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IT IS LENT TO THE RECIPIENT FOR HIS CONFIDENTIAL USE ONLY , AND UPON THE CONDITIONS AND AGREEMENTS FOLLOWING IN CONSIDERATION OF THE LOAN OF THIS DRAWING . THE RECIPIENT
PROMISES AND AGREE TO RETURN IT UPON REQUEST AND THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT, OR OTHERWISE DISPOSED OF DIRECTLY OR INDIRECTLY WITHOUT ENPPI WRITTEN CONSENT, NOR BE USED IN ANY WAY DETRIMENTAL TO THE INTERESTS OF ENPPI.
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B
Revision number
2495
E-STYRENICS
Project N°
REVISION SHEET
Unit
Page
000
number
Enppi Reference: 3688
A
JSS 1621
B
51
Serial N°
Revision number
B
Rev.
2/22
Project N° Unit Document Code Serial N° Rev. Page
SUMMARY
1. SCOPE 5
1.1. General 5
1.2. List of Abbreviations 5
2. REFERENCE STANDARDS, CODES AND DOCUMENTS 5
2.1. General 5
2.2. Compliance with EC (European Community) directives 7
2.2.1. Applicable directives 7
2.2.2. EC declaration of conformity and CE marking 7
3. GENERAL REQUIREMENTS 8
3.1. Application 8
3.2. Proposal 8
4. AMBIENT CONDITIONS 9
5. DESIGN REQUIREMENTS 9
5.1. Installation 9
5.2. Conductors 10
5.3. Insulation 10
5.4. Acceptable manufacturing tolerances 10
5.5. Design life 10
5.6. Water Penetration Protection 10
6. MEDIUM VOLTAGE POWER CABLES 11
6.1. Ratings and codes 11
6.2. Conductor 11
6.3. Conductor screen 11
6.4. Insulation 11
6.5. Insulation screen 11
6.6. Shield 12
6.7. Fillers, cable laying-up and other requirements for multicore cables 12
6.8. Inner sheath 12
6.9. Screen 12
6.10. Armour 12
6.11. Outer jacket 13
6.11.1. Non-fire resistant cables 13
6.11.2. Fire resistant cables 13
7. LOW VOLTAGE POWER AND CONTROL CABLES 14
7.1. Codes 14
7.2. Conductor 14
7.2.1. General 14
1. SCOPE
1.1. General
This specification defines the minimum technical requirements for design, manufacture,
manufacturer acceptance testing, supply and shipment of electrical power, control and
grounding cables for the 300,000 MTA EB/SM Production Facilities.
2.1. General
The cables shall be designed, manufactured and tested according to the requirements
of the relevant applicable IEC (International Electrotechnical Commission) standards
and in compliance with local codes.
The listed Standards and Codes, together with their all parts and subparts, shall be
applied considering their latest applicable issue available at time of contract award.
Other standards
Bidders shall identify any deviations or discrepancies between the country standard
and IEC recommendations.
In no way does this specification supersede the relevant codes except when the
requirements herein are more stringent.
Where applicable, material shall be approved by (IEC, CENELEC or approved
equivalent). All cases of conflict shall be immediately brought to the purchaser's
attention.
No prototype or unproven equipment or equipment built to unapproved manufacturing
standards shall be selected.
Even if the equipment and material supplied are to be installed in Egypt, that is not a
member country of the European Union, it shall be supplied in accordance with all
applicable European Community directives.
In particular, for the supply related to this specification falling within the scope and
applicability limits of each pertinent EC Directive, compliance shall be given with:
By affixing, when required, the CE Marking, the Supplier ensures that the overall
supply meets all the safety requirements as per the CE Marking Directives as well as
that the appropriate conformity assessment procedures have been successfully
completed.
In regard to the CE Marking extent stated on the applicable CE Marking Directives, the
following documentation, within the limits of the Directive requirements, shall be
included in the scope of supply:
Technical documentation.
Essential Safety Requirements (ESR) check list.
Self-declaration of conformity.
Operating instructions.
CE Marking nameplate.
3. GENERAL REQUIREMENTS
3.1. Application
This specification together with the material requisition defines the minimum
requirements for the design, construction, identification, inspection, testing,
documentation, and preparation for shipment of electrical cables which shall include
but not limited to the following types of cables
Excluded are:
Instrumentation cables
Fiber optic cables
3.2. Proposal
4. AMBIENT CONDITIONS
The design of the equipment and of its components shall comply with the following
environmental conditions:
5. DESIGN REQUIREMENTS
5.1. Installation
Cable tray, conduit systems and open air installation in hazardous (Zones 1 and 2,
Zones 21 and 22) and unclassified areas.
In areas where it is mandatory to run partially the cable underground (site maneuvering
purposes … etc) cables shall be installed inside suitable conduits AFTER OWNER
APROVAL for each case individually.
5.2. Conductors
Conductors shall be compacted and having continuous length. The Minimum cross
sectional areas shall be:
Low voltage control cables: 2.5 mm2 and for control cable internal to
control panels and switchboard can be reduced
to 1.5 mm2
For Low Voltage power feeders, the maximum cross section shall be:
240 mm2 for three-core cable either armoured or not armoured,
500 mm2 for single core cable.
For Medium Voltage power feeders, the maximum cross section shall be:
240 mm2 for three-core cable either armoured or not armoured,
630 mm2 for single core cable
5.3. Insulation
When specified, cables shall be fully protected against moisture penetration (water
wicking). Protection against water ingress and transmission shall comply with the
requirements of IEC 60502 which shall include the provision of water blocking tapes.
Tests for water penetration protection shall be in accordance with IEC 60811.
Medium voltage power cables shall be designed in accordance with IEC 60502-2.
6.2. Conductor
6.4. Insulation
6.6. Shield
The shield thickness and its nominal wrapping overlap shall be in accordance with the
requirements of IEC 60502-2.
6.7. Fillers, cable laying-up and other requirements for multicore cables
Multi-conductor cables shall be assembled with a left-hand lay. Length of lay shall not
exceed 35 times phase conductor diameter.
Insulated conductors shall be cabled together with moisture resistant fillers. Fillers shall
be solid and fill the cross section such that the transmission of gas and hydrocarbons
along the length of the cable under normal pressure is avoided.
Inner PVC sheath shall protect the insulation against damage from metallic armour and
shall ensure that the outer shape of the cable remains circular.
6.9. Screen
Screen conductor shall be made of plain annealed copper wires and one or more helix
of annealed copper.
6.10. Armour
Metallic armour wires shall form a helix. Wires shall be wound closely together in order
to have an almost closed and uniform cylindrical surface.
Tape armouring can be accepted as an alternative in those cases where the cable
construction is not suited for wire armouring. Tape armour shall consist of two tapes
wound in the same direction and forming an open helix; the second tape shall cover the
interval between the spirals of the first and shall overlap it by at least a quarter of its
width on both sides.
Lead sheath: if required, a layer of lead is extruded over the bedding layer.
The material of lead sheath is lead alloy grade PB021K of composition as given in BS
EN12548. The thickness of the lead sheath is in accordance with EEMUA (Publication
no. 133). The lead sheath performs the mechanical function of acting as a barrier to
entry of hydrocarbons. In addition, it can also be engaged to perform the electrical
function of sharing the earth fault current with the armour.
Flame retardancy characteristics shall be in accordance with IEC 60332-1 and 60332-
2-24 (category “C”).
Cables shall have flame propagation characteristics which enable them to withstand
the tests according to IEC 60332-3 category A
Fire resistant cables shall have an overall jacket of oil, moisture, and sunlight
(ultraviolet) resistant an extruded zero halogen flame-retardant compound LSZH jacket.
The overall jacket Temperature Index (TI) shall be 250 °C minimum according to
ASTM-D-2863.
Flame retardancy characteristics shall be in accordance with IEC 60332-1 and 60332-
2-24 (category “C”).
Cables shall have flame propagation characteristics which enable them to withstand
the tests according to IEC 60332-3 category A
7. LOW VOLTAGE POWER AND CONTROL CABLES
7.1. Codes
Low voltage power and control cables shall be rated 0.6/1 kV, and designed in
accordance with IEC 60502-1.
7.2. Conductor
7.2.1. General
Fire resistant cables shall have a mica tape having fire resistant characteristics
wrapped around each conductor.
7.3. Insulation
Unless otherwise specified the cable insulation colour identification will be as follow:
Control cables:
Black with sequential numbering indelibly printed in contrasting color plus yellow green
for the last core.
7.4. Fillers, cable laying-up and and other requirements for multicore cables
Multi-conductor cables shall be assembled with a left-hand lay. Length of lay shall not
exceed 35 times phase conductor diameter.
Insulated conductors shall be cabled together with moisture resistant fillers. Fillers shall
be solid and fill the cross section such that the transmission of gas and hydrocarbons
along the length of the cable under normal pressure is avoided.
Ground wire or wires shall have a total cross-sectional area meeting or exceeding IEC
requirements for equipment grounding conductors based on size of phase conductors.
If the total number of conductors allows it, sector-shaped (SM) cross sections are
preferred for sections ≥ 25 mm2.
Inner PVC sheath shall protect the insulation against damage from metallic armour and
shall ensure that the outer shape of the cable remains circular.
7.6. Armour
Metallic armour wires shall form a helix. Wires shall be wound closely together in order
to have an almost closed and uniform cylindrical surface.
Flame retardancy characteristics shall be in accordance with IEC 60332-1 and 60332-
2-24 (category “C”).
Cables shall have flame propagation characteristics which enable them to withstand
the tests according to IEC 60332-3 category A
The required colour for control cable overall jacket to be Brown and blue for shielded
control cables.
Fire resistant cables shall have an overall jacket of oil, moisture, and sunlight
(ultraviolet) resistant an extruded zero halogen flame-retardant compound LSZH jacket.
The overall jacket Temperature Index (TI) shall be 250 °C minimum according to
ASTM-D-2863.
Flame retardancy characteristics shall be in accordance with IEC 60332-1 and 60332-
2-24 (category “C”).
Cables shall have flame propagation characteristics which enable them to withstand
the tests according to IEC 60332-3 category A
The required colour for control cable overall jacket to be Brown and blue for shielded
control cables.
When specified, cables shall be fire resistant in accordance with IEC 60331.
8. GROUNDING WIRE
8.1. Codes
Single conductor grounding wire shall be rated 450/750 V, and designed in accordance
with IEC 60227.
8.2. Conductor
8.3. Insulation
Insulation shall be moisture and heat resistant PVC insulation, rated 70°C.
9. MARKING
Each cable shall be marked on the outer jacket according to relevant applicable codes.
The following minimum information shall be printed with contrasting ink or embossed
on the cable:
Manufacturer’s name
Reference codes
Conductor material
Number of conductors and cross section
Rated voltage
Insulation type
Year of manufacturing
Metric marking shall be ensured every meter– not required for grounding wire
10.1. Inspections
The Manufacturer shall allow the free access of inspectors to the workshop, shall give
all information required and shall make available all copies of internal orders to other
sub-suppliers.
All test results shall be recorded, and attached to test certificates provided by the
supplier before material release.
10.2.1. General
(a) The tests should be carried out in Vendor workshop at his care and expense.
(b) Even in case the Contractor inspector waives to witness the tests, the Vendor
shall draw up the certificate of the tests carried out containing a full report and all
results and the measures of the tests.
(c) The tests shall be carried out in accordance with the requirements of applicable
codes and of the Inspection and Test Plan.
(d) Routine tests shall be conducted on each item and/or assembly in accordance
with the requirements of IEC codes and of the Inspection and Test Plan.
(e) Type tests are for the purpose of proving the characteristics of equipment design.
Evidence of valid type tests covering the equipment offered together with tests
certificate from an Independent testing station, or recognized manufacturer
testing station, shall be submitted with the tender. The type tests shall
encompass the requirements listed in the Inspection and Test Plan.
The routine, sample and type tests will be carried out according to the following
scheme:
Routine tests: on each manufactured length of cable
Sample tests: on each type (section and formation) of cable
Type tests: on each cable typology
For type tests, unless otherwise specified, the Manufacturer will provide only the type
tests certificates.
If not available, type test shall be carried out by the Manufacturer on prototype and/or
samples of the material making up the cable.
Voltage test
Conductor examination
Bending test
Limiting Oxygen Index (LOI) for outer sheath material (where applicable)
The base quotation shall be in strict accord with this specification and the applicable
data sheet. Alternate quotations may also be submitted if deviations from these
specifications or data sheets are clearly stated and a base quotation is offered.
Service-proven designs shall be offered. If a design is offered that has not been proven
in service for at least two years, proposals shall indicate it. Designs scheduled to be
superseded shall not be used.
12. DOCUMENTATION
Drum lengths and weights for each size and type of cable,
Laboratory test certificate for "flame retardant" cables.
cable section drawings;
catalogues and technical bulletins;
recommendations for storage;
procedures for cable pulling;
a list of standards applied;
the test reports;
the compliance certificates with the applicable standards
MANUFACTURER shall provide Test report certificates for all tests carried out on the
cables
13.1. Documentation
Supplier shall, on order award, advise and give to Purchaser all supporting
documentation relevant to any commodity contained in the supply subject to
governmental Export/Import Licence, so that all necessary actions can be promptly
taken in compliance with the related rules or regulations in force.
Supplier shall provide to Purchaser, the preliminary packing list 4 weeks after purchase
order. All shipping documents (invoices, packing lists, FCR, B/L and others), shall be in
English language.
13.2. Delivery
At least 7 days prior to delivery, supplier shall give fax binding confirmation of the
actual Ex-works delivery date of the goods. Supplier shall be fully liable for any dead
freight and demurrage caused by his failure to deliver the goods within the confirmed
date.
Supplier shall deliver the goods only after receipt of purchaser/forwarder’s written
instructions. If requested, supplier shall provide free storage of the goods in a covered
area, for a period previously agreed upon with the purchaser.
Supplier shall provide, free of charge, all handling devices (crane, fork lifts, etc.), labour
and materials (i.e. wooden boards, struts, wedges, ropes, etc.) needed for loading,
stowing and lashing the equipment on conveyances or into containers.
The purchaser reserves the right to verify, by opening the packages at the erection site
or delivery point, that the quantities indicated in the packing list correspond with those
effectively contained in the packing. If, according to the sole judgment of purchaser, the
materials do not match with the quantity and/or types specified in the purchase order
and/or packing list, supplier shall, upon written notification of the irregular supply,
provide for prompt replacement at his own care and charge up to delivery at site.
The inside of the reels shall have no sharp projections, sharp recessions or voids that
can cause damage to the cable surface.
The inside diameter of the drum shall not be less than twice the minimum permissible
bending radius of the cable or larger according to the manufacturer recommendations.
The end of each cable shall be sealed with heat shrink or cold shrink end caps to
prevent moisture from entering cable after manufacture and testing. Both ends of the
cable shall be brought out to facilitate testing.
The cable shall be delivered on reels plainly marked with an engraved metal tag for
complete identification including:
The Supplier should state the maximum storage time limits based on temperature.
Receiving location shall be notified two working days in advance so that handling
equipment will be available.