Approval

Project manager

0 November ‘17 Initially Dan Pîrvulescu Florinel Petrilă Gheorghe Ţăranu

NO. DOCUMENT
REV. DATE DESIGNED CHECKED APPROVED
DESCRIPTION
Revision Sheet
CUSTOMER:
MINISTRY OF ELECTRICITY (MOE)
REPUBLIC OF IRAQ
PROJECT :
IFB no. M21-21-2016
Rehabilitation of Unit 3
Facilities and Common System, Al Mussaib Thermal Power Plant Rehabilitation

CONTRACTOR:

BLACK SEA TECHNOCHIM CO SRL

DESIGNED BY DATE

Dan Pîrvulescu November ‘17

CHECKED BY DATE
TITLE:
THE PROCEDURE FOR INSTALLATION OF POWER
Florinel Petrilă November ‘17
AND CONTROL CABLES
APPROVED BY DATE
Gheorghe Ţăranu November ‘17

Contract No. DOCUMENT NUMBER REV.NO.

IFB no. M-21-2016 XXXXXXXXX 0

TABLE OF CONTENTS
1. PURPOSE..................................................................................................................................3
2. SCOPE.......................................................................................................................................3
3. TERMS, DEFINITIONS AND ABBREVIATIONS......................................................................3
4. REFERENCE DOCUMENTS.....................................................................................................3
5. RESPONSIBILITIES..................................................................................................................4
6. PROCEDURE.............................................................................................................................4
6.1 Preliminary conditions..................................................................................................4
6.2 Cable pulling....................................................................................................................5
6.3 Cable installation into the ground................................................................................5
6.4 Cable installation on cable trays..................................................................................6
6.5 Pulling cables in conduits / tubes................................................................................6
6.6 Cables installed apparent..............................................................................................7
6.7 Cables and conductors identification............................................................................7
6.8 Terminals and splices......................................................................................................7
6.9 Cables connection to equipment...................................................................................7

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 1. PURPOSE
This procedure establishes and describes the installation activities for electric power and
secondary cables.

2. SCOPE
The herein is applicable to installation of electric power and secondary cables within
electrical, automation and data systems and for the technological systems they serve.

3. TERMS, DEFINITIONS AND ABBREVIATIONS

3.1 Term Definition

3.1.1 – Power 3.1.1 – the cable used within circuits of electric power supplying, transmission and
cable distribution, in alternating or direct current.

3.1.2 - Secondary 3.1.2 – the cable used within instrumentation, signaling, control, block up, protection
cable and automation systems of voltage inferior to 400V. This category includes cables
for remote protection, tele-management, data transmission, having a service voltage
lower than 60V used in tele-signaling. Tele-measure, remote controls and remote
protection systems.

3.1.3 – Installation 3.1.3 – a document (cable list, IntEC sheet, DICON sheet, drawing, manufacturer
design specifications and instructions etc.) accepted by the client, containing all necessary
data (the equipment to be connected via a cable, cable type, route, terminal points
to connect the electric connection between two equipment.

4. REFERENCE DOCUMENTS

At the latest applicable revision

Document type Documents

International 4.1 SR EN ISO 9001:2015 – Quality management systems. Requirements.
Standards 4.2 SR EN ISO 14001:2015 – Environment management systems. Requirements
with user guide.
4.3 SR OHSAS 18001:2008 - OH&S Management Systems. Requirements.
4.4 SR ISO / TR 10013:2006 - Guidelines for quality management system‘s
documentation.
4.5 IEC 60228 / 2005 – Conductors of insulated cables.
4.6 NTE 007/08-00 – Norm for electrical cables networks design and installation;
4.7 Tests for electrical cables;
4.8 Cables, terminals and splices manufacturer instructions.
4.9 IEC 60287 – Electric cables – Calculation of the current rating;
4.10 IEC 60502-1 / 2006 – Power cables with extruded insulation and their
accessories for rated voltages from 1 kV (Um=1,2kV) up to 30kV (Um=36kV).
Part 1: Cables for rated voltages of 1 kV (Um=1,2kV) and 3kV (Um=3,6kV).
4.11 IEC 60502-2 / 2006 – Power cables with extruded insulation and their
accessories for rated voltages from 1 kV (Um=1,2kV) up to 30kV (Um=36kV).
Part 2: Cables for rated voltages from 6 kV (Um=7,2kV) up to 30kV
(Um=36kV).

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 NOTE: The user’s responsibility is to ensure that it is using the valid editions of the
documents, by reading the reference list of the documents.

5. RESPONSIBILITIES

Position / Competence
5.1. Site Superintendent
5.1.1. Shall make certain that works shall be accomplished with proper calibrated tools, devices and
instruments.
5.1.2. Shall make certain that only well qualified and trained personnel will perform the work.
5.1.3. Shall provide the working team with contractual documents, updated technical documentation as
well with applicable work procedures.
5.2. Work Supervisor
5.2.1. Shall ensure that the necessary preliminary conditions to start the work are in effect.
5.2.2. Ensures that the installation works are performed according to the installation documentation
and observing present procedure provisions.
5.2.3. Ensures the work performing with qualified and authorized personnel, as necessary.
5.2.4. Is responsible to instruct all subordinated personnel with the provisions of present procedure.
5.2.5. He answers for the good evolution of the work from technical viewpoint, organizationally, of
security of the labor, of fire prevention and of the environment protection.
5.2.6. Confirms the quality of the work in the related quality records.
5.2.7. Notify CTC Department before starting the works and the activities marked with H or W in
specific ITP. Cooperates with CTC Department during whole duration of the works.
5.3 CTC responsible of the work
5.3.1. Shall control the installation works as per specific ITP.
5.3.2. .Shall confirm the quality of works by signing, dating and stamping the related quality records.

6. PROCEDURE
6.1 Preliminary conditions
6.1.1. Before laying the cable, preliminary conditions must be ensured.
6.1.2. Cable trenches have been digged and cable trays, conduits / tubes are installed and
the equipment to connect the cables are installed.
6.1.3. Before pulling cables the correspondence between design and site, regarding the
route shall be verified.
6.1.4. Cables reel was stored for at least 12 hours in a room at minimum 20 °C if air
temperature is lower than the one specified by cable manufacturer as minimum temperature when
pulling cables.
6.1.5. Before pulling cable on the drum continuity and insulation resistance have been
checked and the results are corresponding.
6.1.6. Before pulling each cable shall be identified according to design with a waterproof
tag.
6.1.7. When pulling cables in conduits / tubes, the cleanliness of the conduit / tube and lack
of moisture shall be verified. It is not permitted to pull cables in flashed conduits, with zinc spatters
or moisture.
6.1.8. Before pulling cables in conduits, the following verifications shall be performed:
a) interior diameter of conduit / tube is 1.5 greater than cable external diameter;
b) when several cables must be pulled in a conduit, conduit cross-section is 2+2.5
greater than the sum of cables cross-section.
6.1.9. A cable reserve to compensate deformations and to permit terminals and cable
sleeves renewal shall be provided in the following cases:

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 a) both sides of the penetrations;
b) for all cable sleeves, regardless of installation place, nominal tension or cable
type;
c) at the ends of cable route for cable with nominal tension of 6 kV or higher,
regardless of cable type;
d) when passing between structures with different vibration behavior.
6.1.10.The following minimum lengths shall be provided for the reserves:
a) for sleeves and penetrations the length necessary to remake twice the respective
sleeve;
b) for terminals the length necessary to remake once the respective terminal.

6.2 Cable pulling

6.2.1. If is necessary to move them, the cable reels shall be rolled only in the sense
avoiding unreeling. In site, the cable reel shall be installed on reeling device.
6.2.2. It is recommended to use guidance wheels on the horizontal trays. Spacing between
guide wheels shall be:
- maximum 3 m for cables not heavier than 24 kg/m;
- maximum 5 m for cables less than 3 kg/m.
6.2.3. At trays curve, the guide wheels shall be placed to ensure minimum bending radius
specified by the manufacturer, or, when they are not available, those provided by the applicable
norms.
6.2.4. Cable pulling in conduits / tubes shall be done with a “cable-puller” (flexible steel
cable or band or plastic material rope) suitable to cable pulling tension.
6.2.5. All cables over 34 mm diameter shall be pulled by conductor and sheath. Control
cables with multiple conductors will be pulled using fastened strain basket.
6.2.6. Cable pulling tension shall be as per manufacturer specification. When mechanized
pulling is used the tension will be limited using dynamometers or dynamometric limiting devices.
6.2.7. In case that a greater pulling tension is necessary to pull cables, pulling will be
facilitated manually handling the cable along the cable route and using lubricants compatible with
cable sheath (as talc powder).

6.3 Cable installation into the ground

6.3.1. Cables shall be laid in ditches between two 10 cm layers of sand each, upwards of a
warning device shall be laid (as warning tape and / or warning plates) and soil resulted from
digging (from which all corpses that may produce cable damage have been removed).
6.3.2. It is accepted to cover cables in ditches with processed soil (selected from ditch
embankment so that the grains are no more than 30 mm, with no stones, boulders or other
foreigner bodies) and compacted by tampering until a 10-15 cm thickness and a flat no-crack
surface is obtained, the layer above the warning device shall be also well compacted by tampering.
6.3.3. It is recommended to use warning plates in the following situations:
a) when a supplementary mechanical protection is necessary;
b) in cases of shelved cable ditches (between the cable layers);
c) above cable sleeves.
6.3.4. Cables installation in overlapped (shelved) layers shall be avoided.
6.3.5. Between cables with different voltage or between medium voltage cables (of the
same voltage) installed in the same ditch with 10 cm distance between then spacers shall be
installed along the cable route at intervals that ensure the minimum requested distance between
cables.

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 6.3.6. In cities and inhabited areas cables shall be installed, usually, in the non-passable
part of the streets (under the sidewalk) or, in certain conditions, in the green areas of the inhabited
areas.
6.3.7. Cables installed in the passable area of the streets shall have appropriate mechanical
protection.
6.3.8. The order of cables installation under the sidewalk, from building to the passable area
are (keeping the distances between the cables):
a) low voltage distribution cables;
b) medium voltage distribution cables;
c) pilot-wire cables for tele-management
d) public lighting cables.

6.4 Cable installation on cable trays

6.4.1. Cables shall be laid in trays parallel to the edge of tray. Crossing is only permitted at
entry / exit points from trays.
6.4.2. Low-voltage power and control cables with a diameter smaller than 50 mm shall be
installed in cable trays without spacing.
6.4.3. Cables shall be fixed with plastic straps accepted by the client as close as possible to
entrance / exit points of trays.
6.4.4. Single-phase power cable shall be installed (as per design) in a triangle (club)
configuration, using nonmagnetic spacers and straps for fastening. Plastic spacers and straps are
accepted if they are correct dimensioned.
6.4.5. Three-phase power cables, for which spacing is required by design or installation
documentation, are to be laid in trays maintaining a minimum spacing of 0.25 outside diameter,
using for fastening the plastic straps.
6.4.6. Cables that needs to exit from the bottom of the tray will be protected with a piece of
cable descent “drop-out”.
6.4.7. The cables that are routed up to panels located at a superior elevation must be
supported with a “montant” type profile and fixed with plastic straps at minimum 300 mm under the
panels.
6.4.8. When power and control cables are to be installed on the same tray, a separation of
300 mm must be maintained between the two categories of cables.
6.4.9. Filling of trays shall not be more than 65% for power cables and 80% for control
cables.

6.5 Pulling cables in conduits / tubes

6.5.1. Cables shall be pulled in conduits / tubes using fastened strain baskets. Before
pulling a “cable puller” (flexible steel cable or steel band or synthetic rope) shall be installed in the
conduit / tube.
6.5.2. A lubricant compatible (such as talc or 77 Ideal Yellow) with cable sheath shall be
used when necessary.
6.5.3. Before pulling sealing glans parts shall be installed on the cable and the conduit.
6.5.4. Any two of the classes of cables listed below, shall be not placed in the same conduit:
a) AC power cables, current and potential transformers circuit;
b) DC power supplies cables;
c) Control and instrumentation cables.

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 6.6 Cables installed apparent
6.6.1. Cable supports shall be installed parallel to constructive lines of the buildings when
installing cables apparent.
6.6.2. If not otherwise specified by design, distances between supports shall be as follows:
Horizontal Vertical
(mm) (mm)
Unsheathed cables 500 1000
Sheathed cables 800 1500
.
6.6.3. If the vertical length of cable route is more than 7.5 m and cable weight is greater,
than the pulling tension distances between supports will diminish.

6.7 Cables and conductors identification

6.7.1. A soon as installation is finished, each cable and / or conductor shall be identified and
tagged at the entry point to the equipment, penetration or cross connections with other cables
according to client requirements.
6.7.2. Identification details from tag shall be the one specified by design or according to
client requirements.
6.7.3. Tags material shall be the one specified by design.
6.7.4. Shield grounding instrumentation should be insulated with green sleeve and heat
shrink sleeve.

6.8 Terminals and splices

6.8.1. Terminals and splicing (if the last ones are agreed / approved by the client) is to be
performed in accordance with the manufacturer’s instructions using tools and die specified as well
as trained and authorized personnel (if required).
6.8.2. Always cable lugs shall be crimped on cable starting from the cable end to the end of
the sleeve, and in splices case, crimping will start from the middle of the tube to the ends (see the
figure below).

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 6.9 Cables connection to equipment
6.9.1. Cable terminal head shall be fastened in the equipment as per design requirements
using plastic straps.
6.9.2. If not otherwise specified by design, the cable shall be fastened at least 0.5 m before
connection.
6.9.3. A reserve sufficient for an eventual reconnection shall be ensured in the equipment.
6.9.4. The conductors will be identified according to point 6.6 and will be connected to
equipment terminals according to design.
6.9.5. The metallic shield of the cables shall be connected to the grounding system
according to design requirements.
6.9.6. It is not allowed to connect more than to conductors into a terminal / connector.
6.9.7. Conductors fastening screw shall be tightened according to connector’s manufacturer
torque moments.

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