacyjny / Identification number
Gas Power
1GP033986
Systems Equipment Specification - I&C Cables Zm./ Data / Date Język / Str./
Rev. Lan Sheet
A en 1/9
GBM Gas Master Doc Temp (ZZZ)
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All rights reserved. The information herein is Proprietary and Technically Exclusive content that is solely owned by General Electric Company and/or its affiliates. Thus, it is being provided with the
explicit expectation of restricted and privileged use. All recipients of this information shall be deemed to have agreed not to make duplications, reproductions of any nature by any means,
modifications, disclosures, or use any portion of this material; except as is expressly authorized in writing by the General Electric Company, and/or its legitimate affiliates.
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Cross checked Przegląd branżowy / Cross checked

Dział / Department Nazwisko / Name Data / Date Podpis / Signature

Spis treści / Table of Contents:

1. Objective ............................................................................................................................................................... 3
2. Scope of Application ........................................................................................................................................... 3
3. Reference Documents ........................................................................................................................................ 3
4. Codes and Standards ......................................................................................................................................... 3
5. Terminology, Definitions, Abbreviations ........................................................................................................ 4
6. Requirements ....................................................................................................................................................... 4
6.1. Cable Technical Requirements ....................................................................................................................... 4
6.2. Special Cables .................................................................................................................................................. 5
6.2.1. High temperature cable (If applicable) ........................................................................................ 5
6.3. Laying conditions .............................................................................................................................................. 5
6.4. Cable Marking Requirements .......................................................................................................................... 6
6.5. Drum Requirements and Cable Length .......................................................................................................... 6
6.6. Drum Marking Requirements........................................................................................................................... 6
7. Test Requirements .............................................................................................................................................. 7
8. Documentation..................................................................................................................................................... 7
9. CONTRACT EXTRACT ........................................................................................................................................ 8
Cable management .................................................................................................................................. 8

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1. OBJECTIVE

This document defines the requirements for (I&C) Instrumentation and Control Cables.

Instrumentation and Control Cables are used to connect signals from field devices to the I/O modules
of the DCS system by means of hardwiring.

2. SCOPE OF APPLICATION

The electrical characteristic of the signals are:

 24 VDC from potential free contacts from field devices such as level switches, position
switches, valves, contacts and interposing relays from electrical panels.

 0/4...20 mA from field transmitters such as temperature, pressure and position transducers

3. REFERENCE DOCUMENTS

 none

4. CODES AND STANDARDS

ASTM D2863 Standard Test Method for Measuring the Minimum Oxygen Concentration to
Support Candle-Like Combustion of Plastics (Oxygen Index)

DIN VDE 0815 Cabling elements and colour coding

EN 50288-7 Multi-element metallic cables used in analogue and digital communication and
control Sectional specification for instrumentation and control cables

EN 50289 Communication/Instrumentation Cables: specifications for test method

EN 50525-3-11 Electric cables. Low voltage energy cables of rated voltages up to and
including 450/750 V (U0/U). Cables with special fire performance. Flexible
cables with halogen-free thermoplastic insulation, and low emission of smoke

IEC 60757 Code for Designation of Colours

EN60079-14 Explosive atmospheres Electrical installations design, selection and erection

IEC 60332-3-24 Tests on electric cables under fire conditions – Part 3-24: Test for vertical
flame spread of vertically-mounted bunched wires or cables – Category C

IEC 60364-5-51 Electrical installations of buildings - Part 5-51: Selection and erection of
electrical equipment - Common rules

IEC 60811 Common test methods for insulating and sheathing materials of electric cables

ISO9001 Model for quality assurance in design/development, production, installation

and servicing

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5. TERMINOLOGY, DEFINITIONS, ABBREVIATIONS

DCS - Distributed control system

I&C - Instrumentation and Control

BOQ - Bill of quantities

CPR - Construction Products Regulations

6. REQUIREMENTS

6.1. Cable Technical Requirements

Cable designation nx0.75 mm2 (with n = 1,2,4,8,12 …)

Electrical and physical properties according EN 50288-7
Conductor Tinned copper, stranded as per IEC 60228

Conductor cross section (one core) 0.75 mm2

(for specified cables)

Conductor insulation PVC (halogen-free)

Number of Pairs / Triads 1P, 2P, 4P, 8P, 12P …
Assembling and color code  Two cores are twisted in a pair
 Four pairs are stranded into a bundle
Outer sheath
 The bundles are identified by a
Collective screen numbered polyester tape
Individual screen  Core numbering and color
Conductor
Drain Wire Pair Wire a Wire b
(overall) Pair # 1 1/black 1/white
Pair # 2 2/black 2/white
Drain Wire .. .. ..
(individual)

Triad Wire a Wire b Wire c

Triad # 1 1/black 1/white 1/red
Triad # 2 2/black 2/white 2/red
.. .. ..

Individual screen Aluminium coated PET foil with tinned Cu

(only for specified cables) drain wire 0.5 mm2, coverage > 100%
Collective screen Aluminium coated PET foil with tinned Cu
drain wire 0.5 mm2, and tinned Cu braid,
coverage > 80%
Outer sheath Halogen-free PVC, color grey (RAL 7032),
UV resistant.
Peak operating voltage 300/500 V
Operating temperature -25 to +70°C

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Voltage Test core – core 1000 VAC 50 Hz 1 min

core – screen 1000 VAC 50 Hz 1 min
according EN 50288-7
Behavior under fire conditions according EN 60332-3 Cat C
CPR Class As per PN-EN 13501-6 and PN-EN 50575
(Minimum Dca-s2,d1,a3 or higher class)
Armor no
Cable Properties The cables must be suitable for indoor,
outdoor, underground and under-water
installations

6.2. Special Cables

6.2.1. High temperature cable (If applicable)

These cables should be suitable for working temperature of 200 °C. Insulation of cable shall be silicon
or equivalent suitable for higher temperature. These cable are mentioned as High temperature cable
(HT) in BOQ document.

6.3. Laying conditions

Pulling/Installation temperature range -5°C to +50°C

Bending radius > 10 x outer diameter

Pulling forces < 50 N/mm2 x ∑ of conductor cross-section in mm2

Suitable for open or closed cable tray, indoor and outdoor.

Suitable for underground conduit or pipe, with possible water ingress from pull pit or pipe cracks, wet
or moist condition, conditions may continue over prolonged period of entire plant lifetime.

Suitable for use in hazardous areas (Ex Zone) in accordance with EN60079-14 and suitable cable
glands.

Reference conditions according IEC 60364-5-51:

 Ambient temperature: AA7 /-25ºC - +55ºC
 Atmospheric humidity: AB7 (relative: 10% –100%, absolute: 0.5g/m3 – 29g/m3)
 Presence of water: AD5 / jets
 Presence of corrosive or polluting substances: AF2 / atmospheric
 Presence of flora and/or moulds growth: AK1 / no hazard
 Presence of fauna: AL1 / no hazard
 Solar radiation: AN1 / low, intensity <500W/m2

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6.4. Cable Marking Requirements

The cable shall be embossed or ink-jet marked with the following data:
 Sequential marking of length of the cable in meters at every one meter. The embossing /
engraving shall be progressive, automatic, in line and marking shall be legible and indelible.
 Cable designation
 Name of manufacturer
 Date of manufacturing

Example:
<1234M LiYCY 8x2x0.75MM2 PiMF/TriMF* MANUFACTURERNAME YEAR
*) PiMF (pairs in metal foil)
TriMF (triples in metal foil) as applicable

6.5. Drum Requirements and Cable Length

Cable drums shall be non-returnable and shall be made of timber. The ends of all cable lengths shall
be sealed to prevent ingress of moisture. Cables on drum shall be protected by a wrapped foil and
wooden sheets.

The cable on the drum shall be uninterrupted. The ordered length shall be spread to as little drums as
possible; drums shall be filled to its capacity.

Cable Type Minimum acceptable

length on drum
1 pair 2000 m
2 pair 1000 m
4 pair 1500 m
8 pair 2000 m
12 pair 2000 m
16 pair 2000 m
24 pair 2000 m

Cable length on drum and number of cable drums is to be communicated.

6.6. Drum Marking Requirements

The cable drum shall be marked on the outside of one flange with the following data:
 Cable voltage and number of pairs
 Conductor stranding, material and size
 Insulation type and thickness, outer diameter of cable
 Length and weight of cable on drum
 Gross weight and dimensions of drum
 Manufacturer's name and country of origin
 Expedition address and purchase order number
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 Serial number of drum

 Direction of rolling of drum

The cable on the drum shall be provided with the sequential length-meters, marked at consecutive
intervals of one (1) meter. The length markings shall be started at the inner ends of the drum.

7. TEST REQUIREMENTS

The following tests shall be performed in accordance with the latest issue of the applicable standard.
Existing type test certificates are acceptable.

Test Applicable standard

Routine test on each manufactured length according EN 50288-7

- conductor resistance
- dielectric strength
- Insulation resistance

Sample Test on sample per production lot according IEC 60811

- Check of dimension:
- thickness of insulation
- thickness of non-metallic sheath
- outer diameter

Type Test according EN 50525-3-11

- mechanical test
- Insulation resistance
- Mutual Capacitance
- Capacitance unbalance
- Inductance
- L/R ratio

Type Test on Cables under Fire Conditions

- Oxygen index according ASTM D2863

- Temperature index according ASTM D2863
- Fire retardance according IEC 60332-3 Cat. A or C

8. DOCUMENTATION

The following documentation is to be provided

 Cable datasheet
 for each drum: Drum ID, cable type, length etc.
 Test certificates and type test certificates
 Cable handling manual.

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9. CONTRACT EXTRACT

Cable management

Cables must meet the requirements of the most recent PN-EN IEC standards, CPR Directive, as well as:
1. Signal cables shall have stranded conductors and 0.3/ 0.5 kV insulation,
2. Power supply cables shall have 0.6/1 kV insulation,
3. Cross-section of the signal conductor must not be smaller than 0.5 mm2,
4. Conductor cross-section of the power supply cable which feeds the I&C equipment must not be smaller
than 1.5 mm2.
5. Signal cables and power supply cables shall be separated wherever possible.
6. Collective twin screened pairs with 24 or 48 conductors are permitted,
7. Collective signal cables should be provided with conductor reserve of at least 15%,
8. Optical fiber cables should be provided with fiber reserve of at least 30%, not less than four fibers – 2
pairs,
9. For communication cables with a length exceeding 90 m, optical fiber cables should be used,

10. In a particularly hazardous area (high-temperature or risk of mechanical damage) cables with proper
resistance class should be used (e.g. in accordance with PN-EN 60332 standard or equivalent European
standards),
11. Signals for the needs of special measurements shall be transmitted by means of shielded cables in
accordance with the requirements of equipment manufacturers (e.g.: shielded pairs, shielded triples),
12. Signals having the same potential shall be transmitted by multi-conductor cables,
13. All cables (except for optical fiber cables) and conductors must be made as stranded copper conductors
with halogen-free or PVC insulation; in special cases cables with an additional shield should be provided
(steel-wire armored),
14. For intrinsically safe equipment, cables of appropriate type which also meet the above-specified
requirements are recommended.
15. Cables with halogen free or PVC insulation and external sheath to prevent the flame propagation shall be
applied meeting the requirements of PN-EN 603322-24 category C, or equivalent European standards.
This requirement does not apply to special cables, e.g. intrinsically safe, high temperature or oil resistant,
coaxial, TCP/IP network cables, as well as earthing and internal connection cables in cabinets/boxes,
which should comply with the standards for this type of cables.
16. Signal cables, power supply cables (impulse tubes, digital data transmission cables, etc.) shall be laid
taking into account the requirements set out in the SEP-E-004 standard and the requirements of the
applied DCS.
17. I&C cables shall be conducted with the use of main cable routes, designed and executed within the
framework of the electrical part, on separate cable ladders and racks.
18. Cables in enclosed rooms should be conducted under raised floors on cable racks and trays or in special
ducts. For outdoor cables, the Contractor shall design and provide appropriate cable racks and trays,
starting from the main cable routes up to the individual I&C equipment (intermediate boxes, measuring
sensors and transmitters, etc.).
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19. Cables at site shall be laid underground in cable conduits, cable ducts or on cable racks and trays. Buried
cables shall be additionally protected in places where there is a risk of their damage. They shall be
protected by means of protective elements, such as steel pipes, concrete culverts, etc.
20. Cables of different classes shall be laid on different racks and ladders in the following sequence from top
to bottom: HV power cables, LV power cables, signaling cables
21. (deleted)
22. Electric shock protection system inspection certificates shall be provided by the Contractor in accordance
with PN-HD 60364-4-41 Polish standard.
23. The routes of the bus network for the master communication (redundant) should be independent and
should protect cables from physical damage and impact of external electromagnetic fields,
24. The main cable routes shall be provided with a reserve of at least 30%.
25. Optical fiber cables shall be laid in cable conduits,
26. All cables shall be permanently marked on both ends, as well as at places of penetrations. Marking
technology shall be adjusted to the local conditions and shall secure legibility over a long period of time.
KKS codes shall be compliant with the Employer’s requirements.

Compensating/thermoelectric cables:

1. Compensating/thermoelectric cables shall be made in accordance with the European standards;

2. compensating/thermoelectric cables shall be used for thermocouples of K, R and other types.
3. Conductor sheathing and insulation of compensating/thermoelectric cables shall be selected taking into
account the possible ambient temperature in the place of the cable arrangement;
4. Compensating/thermoelectric cables shall have stranded conductors;
5. (deleted)
6. Compensating/thermoelectric cables shall have a cross-section of 1 mm2.

The principles of selection, layout, marking and acceptance tests specified in the Appendix to the I&C part
PFU_02.Zal6 shall apply to the cable routes and cables in the I&C part.

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