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This Document is intended for use by ADNOC and its nominated Consultants, Contractors, Manufacturers and Suppliers.
ABU DHABI NATIONAL OIL COMPANY (ADNOC)
GHASHA CONCESSION PROJECTS
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 2 – ONSHORE FACILITIES
CONTRACTOR DOC NO:
AGREEMENT NO: 4700021829
4422-NN-SG-000000000012-00
PROJECT SPECIFICATION - ELECTRICAL POWER,
Document class: 2B
CONTROL AND EARTHING CABLES
COMPANY DOC NO: 2-CN0000-10-SPE-0009-00 Page 2 Of 13 Rev. 00
B2 31/Oct/2023 As per This document is rolled over from PCSA document no.
track changes 2-CN0000-10-SPE-0009-00_B1
00 15/Jan/2024 - No comments
This Document is intended for use by ADNOC and its nominated Consultants, Contractors, Manufacturers and Suppliers.
ABU DHABI NATIONAL OIL COMPANY (ADNOC)
GHASHA CONCESSION PROJECTS
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 2 – ONSHORE FACILITIES
CONTRACTOR DOC NO:
AGREEMENT NO: 4700021829
4422-NN-SG-000000000012-00
PROJECT SPECIFICATION - ELECTRICAL POWER,
Document class: 2B
CONTROL AND EARTHING CABLES
COMPANY DOC NO: 2-CN0000-10-SPE-0009-00 Page 3 Of 13 Rev. 00
HOLD LIST
This Document is intended for use by ADNOC and its nominated Consultants, Contractors, Manufacturers and Suppliers.
ABU DHABI NATIONAL OIL COMPANY (ADNOC)
GHASHA CONCESSION PROJECTS
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 2 – ONSHORE FACILITIES
CONTRACTOR DOC NO:
AGREEMENT NO: 4700021829
4422-NN-SG-000000000012-00
PROJECT SPECIFICATION - ELECTRICAL POWER,
Document class: 2B
CONTROL AND EARTHING CABLES
COMPANY DOC NO: 2-CN0000-10-SPE-0009-00 Page 4 Of 13 Rev. 00
TABLE OF CONTENTS
This Document is intended for use by ADNOC and its nominated Consultants, Contractors, Manufacturers and Suppliers.
ABU DHABI NATIONAL OIL COMPANY (ADNOC)
GHASHA CONCESSION PROJECTS
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 2 – ONSHORE FACILITIES
CONTRACTOR DOC NO:
AGREEMENT NO: 4700021829
4422-NN-SG-000000000012-00
PROJECT SPECIFICATION - ELECTRICAL POWER,
Document class: 2B
CONTROL AND EARTHING CABLES
COMPANY DOC NO: 2-CN0000-10-SPE-0009-00 Page 5 Of 13 Rev. 00
1. PROJECT OVERVIEW
This Document is intended for use by ADNOC and its nominated Consultants, Contractors, Manufacturers and Suppliers.
ABU DHABI NATIONAL OIL COMPANY (ADNOC)
GHASHA CONCESSION PROJECTS
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 2 – ONSHORE FACILITIES
CONTRACTOR DOC NO:
AGREEMENT NO: 4700021829
4422-NN-SG-000000000012-00
PROJECT SPECIFICATION - ELECTRICAL POWER,
Document class: 2B
CONTROL AND EARTHING CABLES
COMPANY DOC NO: 2-CN0000-10-SPE-0009-00 Page 6 Of 13 Rev. 00
2. PURPOSE
The purpose of this document is to define the minimum requirements for the design,
manufacture, installation, inspection, testing, documentation and supply of Electrical
Power, Control and Earthing Cables (33kV and below ) for installation at Onshore , of
Hail & Ghasha Development Project.
Compliance with the specification, codes and standards does not relieve the Supplier of
the responsibility for supplying equipment of proper design and construction, fully suitable
for all specified operating conditions.
This specification shall be read in conjunction with the relevant data sheets.
Supplier/Vendor shall conform fully to the requirements of this specification and shall
provide adequate performance and rating margins.
3. TERMINOLOGY
3.1 Definitions
This Document is intended for use by ADNOC and its nominated Consultants, Contractors, Manufacturers and Suppliers.
ABU DHABI NATIONAL OIL COMPANY (ADNOC)
GHASHA CONCESSION PROJECTS
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 2 – ONSHORE FACILITIES
CONTRACTOR DOC NO:
AGREEMENT NO: 4700021829
4422-NN-SG-000000000012-00
PROJECT SPECIFICATION - ELECTRICAL POWER,
Document class: 2B
CONTROL AND EARTHING CABLES
COMPANY DOC NO: 2-CN0000-10-SPE-0009-00 Page 7 Of 13 Rev. 00
3.2 Abbreviations
AGES ADNOC Group Engineering Standards and
Specifications
AWA Aluminum Wire Armour
DC Drill Centre
DEP Design and Engineering Practices
FAT Factory Acceptance Test
FEED Front End Engineering Design
GOP Ghasha Offshore Processing
GRP Glass Reinforced Polyester
HSE Health, Safety, and Environment
HGD Hail & Ghasha Development
IP Ingress Protection
OPP Onshore Processing Plant
RP Reduced Propagation
SAT Site Acceptance Test
4. REFERENCE DOCUMENTS
The latest versions and amendments of all applicable UAE Legislation and Environmental
Regulations, ADNOC Group Engineering Standards and Specifications (AGES),
COMPANY Occupational Health Management Standards and HSE Regulations, the Hail
& Ghasha Development Project Specifications and Data Sheets, and all relevant
International Codes and Standards on the EFFECTIVE DATE of CONTRACT shall be
used.
This Document is intended for use by ADNOC and its nominated Consultants, Contractors, Manufacturers and Suppliers.
ABU DHABI NATIONAL OIL COMPANY (ADNOC)
GHASHA CONCESSION PROJECTS
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 2 – ONSHORE FACILITIES
CONTRACTOR DOC NO:
AGREEMENT NO: 4700021829
4422-NN-SG-000000000012-00
PROJECT SPECIFICATION - ELECTRICAL POWER,
Document class: 2B
CONTROL AND EARTHING CABLES
COMPANY DOC NO: 2-CN0000-10-SPE-0009-00 Page 8 Of 13 Rev. 00
4.4 Project Documents
Sl. No. Document No. Document Title
1. 2-CN0000-10-PHL-0017-00 Electrical Design Basis
2. 2-CN0000-59-PHL-0001-00 Project Design Basis - Basic Engineering
Design Data (BEDD)
3. 2-CN0000-59-PRO-0003-00 Project Procedure for Tagging Procedure
4. 2-CN0000-10-SPE-0042-00 Project Specification - Electrical Items on
Packaged Equipment
5. 2-CN0000-10-SPE-0041-00 Project Specification - Electrical Bulk
Materials
6. 2-CN0000-25-SPE-0008-00 Preservation & Export Packing Specification
7. 2-CN0000-10-DSS-1006-00 Data Sheet for Electrical Cables (33kV and
below)
5. ORDER OF PRECEDENCE
Design and engineering for the Facilities shall be undertaken in accordance with
regulations, codes, standards and specifications in the order of precedence stated below:
• UAE Local Laws and Regulations,
• COMPANY HSE Standards
• Project Specification / Datasheets as approved by COMPANY
• COMPANY Group Engineering Standards and Specifications (AGES)
• ADNOC ONSHORE Specifications and Standards
• International Codes & Standards.
In cases of conflicts between documents in the same level of hierarchy, the most stringent
and safest requirement shall prevail. In such cases, CONTRACTOR shall provide its
interpretation for most stringent and safest in writing for COMPANY’s approval, and
COMPANY’s decision shall be final.
CONTRACTOR to obtain latest international standards. Applicable revision to be at the
date of CONTRACT signing.
This Document is intended for use by ADNOC and its nominated Consultants, Contractors, Manufacturers and Suppliers.
ABU DHABI NATIONAL OIL COMPANY (ADNOC)
GHASHA CONCESSION PROJECTS
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 2 – ONSHORE FACILITIES
CONTRACTOR DOC NO:
AGREEMENT NO: 4700021829
4422-NN-SG-000000000012-00
PROJECT SPECIFICATION - ELECTRICAL POWER,
Document class: 2B
CONTROL AND EARTHING CABLES
COMPANY DOC NO: 2-CN0000-10-SPE-0009-00 Page 9 Of 13 Rev. 00
Sl. AGES Document No. & Title Project Document No. & Title
No.
AGES-GL-02-001 2-CN0000-10-PHL-0017-00
1.
Electrical Engineering Design Guide Electrical Design Basis
AGES-SP-02-019 2-CN0000-10-SPE-0041-00
2. Project Specification - Electrical Bulk
Electrical Bulk Material
Materials
AGES-SP-04-006 2-CN0000-16-SPE-0027-00
3. Instrument and Control Cable Project Specification - Instrument and
Specification Thermocouple Cables
AGES-SP-07-004 2-CN0000-25-SPE-0011-00
4. Painting and Coating Specification Painting & Coating Specification
AGES-SP-07-011 2-CN0000-25-SPE-0008-00
5. Preservation & Export Packing Preservation & Export Packing
Specification Specification
AGES-PH-02-001 2-CN0000-10-PHL-0011-00
6. Earthing, Bonding, and Lightning Earthing and Lightning Protection
Protection Philosophy Philosophy
AGES-SP-02-015 2-CN0000-10-SPE-0048-00
Project Specification - Inspection,
7. Field Commissioning of Electrical
Installation and Equipment Testing and Commissioning of
Electrical Equipment (ONSHORE)
Definitions for COMPANY and PROJECT shall be followed as per Section 3.1 of this
document.
This Document is intended for use by ADNOC and its nominated Consultants, Contractors, Manufacturers and Suppliers.
ABU DHABI NATIONAL OIL COMPANY (ADNOC)
GHASHA CONCESSION PROJECTS
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 2 – ONSHORE FACILITIES
CONTRACTOR DOC NO:
AGREEMENT NO: 4700021829
4422-NN-SG-000000000012-00
PROJECT SPECIFICATION - ELECTRICAL POWER,
Document class: 2B
CONTROL AND EARTHING CABLES
COMPANY DOC NO: 2-CN0000-10-SPE-0009-00 Page 10 Of 13 Rev. 00
The following amendments and additions shall apply to ADNOC Specification for Electrical
Power, Control and Earthing Cables, AGES-SP-02-011 Rev 1.
(Add)
(Replace)
(With)
In case of conflict, the order of document precedence shall be followed as per Section – 5
of this document.
(Replace)
(With)
The design, construction and functions of electrical materials and facilities envisaged shall
be suitable for H&G Project. Site condition shall be considered based on Project
Specification Electrical Engineering Design Guide (Electrical Design Basis), 2-CN0000-10-
PHL-0017-00 (AGES-GL-02-001) and Engineering Design Data 2-CN0000-59-PHL-0001-
00.
This Document is intended for use by ADNOC and its nominated Consultants, Contractors, Manufacturers and Suppliers.
ABU DHABI NATIONAL OIL COMPANY (ADNOC)
GHASHA CONCESSION PROJECTS
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 2 – ONSHORE FACILITIES
CONTRACTOR DOC NO:
AGREEMENT NO: 4700021829
4422-NN-SG-000000000012-00
PROJECT SPECIFICATION - ELECTRICAL POWER,
Document class: 2B
CONTROL AND EARTHING CABLES
COMPANY DOC NO: 2-CN0000-10-SPE-0009-00 Page 11 Of 13 Rev. 00
Cable design life shall be 30 years.
(Add)
Cables used in process areas of Onshore shall be provided with Tri barrier laminate layers,
to prevent ingress of hydrocarbon contamination.
(Replace)
PB*
(With)
(Replace)
Cables used in process areas of Onshore which are subject to hydrocarbon contamination
shall be provided with Tri barrier laminate layers, cable type shall be;
Cu/XLPE/AL/HDPE//PA/GSWA**/PVC
(Replace)
Replace entire section as follows.
(With)
This Document is intended for use by ADNOC and its nominated Consultants, Contractors, Manufacturers and Suppliers.
ABU DHABI NATIONAL OIL COMPANY (ADNOC)
GHASHA CONCESSION PROJECTS
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 2 – ONSHORE FACILITIES
CONTRACTOR DOC NO:
AGREEMENT NO: 4700021829
4422-NN-SG-000000000012-00
PROJECT SPECIFICATION - ELECTRICAL POWER,
Document class: 2B
CONTROL AND EARTHING CABLES
COMPANY DOC NO: 2-CN0000-10-SPE-0009-00 Page 12 Of 13 Rev. 00
7.9 Amendments to Section E - Appendices
This Document is intended for use by ADNOC and its nominated Consultants, Contractors, Manufacturers and Suppliers.
ABU DHABI NATIONAL OIL COMPANY (ADNOC)
GHASHA CONCESSION PROJECTS
HAIL AND GHASHA DEVELOPMENT PROJECT
PACKAGE 2 – ONSHORE FACILITIES
CONTRACTOR DOC NO:
AGREEMENT NO: 4700021829
4422-NN-SG-000000000012-00
PROJECT SPECIFICATION - ELECTRICAL POWER,
Document class: 2B
CONTROL AND EARTHING CABLES
COMPANY DOC NO: 2-CN0000-10-SPE-0009-00 Page 13 Of 13 Rev. 00
APPENDIX-1
AGES-SP-02-011 (REV.1)
ADNOC GROUP PROJECTS AND ENGINEERING ELECTRICAL POWER, CONTROL AND
EARTHING CABLE SPECIFICATION
(NO. OF PAGES: 41)
This Document is intended for use by ADNOC and its nominated Consultants, Contractors, Manufacturers and Suppliers.
ADNOC Classification: Internal
AGES-SP-02-011
ADNOC Classification: Internal
REVISION HISTORY
Group Projects & Engineering is the owner of this Specification and responsible for its custody, maintenance and
periodic update.
In addition, Group Projects & Engineering is responsible for communication and distribution of any changes to this
Specification and its version control.
This specification will be reviewed and updated in case of any changes affecting the activities described in this
document.
DEFINITIONS
“ADNOC Group” means ADNOC together with each company in which ADNOC, directly or indirectly, controls fifty
percent (50%) or more of the share capital.
“Approving Authority” means the decision-making body or employee with the required authority to approve
Policies & Procedures or any changes to it.
“Business Line Directorates” or “BLD” means a directorate of ADNOC which is responsible for one or more
Group Companies reporting to, or operating within the same line of business as, such directorate.
“Business Support Directorates and Functions” or “Non- BLD” means all the ADNOC functions and the
remaining directorates, which are not ADNOC Business Line Directorates.
“Group Company” means any company within the ADNOC Group other than ADNOC.
TABLE OF CONTENTS
GENERAL ...................................................................................................................................... 7
INTRODUCTION .................................................................................................................. 7
PURPOSE ............................................................................................................................ 7
DEFINITIONS AND ABBREVIATIONS............................................................................... 7
SECTION A – GENERAL.......................................................................................................................... 10
REFERENCE DOCUMENTS ....................................................................................................... 10
INTERNATIONAL CODES AND STANDARDS ............................................................... 10
ADNOC SPECIFICATIONS ............................................................................................... 12
STANDARD DRAWINGS .................................................................................................. 12
OTHER REFERENCES ..................................................................................................... 12
DOCUMENT PRECEDENCE ....................................................................................................... 13
SPECIFICATION DEVIATION / CONCESSION CONTROL ....................................................... 13
DESIGN CONSIDERATIONS / MINIMUM DESIGN REQUIREMENTS ...................................... 13
SYSTEM PARTICULARS.................................................................................................. 13
OBSOLESCENCE ............................................................................................................. 14
DESIGN PARAMETERS ................................................................................................... 14
ENVIRONMENTAL / SITE DATA ...................................................................................... 14
AREA CLASSIFICATION .................................................................................................. 14
SECTION B – TECHNICAL REQUIREMENTS ........................................................................................ 15
TECHNICAL REQUIREMENTS ................................................................................................... 15
HV POWER CABLES (UP TO 33KV) - GENERAL REQUIREMENTS ............................ 15
LV POWER, CONTROL AND EARTHING CABLES - GENERAL REQUIREMENTS .... 19
LV SINGLE CORE CONDUIT CABLE (WIRE) ................................................................. 23
ADDITIONAL SPECIFIC REQUIREMENTS ................................................................................ 24
CABLE TERMINATIONS AND JOINTS ........................................................................... 24
SECTION C – OTHER REQUIREMENTS ................................................................................................ 25
DETAILS OF SCOPE SUPPLY ................................................................................................... 25
GENERAL .......................................................................................................................... 25
SUPPLIER’S RESPONSIBILITY ....................................................................................... 25
QUALITY CONTROL AND ASSURANCE .................................................................................. 25
SUB-CONTRACTORS, SUB-SUPPLERS................................................................................... 25
MATERIAL CERTIFICATION ...................................................................................................... 25
LIST OF TABLES
LIST OF FIGURES
NONE
GENERAL
Introduction
This specification describes minimum requirements for the design, manufacturer, testing at works and supply of
power cables (up to 220kV), control and earthing cables.
The Specification Parts A to D provide general requirements for all cables up to 220kV and detailed type and
construction details for cables up 33kV. Section E provides additional details on preferred cable types for voltages
above 33kV. The design, manufacture and testing of these cables is to be agreed with COMPANY before final
selection based on Project and Operating group requirements. Specific requirements for cable construction and
testing, etc. shall be provided on data sheets.
Purpose
The purpose of this specification is to ensure consistency in selection, design and construction of power, control
and earthing cables.
For project and site specific additional requirements, refer to supplementary requirements stated in respective
project’s Purchase Requisition documentation.
1.3.1 Definitions
The following defined terms are used throughout this specification.
‘[PSR]’ indicates a mandatory Process Safety Requirement
“COMPANY” means ADNOC, ADNOC Group or an ADNOC Group Company, and includes any agent or
consultant authorized to act for, and on behalf of the COMPANY.
“CONTRACTOR” means the parties that carry out all or part of the design, engineering, procurement, construction,
commissioning or management for ADNOC projects. CONTRACTOR includes its approved MANUFACTURER(s),
SUPPLIER(s), SUB-SUPPLIER(s) and SUB-CONTRACTOR(s).
“MANUFACTURER” means the Original Equipment Manufacturer (OEM) or MANUFACTURER of one or more of
the component(s) which make up a sub-assembly or item of equipment assembled by the main SUPPLIER or his
nominated SUB-SUPPLIER.
‘may’ means a permitted option
‘shall’ indicates mandatory requirements
‘should’ means a recommendation
“SUB-CONTRACTOR” means any party engaged by the CONTRACTOR to undertake any assigned work on their
behalf. COMPANY maintains the right to review all proposed SUB-CONTRACTORs; this right does not relieve the
CONTRACTOR of their obligations under the Contract, nor does it create any contractual relationship between
COMPANY and the SUB-CONTRACTOR.
“SUPPLIER” means the party entering into a Contract with COMPANY to provide the materials, equipment,
supporting technical documents and/or drawings, guarantees, warranties and/or agreed services in accordance
with the requirements of the purchase order and relevant specification(s). The term SUPPLIER includes any legally
appointed successors and/or nominated representatives of the SUPPLIER.
“SUB-SUPPLIER” means the sub-contracted SUPPLIER of equipment sub-components software and/or support
services relating to the equipment / package, or part thereof, to be provided by the SUPPLIER. COMPANY
maintains the right to review all proposed SUB-SUPPLIERS, but this right does not relieve the SUPPLIER of their
obligations under the Contract, nor does it create any contractual relationship between COMPANY and any
individual SUB-SUPPLIER.
1.3.2 Abbreviations
The abbreviations used throughout this specification are shown in Table 1.1
Table 1.1 List of Abbreviations
Abbreviations
AC Alternating Current
Al Aluminium
BS British Standards
CCA Continuous Corrugated Aluminium sheath
Cu Copper
CSP Chlorosulfonated Polyethylene
DC Direct Current
EPC Engineering, Procurement and Construction
EVAPA is a blend of EVA and PA
EPR Ethylene Propylene Rubber
EVA Ethyl Vinyl Acetate
FAT Factory Acceptance Test
GSWA Galvanised Steel Wire Armour
GSWB Galvanised Steel Wire Braid
HCL Hydrogen Chloride
HDPE High Density Polyethylene
HOFR Heat Oil and Flame Resistant
HV High Voltage (>1000V)
Hz Hertz
Abbreviations
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronics Engineers
ISO International Organization for Standardisation
ITP Inspection and Test Plan
kV Kilovolt
LC Lead cover
LSHF Low Smoke Halogen Free
LV Low Voltage (≤1000V)
MDPE Medium Density polyethylene
PA Polyamide
PB Lead
PP Polypropylene
PVC Polyvinyl Chloride
SVL Surge Voltage Limiter
UV Ultraviolet
VSD Variable Speed Drive
XLPE Cross-linked Polyethylene
SECTION A – GENERAL
REFERENCE DOCUMENTS
BRISTISH STANDARDS
BSI BS 7671 Requirements for Electrical Installations - IET Wiring Regulations
BS 5467 Electric cables. Thermosetting insulated, armoured cables for
voltages of 600/1000V and 1900/3300 V
BS 6231 Electric cables-Single core & PVC insulated flexible cables of rated
voltage 600/1000V for switchgear & controlgear wiring
BS 6346 Electric cables. PVC insulated, armoured cables for voltages
of 600/1000 V and 1900/3300 V (Note: Standard withdrawn and not
replaced 2005 but still referenced by some manufacturers)
BS 6622 Electric cables – Armoured cables with thermosetting insulation for
rated voltages from 3.8/6.6 kV to 19/33 kV – Requirements and test
methods.
BS 7655-2.6 Specification for Insulating and Sheathing Materials for Cables.
Cross-Linked Elastomeric Sheathing Compounds. Sheathing
Compounds for Ships' Wiring and Offshore Applications.
BS EN 10257 Zinc or zinc alloy coated non alloy steel wire for armouring either
power cables or telecommunication cables
BS EN 12548 Lead and Lead Alloys - Lead Alloy Ingots for Electric Cable
Sheathing and for Sleeves
BS EN 50307 Lead and lead alloys - Lead and lead alloy sheaths and sleeves of
electric cables
IEEE STANDARDS
IEEE 575 IEEE Guide for Bonding Shields and Sheaths of Single-Conductor
Power Cable Rated 5kV through 500kV
ADNOC Specifications
Where a document listed below is not available or considered to be not applicable to the Project, each ADNOC
COMPANY shall use their own relevant document. Additional reference documents may also be added by each
ADNOC Company.
Standard Drawings
Other References
DOCUMENT PRECEDENCE
The specifications and codes referred to in this specification shall, unless stated otherwise, be the latest approved
issue at the time of contract award.
It shall be the CONTRACTOR's responsibility to be, or to become, knowledgeable of the requirements of the
referenced Codes and Standards.
The CONTRACTOR shall notify the COMPANY of any apparent conflict between this specification, the related
data sheets, the Codes and Standards and any other specifications noted herein.
Resolution and/or interpretation precedence shall be obtained from the COMPANY in writing before proceeding
with the design/manufacture.
In case of conflict, the order of document precedence shall be:
a. UAE Statutory requirements
b. ADNOC HSE Standards
c. Equipment datasheets and drawings
d. Project Specifications and standard drawings
e. Company Specifications
f. National / International Standards
System Particulars
Power Cables covered in this specification will be used on the following systems:
a. 220kV - 3 - phase, 3 wire, 50Hz, neutral solidly earthed.
b. 132kV - 3 - phase, 3 wire, 50Hz, neutral solidly earthed
c. 66kV - 3 - phase, 3 wire, 50Hz, neutral solidly or resistance earthed
d. 33kV - 3 - phase, 3 wire, 50Hz, neutral solidly or resistance earthed
e. 11kV - 3 - phase, 3 wire, 50Hz, neutral resistance earthed
Obsolescence
Not Applicable.
Design Parameters
Refer to Data Sheet
Service conditions shall be as per AGES-GL-02-001 Sections 5.6 (Environmental /Site Data) and 6.13 (cable sizing)
and used as basis for cable sizing.
Any more stringent site-specific conditions shall be indicated on data sheets. Soil thermal resistivity values
obtained by test and interpreted as per Geotechnical survey may be used in place of specified worst-case values,
provided they represent a true value of the material to be used for final installation (tested materials to be used for
backfill with understood compaction and water content).
Area Classification
Hazardous Area Classification and Equipment Selection shall be in accordance with AGES-GL-02-001 for
equipment selection.
Cables shall be suitable for installation in, or passing through, Potentially Explosive Hazardous Areas and shall be
in compliance with the relevant requirements of IEC 60079-14 Clause 9.
Cable entries and glanding/termination arrangements shall be in compliance with the relevant requirements of IEC
60079-14 Clause 10.
TECHNICAL REQUIREMENTS
The below sections provide specifications for differing cable voltages and installations. In cases where cables are
laid from process to non-process areas, underground to above ground areas etc., the more stringent specifications
shall be applicable. Cable runs shall not be provided with joints in order to match any applicable less stringent
area/installation requirements with reduced specification cables without specific approval from COMPANY.
6.1.1 The design and construction of the HV electrical power cables up to 33kV shall be in accordance with
the codes and standards as specified in Section 2.
For cabling in existing plants, design philosophies and installations of existing facilities shall be followed.
6.1.2 All HV electrical power cables shall have the conductor cores identified as follows:
a. Single core - black.
b. Three cores - red, yellow, blue
6.1.3 The colour of the outer sheathing for onshore HV cables shall be:
a. 33kV cables - Orange RAL 2004
b. 11kV cables - Red RAL 2002
c. 3.3kV & 6.6kV cables - Yellow RAL 1016
unless approved otherwise or as indicated on data sheets.
For fire resistant cable, orange straps shall be applied over the outer sheath for identification every 1
meter. This shall be not affected by the environment of installation.
6.1.4 The colour of the outer sheathing for Offshore HV cables shall be:
33kV, 11kV, 3.3kV & 6.6kV cables - Red RAL 2002 with marking to indicate voltage grade.
For fire resistant HV cable, the outer sheathing shall be Orange with embossing to indicate voltage grade.
6.1.5 The cables shall be capable of continuous operation at highest system voltage as specified with
maximum conductor operating temperature of 90°C and maximum temperature under fault conditions of
not more than 250°C.
6.1.6 Hydrocarbons resistant sheathed cables shall be used in plant areas and where spillage of oil or
hydrocarbons are expected.
Or
Cu / XLPE / AL/HDPE/PA /GSWA** / PVC
Offshore Installations:
Cu / EPR*** / SW4 / GSWB / LSHF****
Where:
PB* : Lead sheath cables or equivalent eco-friendly sheathing shall be used subject to
COMPANY approval for underground cables in hydrocarbon contaminated soil
GSWA** : For single core cables Tinned copper or AWA shall be used instead of GSWA
(see below section on Metallic Armour)
EPR*** or XLPE : Design philosophies and installations of existing facilities shall be followed, as
applicable.
Any specific requirements regarding cable construction shall be further detailed in the Project data sheets.
6.1.8 For installations requiring higher flexibility and smaller bending radius, braided armouring and higher
number of stranding of the conductors shall be used. In case of such requirements, suitable cable class
in accordance with IEC 60228 shall be indicated in the data sheets.
6.1.9 LSHF cables shall be installed in manned areas, confined spaces, etc. and where escape to an area with
clean air is not possible.
6.1.10 All offshore and onshore cables shall be either intrinsically flame retardant to IEC 60332 or fire resistant
to IEC 60331 as indicated in the data sheets.
6.1.11 Materials
Conductor
a. The cable conductors shall be class 2 (unless otherwise specified for flexible cables) round circular
stranded, annealed high conductivity copper (99.99% purity), laid up and rendered smooth and free
from defects likely to damage the insulation and shall in accordance with IEC 60228.
b. EVAPA insulated Cables shall be made of tinned annealed stranded copper conductor and XLPE
insulated cables shall be made of plain annealed stranded copper conductor.
c. Conductors shall be unbroken for full length. Spliced conductors are not acceptable.
Screening
The conductor screening and insulation screening shall be in accordance with subsection 7.2 & 7.3 of
IEC 60502-2 respectively.
Insulation
a. Offshore Installations:
High voltage power cables shall be insulated with ethylene propylene rubber (EPR).
b. Onshore Installations:
High voltage power cables shall be insulated with cross-linked polyethylene (XLPE) for onshore
installations.
Laying Up
The laying of cores of cables shall be as per IEC 60502.
Filler and binder materials shall be polyethylene or polypropylene or of equivalent non-hygroscopic &
nonfibrous. The bedding is required to ensure that the overall cable is robust and round in shape, without
internal gaps and of uniform cross section subject to allowable tolerances throughout the length of the
cable.
Inner Sheathing
For XLPE insulated cables, an inner sheath of extruded PVC compound shall be provided over the
bedding. It shall be resistant to ozone, dielectric discharge and surface tracking. The thickness of inner
sheath shall comply with Table 8 of IEC 60502-2 (Edition 3.0).
For EPR insulated cables, an inner sheath of CSP or EVA compound shall be provided over the above
bedding. If EVA is offered, then the material shall be equivalent or better than CSP, UV resistant, heavy-
duty heat and oil resistant.
For EPR cable inner sheath shall be HOFR type RS3 and the improved characteristics of SW4 in
accordance with BS 7655.
Alternate materials such as EVA (Ethylene Vinyl Acetate), type SHF2 in accordance with IEC 60092-539
360 and UV resistant, or equivalent can be acceptable.
For XLPE cables, an inner sheath of PVC compound (type ST2) shall be provided over the insulation
screen.
For all cables, inner sheath shall be flame retardant to IEC 60332-3-21/22.
Mica glass and polyester tapes shall be used where manufacturer considers necessary to meet the
technical requirements specified.
Separation Sheath
Suitable separation sheath shall be applied over the hydrocarbon resistant material.
Metallic Armour
a. The power cables shall be provided with armouring unless otherwise specified.
b. For XLPE cables, Armouring shall be single layer galvanized steel wires with synthetic tape for multi
core cables whereas aluminium wire or tinned copper armour shall be used for single core cables.
The same shall be finalized in the datasheets.
c. For EPR cables, armouring shall be corrosion resistant non-magnetic braided (tinned phosphor
bronze wire or equivalent) material for single core cables and Galvanized Steel Wire Braid (GSWB)
for multi-core cables.
d. The armour shall provide the mechanical protection for the cable. Also, the electrical conductivity of
the armour shall be such that it is capable of carrying the earth fault current.
e. Armour for cables rated 3.3kV to 33kV shall be provided in accordance with section 13 of IEC 60502-
2 (Edition 3.0 dated 2014-02).
Outer Sheath
a. The outer sheath shall be extruded over the armour.
b. The tolerance of overall cable diameter shall not be more than ±1mm.
c. For EPR insulated cables, if EVA is offered, then the material shall be UV resistant (ISO4892 or
equivalent), heavy duty, heat and oil resistant.
d. For XLPE insulated cables, an outer sheath of PVC (Type ST2) insulation, UV resistant (ISO4892 or
equivalent), heavy duty, heat and oil resistant and termite resistant.
e. The outer sheath shall be intrinsically flame retardant as per IEC 60332-3-21/22.
f. For LSHF cables, manufacturer shall offer his Standard material that, meets LSHF requirements
keeping on the retardancy property supporting documents to be submitted for review. HCL emissions
evolved during combustion shall be less than 0.5% by weight of material. The oxygen index of both
bedding and sheath shall not be less than 30. LSHF cables shall not be directly exposed to sun.
Shade shall be provided to prevent direct sunlight.
b. Cores of a three-core cables rated above 3.3kV and up to 33kV shall be assembled in accordance
with section 8 of IEC 60502-2.
6.1.14 Identification
a. Core/Phase Identification
For cable core colour Identification, refer section 6.1.2.
b. Cable Identification
The following information shall be marked on cable outer sheath every 5 meter along the entire length:
i. Manufacturer name,
ii. Number of cores,
iii. Conductor size,
iv. Insulation type,
v. Voltage grade,
vi. Year manufactured,
vii. Running length.
6.2.1 The design and construction of the electrical LV power, control and Insulated Earthing cables shall be in
accordance with the codes and standards as specified.
6.2.2 The colour of the outer sheathing for LV power cables shall be black.
6.2.3 All electrical LV power cables shall have the conductor cores identified as follows (any variations or
acceptable alternatives will be identified on data sheets:
a. Single core - red or black.
b. Two cores - red and black.
c. Three cores - red, yellow, blue for 3 phase services.
- red, black, yellow/green for single phase services.
d. Four cores - red, yellow, blue & black for 3 phase + Neutral.
- red, yellow, blue & yellow/green for 3 phase & earth.
e. Five cores - red, yellow, blue and black and yellow with green stripes for 3 Phase +
Neutral + Earth
f. Earthing cable/wire - green/yellow for Electrical earthing cable (Instrument Clean Earthing cables
shall be provided with green outer-sheath, and Instrument IS Earthing cables shall be provided with
green outer-sheath with blue coloured markings at its terminations).
g. Control cable (multicore) – white colour with black core numbers on the insulation every linear
metre.
The colour of the outer sheathing shall be black for flame retardant and orange for fire resistant cables.
6.2.4 The cables shall be capable of continuous operation at highest system voltage as specified with
maximum conductor operating temperature of 90°C and maximum temperature under fault conditions of
not more than 250°C.
6.2.5 Hydrocarbons resistant sheathed cables shall be used where spillage of oil or hydrocarbons are expected.
Offshore Installations:
Cu / EPR / LSHF*** / GSWA** / LSHF***
Where:
PB* : Lead sheath cables or equivalent eco-friendly sheathing shall be used subject to
COMPANY approval for underground cables in hydrocarbon contaminated soil
GSWA** : For single core cables AWA shall be used instead of GSWA
Any specific requirements shall be further detailed in the Project data sheets.
6.2.7 For installations requiring higher flexibility and smaller bending radius, braided armouring and higher
number of stranding of the conductors shall be used. In case of such requirements suitable cable class
in accordance with IEC 60228 shall be indicated in the data sheets. Cable specification for cables for
special applications requiring high flexibility, such as lifts or crane catenaries, shall be Approved by
COMPANY.
6.2.8 LSHF cables shall be installed in manned areas, confined spaces, etc. where escape to an area with
clean air is not possible.
6.2.10 All offshore and onshore cables shall be either intrinsically flame retardant to IEC 60332 or fire resistant
to IEC 60331 as indicated in the data sheets.
6.2.11 Materials
Conductor
a. The cable conductors shall be class 2 (unless otherwise specified for flexible cables) round circular
stranded, annealed high conductivity copper (99.99% purity), laid up and rendered smooth and free
from defects likely to damage the insulation and shall in accordance with IEC 60228.
b. EPR insulated Cables shall be made of tinned annealed stranded copper conductor and XLPE
insulated cables shall be made of plain annealed stranded copper conductor.
c. Smaller sizes shall be circular in formation. Larger conductors shall be shaped to produce a compact
design (i.e., sector formation). Multi-core cables having two cores or more shall have all cores of
uniform cross section.
d. Conductors shall be unbroken for full length. Spliced conductors are not acceptable.
e. Minimum size shall be as per AGES-GL-02-001 Section 6.13.5.
Screening
Not applicable for LV cables (For VSD to motors or heater thyristor control panels to process heaters,
screened cables shall be utilized).
Insulation
a. Offshore Installations:
Low voltage power cables shall be insulated with ethylene propylene rubber (EPR).
b. Onshore Installations:
Low voltage power cables shall be insulated with cross-linked polyethylene (XLPE) for onshore
installations.
Insulation shall be rated for 90°C maximum conductor temperatures.
c. Earthing cables
Earthing cables shall be single core, PVC sheathed, 0.45/0.75kV (IEC) or 600/1000V (BS) Grade.
Laying Up
The laying of cores of cables shall be as per IEC 60502-1. Non-hygroscopic fillers, binders etc. shall be
used. This is required to ensure that the overall cable is robust and round in shape, without internal gaps
and of uniform cross section subject to allowable tolerances throughout the length of the cable. The
materials for fillers & binders shall be compatible with the insulation materials.
Inner Sheathing
For XLPE insulated cables, an inner sheath of extruded PVC compound shall be provided over the laid-
up cores. The thickness of inner sheath shall comply with table 8 of IEC 60502-1.
For EPR cable inner sheath shall be HOFR type RS3 and the improved characteristics of SW4 in
accordance with BS 7655.Alternate materials such as EVA (Ethylene Vinyl Acetate), type SHF2 in
accordance with IEC 60092-539 and UV resistant, or equivalent can be acceptable.
For all cables, inner sheath shall be flame retardant to IEC 60332-3-21/22.
Mica glass and polyester tapes shall be used where manufacturer considers necessary to meet the
technical requirements specified.
Separation Sheath
Suitable separation sheath shall be applied over the hydrocarbon resistant material.
Metallic Armour
a. The power cables shall be provided with armouring unless otherwise specified.
b. Armouring for multi-core cables shall be single layer galvanized steel wires with synthetic tape
whereas aluminium wire armour shall be used for single core cables.
c. The armour shall provide the mechanical protection for the cable. Also, the electrical conductivity of
the armour shall be such that it is capable of carrying the earth fault current specified in data sheets.
d. Armour shall be provided in accordance with section 12 of IEC 60502-1 (Edition 3.0 dated 2021-02).
e. For EPR cables, armouring shall be corrosion resistant non-magnetic braided material for single core
cables and Galvanized Steel Wire Braid (GSWB) for multi-core cables.
Outer Sheath
a. The outer sheath shall be extruded over the armour.
b. The tolerance of overall cable diameter shall not be more than ±1mm.
c. The outer sheath shall be intrinsically flame retardant as per IEC 60332-3-21/22 and termite resistant.
d. For LSHF cables, manufacturer shall offer his Standard material that, meets LSHF requirements
keeping on the retardancy property supporting documents to be submitted for review. HCL emissions
evolved during combustion shall be less than 0.5% by weight of material. The oxygen index of both
bedding and sheath shall not be less than 30.
Identification
a. Core/Phase Identification
Conductor identification shall be by coloured insulation material (for Power) and core numbering (for
Control).
b. Cable Identification
The following information shall be marked on cable outer sheath every 5 meter along the entire length:
i. Manufacturer name,
ii. Number of cores,
iii. Conductor size,
iv. Insulation type,
v. Voltage grade,
vi. Year manufactured.
vii. Running length.
6.3.1 Specific requirements for PVC insulated single core cable (wire) for use in conduit (for lighting and
receptacle circuits in buildings) are:
Voltage grades - 450/750V (IEC) or 600/1000V (BS)
Conductor - Stranded annealed copper
Insulation - Extruded polyvinyl chloride (coloured Red, Yellow, Blue, Black, etc., as required).
General
The SUPPLIER Scope of Work shall include, but shall not be limited to, design, manufacture, inspection, testing,
preparation for shipment, special tools and supply of documentation and manuals, and other services.
SUPPLIER’S Responsibility
The SUPPLIER shall be responsible for the supplied equipment in every respect including design, selection of
materials and components, manufacturing and testing.
The SUPPLIER’s responsibility shall extend to his sub-contractors and sub-suppliers, if any.
The SUPPLIER shall be responsible for the production of all drawings and all documents related to the electrical
materials.
It shall be the SUPPLIER’s responsibility to furnish all items essential for the safe and satisfactory installation and
operation of the equipment.
The make and Country of Origin of all electrical materials shall be per approved Supplier list.
SUB-CONTRACTORS, SUB-SUPPLERS
The SUPPLIER shall assume unit responsibility and overall guarantee for the cables and associated equipment.
The SUPPLIER shall transmit all relevant purchase order documents including specifications to his SUB-
SUPPLIERS and Sub-Contractors.
It is the SUPPLIER'S responsibility to enforce all purchase order and specification requirements on his SUB-
SUPPLIERS and Sub-Contractors.
The SUPPLIER shall submit all relevant SUB-SUPPLIER and Sub-Contractor drawings and engineering data to
the CONTRACTOR.
The SUPPLIER shall obtain and transmit all SUB-SUPPLIER’S and Sub-Contractor warranties to the
CONTRACTOR/COMPANY, in addition to the system warranty.
MATERIAL CERTIFICATION
Not Applicable
General
Before leaving the SUPPLIER’S works, the cables shall be inspected and tested in accordance with the relevant
IEC or BS Standards as listed in Section A of this specification.
The SUPPLIER shall provide an Inspection and Testing Plan (ITP) at least 8 weeks’ notice prior to the testing date.
The ITP shall be submitted for review and acceptance by the COMPANY and include Witness and Hold points in
the programme for SUPPLIER, CONTRACTOR, and the COMPANY.
The COMPANY/CONTRACTOR or his nominee shall inspect the equipment and witness the required tests
indicated in the Requisition at the time the equipment is offered for final inspection.
A detailed test procedure of factory tests shall be submitted at least 3 months in advance of any testing, detailing
the proposed inspection, testing and witness testing programme throughout the design and build of the equipment.
Test certificates for each item of equipment shall be submitted prior to delivery for COMPANY acceptance.
With reference to the above, the term “item of equipment” refers to all materials supplied e.g., a drummed length
of cable, termination or joint kit, special tools etc.
Test Reports
Test reports in accordance with the relevant IEC/BS standards including the following shall be submitted to
COMPANY.
a. The design values
b. The tolerance values
c. The real values as measured, including, if any, the intermediate values causing provisional refusal.
SUPPLIER shall compile the records of all inspections and tests including routine tests and special tests in one
document and shall submit as part of technical documentation.
Type Tests
12.3.1 SUPPLIER shall submit the type test certificates for each cable type for tests as required in the applicable
IEC and BS standards
12.3.2 Test certificates shall be from an internationally recognised, independent testing authority, and shall be
subject to COMPANY acceptance.
12.3.3 Unless any specific tests have been specified or indicated in the data sheets, type tests shall not be
witnessed. However, the following type test certificates for tests carried out against the applicable IEC
60502-1 or IEC 60502-2 test regime shall be made available to COMPANY and submitted with the Bid
for all cable types:
a. Oil immersion test
b. Ageing test
c. Water absorption
12.3.4 In addition, for HV cables the following type test certificates for tests carried out against the applicable
IEC 60840 or IEC 62067 test regime shall be made available to COMPANY:
a. Tensile Bending test,
b. Coiling Test,
c. Tan δ measurement (IEC 61620),
d. Heat Cycle test,
e. Shrinkage test for XLPE insulation,
f. Lightning Impulse test,
g. AC Voltage test for 4 hours,
h. Partial Discharge Test (IEC 60885-3),
i. Resistivity of semi-conducting screens and sheaths (IEC 62067),
j. Non Electrical type tests in accordance with IEC 60502 (for cables up to 36kV)
k. Water Penetration test on power core in accordance with CIGRE Electra 189.
Routine Tests
12.4.1 The required routine tests, test conditions and acceptance criteria for the cables shall be in accordance
with the latest edition of IEC-60502-1 for cables up to 3kV, IEC 60502-2 for cables from 6kV to 33kV and
IEC 60502-4 for cable accessories up to 33kV. Routine and Sample tests (Note sample tests are to be
separately requested on data sheets) shall be carried out on each type and size of cables as per the
agreed ITP.:
a. High Voltage Test,
b. Continuity and Resistance Test for Conductor/Screen,
c. Armour Resistance Test,
d. Partial Discharge Test (for HV cables),
e. Thickness of Insulation,
f. Thickness of Non-metallic sheaths,
g. Insulation Resistance (Voltage) Test,
h. Hot set test for XLPE insulations and elastomeric sheaths,
i. Check for correct colour and markings on insulation and sheath,
j. Measurement of external diameter,
k. Visual check on general appearance and finish,
l. Check for correct markings on drums,
m. Dimensional check (including over and under armour diameters).
n. Flame-retarding tests for sheath (sample test as per datasheet)
o. Oil Immersion test for sheath (sample test as per datasheet)
p. Ageing test for sheath (sample test as per datasheet)
q. Fire tests for all fire resistant cables (sample test as per datasheet)
12.4.2 The following routine tests shall be completed on all cable accessories:
a. Visual inspection of overall finish, painting, welds, metal works, lifting lugs, terminal fastening,
insulation, terminations, fixings, etc.
b. Dimensional checks – mounting, terminals, centre lines, overall dimensions and weight.
c. Check of the rating plate, nameplate and any additional markings and labels required by this
document.
d. Insulation tests.
Additional Tests
If Required, to be stated in Material Requisition and/or datasheet
Special Tests
If Required, to be stated in Material Requisition and/or datasheet
Site Tests
Refer to AGES-SP-02-015, Field Commissioning of Electrical Installation and Equipment, for requirements for site
testing of cables and accessories. All site tests are to be in accordance with IEC standards and in agreement with
cable or accessory MANUFACTURER with regards test Voltage magnitude, durations and Frequency of test
voltage.
SPARE PARTS
a. The SUPPLIER shall propose:
i. A list of commissioning spare parts (if applicable for cable accessories)
ii. A list of 2 years operation spare parts (if applicable for cable accessories)
iii. A list of special tools required for erection, commissioning and maintenance
b. Special tools required for drum handling, cable pulling, testing, commissioning and maintenance
shall be shipped together with the cables and accessories.
c. Each spare part shall be separately packed and clearly identified for storage management.
Painting
14.1.1 Surface preparation and painting for cable accessories shall be in accordance with the COMPANY
standard.
14.1.2 Alternatively, SUPPLIER may propose the standard for enhanced protection against corrosion in outdoor
climates. The paint system applied shall provide adequate protection against the adverse effects of the
climatic conditions specified. Full details of SUPPLIER'S painting specification shall be provided with the
proposal for COMPANY approval.
14.2.1 Preparation for shipment shall be in accordance with the SUPPLIER'S standards and as noted herein.
SUPPLIER shall be solely responsible for the adequacy of the preparation for shipment provisions with
respect to materials and application, and to provide equipment at the destination in ex-works condition
when handled by commercial carriers.
14.2.2 Adequate protection shall be provided to prevent mechanical damage and atmospheric corrosion in
transit and at the jobsite. Equipment and materials shall be protected to withstand ocean transit and
extended period of storage at the job site for a minimum period of 18 months. Equipment shall be
protected to safeguard against all adverse environments, such as: humidity, moisture, rain, dust, dirt,
sand, mud, salt air, salt spray, and seawater.
14.2.3 Preparation for shipment and packing will be subject to inspection and rejection by
COMPANY’S/CONTRACTOR’S inspectors. All costs occasioned by such rejection shall be to the
account of the SUPPLIER.
14.2.4 After inspection and test, equipment shall be completely free of water and dry before start of preparation
for shipment.
14.2.5 Cables shall be drummed in maximum continuous lengths on non-returnable cable drums. Cable end
caps shall be provided 10 each per drum.
14.2.6 Cables ends shall be sealed and fixed to the drum. Cable drums shall be fitted with battens, fixed around
the entire periphery of the drum.
14.2.7 All cable drums shall have their identification reference clearly stencilled on the outside of both flanges.
14.2.8 Drum identification labels shall be permanently attached on the outside and inside of the drum flange.
Labels shall be stainless steel and give the following information:
a. Drum identification number
b. Voltage grade
c. Cable construction (i.e. XLPE, LC, PVC SWA, PVC)
d. Number of cores and cross-sectional area
e. Cable Length
f. Total Drum Weight (gross weight in kg)
g. Purchase Order number and item number
h. Project Name
i. MANUFACTURERS name, job number and factory reference
j. Temperature Rating
14.2.9 In addition to the information required by the specified standards, the following information shall be
marked every one metre along the entire cable length on the external surface of the outer sheath.
a. Number of Cores
b. Size of Conductor
c. Voltage rating
d. MANUFACTURER'S name and cable type
e. Stock code number (COMPANY shall advise stock code philosophy)
f. The drum progressive length of cable at every meter (zero point being the cable end at its inner coil
on the cable drum)
g. Year of manufacture
Example: 4 Core 25 mm2, 1kV grade, XYZ Company, Type ABCD, xxx code, yyy meter, 2017
COMMISSIONING
The requirements for Commissioning shall be included in the Material Requisition document.
TRAINING
The requirements for Training shall be included in the Material Requisition document.
General
SUPPLIER shall submit the type and number of drawings and documentation for CONTRACTOR’S authorization
or information as listed in the Material Requisitions and Purchase Orders.
Schedule of documents and data submittal shall be as agreed in the purchase order.
Comments made by CONTRACTOR on drawing submittal shall not relieve the SUPPLIER of any responsibility in
meeting the requirements of the specifications. Such comments shall not be construed as permission to deviate
from requirements of the Purchase Order unless specific and mutual agreement is confirmed in writing.
Each drawing shall be provided with a block in the bottom right-hand corner incorporating the following information:
a. Official trade name of the SUPPLIER.
b. SUPPLIER'S drawing number.
c. Drawing title giving the description of contents whereby the drawing can be identified.
d. A symbol or letter indicating the latest issue or revision.
e. Purchase order number and item tag numbers.
Revisions:
a. Document and drawing revisions shall be identified with symbols adjacent to the alterations.
b. A brief description of each revision shall be given in tabular form.
c. If applicable, the authority and date of the revision shall be listed. The term “Latest Revision” shall not be
used.
All documents shall show the relevant order number, item tag numbers and SUPPLIER’S references and shall be
distributed as specified in the purchase order documents.
Graphic symbols for electrical diagrams shall be according to IEC 60617-DB. Device code numbers shall be as
per ANSI C-37.2 -1996.
All documents and drawings shall be in English.
Installation, operating and maintenance manuals shall be arranged as follows:
a. The front cover, spine and inside page shall state the purchase order number and SUPPLIER’S reference
number.
b. The inside front page shall carry an index listing the contents of each section of the manual.
c. Individual sections shall be completed and shall refer to the equipment actually supplied.
d. Published data shall also be included, including published data for bought-in items.
e. Full detail for installation, testing and commissioning shall be included.
f. Recommended test data shall be stated, covering initial and also regular testing shall be given. For
example, high voltage AC or DC test values.
g. Items requiring regular inspection, checking, testing and maintenance shall be listed and the time scale
clearly indicated.
Required Documentation
The SUPPLIER shall provide, as a minimum, the following documentation relevant to Cables and accessories in
English language:
With Project
Document
Bid Documentation
17.3.1 The following data shall be furnished (by completion of data sheets or provision of catalogue data) by
the SUPPLIER/MANUFACTURER together with respective tolerances where applicable:
h. Insulation thickness
i. Diameter under armour
j. Diameter over armour
k. Overall Diameter
l. Current rating in air and ground for the ambient conditions specified.
DATASHEET TEMPLATES
Data sheets for Cables and Accessories shall be inserted and decided by COMPANY
Data sheet (Document number) TBA.
STANDARD DRAWINGS
TBA
SECTION E – APPENDICES
22.1.1 Underground Onshore Installations (in process areas subjected to hydrocarbons contamination):
Cables shall be to IEC 60840, Single Core, with the following construction
Cu / XLPE / PB* / MDPE / AWA / PE
Or
Cu / XLPE / PVC / CCA / PVC / AWA / PE
Or
Cu / XLPE / AL/HDPE/PA / AWA / PE
Where:
PB* : Lead sheath cables or equivalent eco-friendly sheathing shall be used subject to
COMPANY approval for underground cables in hydrocarbon contaminated soil
Conductors
The 66kV and 132kV cables shall have cross sectional area for meeting the prospective fault current for
1 second unless otherwise specified in the data sheet.
For all cables, conductors shall be class 2. Cable conductors shall be of high conductivity, Compacted
stranded plain annealed copper with circular or shaped cross-section as per IEC 60228. The conductor
shall be free from metallic and foreign particles, which may contaminate the insulation or cause high
stress points.
The strands before shaping shall be smooth, uniform in quality, free from scale, inequalities, slits, splits,
and other defects. The plain annealed copper shall be filled with water-blocking semiconducting
compound. The water swelling tapes around each layer of conductor wires to form a water barrier to
prevent water penetration along the conductor in case the cable is broken. A radial water barrier over the
conductor alone is not acceptable. Typical minimum thickness of the water swelling tapes is 0.2mm.
The conductor screen shall consist of a binder tape applied over the conductor and a layer of black
extruded super-smooth, semi-conducting compound which shall be firmly bonded to the inner surface of
the insulation.
The minimum thickness of the extruded conductor screen shall be as specified in the Datasheet.
The outer surface of the conductor screen shall be cylindrical, smooth, and free of protrusions and
irregularities. The outer surface of the conductor screen shall be firmly and continuously bonded to the
inner surface of the insulation and shall have no tendency to separate from the insulation due to the
effect of bending during installation, load cycling and short circuit under service conditions.
The resistivity of the extruded conductor screen shall not exceed 1000 Ω-m at 90°C.
b. Insulation
The insulation shall be homogenous extruded ultra-clean cross-linked polyethylene (XLPE) complying
with the requirements as specified in the relevant latest IEC standard.
The insulation shall be free from micro voids, contaminants, protrusions and moisture as specified in the
above standard.
The lowest measured insulation thickness shall not fall below 90% of nominal insulation thickness.
The thickness of the insulation shall be as specified in the data sheets.
c. Insulation Screen
The insulation screen shall be Extruded Semiconducting compound and water blocking semi-conductive
tape over the insulation screen.
The resistivity of the extruded insulation screen shall not exceed 500Ωm at 90°C. The minimum thickness
of the insulation screen shall be as specified in the Datasheet.
The inner surface of the insulation screen shall be smooth and free of protrusions and irregularities.
The inner surface of the insulation screen shall be firmly and continuously bonded to the outer surface
of the insulation and shall have no tendency to separate from the insulation due to the effect of bending
during installation, load cycling and short-circuit under service conditions.
Separation sheath
Inner sheath or core sheath shall be of semiconducting Polyethylene and lead alloy sheath according to
BS EN 12548.
The minimum thickness of the lead sheath shall not fall below 5% +0.1mm of the nominal thickness.
The sheath and screen shall be capable of carrying, without damage, the fault current for one second
under the most severe fault condition. Lead alloy sheaths shall also have good creep ductility to provide
the necessary mechanical strength for the cable due to the effect of bending during installation, load
cycling and short circuit under service conditions.
Lead or aluminium sheathing shall be of uniform thickness and homogeneous construction, close fitting,
seamless and free from porosity or defects and remain stable in service. Composition of sheathing and
its thickness shall be suitable for resisting fatigue due to vibration and the construction shall be capable
of withstanding the external and internal mechanical stresses likely to be encountered during
manufacture, testing, transport, installations and service without puncture, fracture or stress cracking.
The lead alloy, corrugated aluminium or AL/HDPE/PA sheath shall have excellent corrosion resistance
and provide radial protection from moisture, hydrocarbon and acid/alkali chemical ingress.
Bedding
Bedding for Armouring shall be semiconducting nylon tapes. Thickness of bedding & diameter over
bedding shall be specified in data sheet.
Armouring
66kV and 132kV cables shall be provided with Aluminium Wire Armour. The armour shall provide the
mechanical protection for the cable. The electrical conductivity of the armour shall be such that, it is
capable of carrying the earth fault current specified in data sheets.
Outer Sheath
Outer sheath of cable shall be extruded layer of Low smoke halogen free (LSHF) intrinsically flame
retardant with a thin semi-conductive layer outside. Outer sheath shall be black colour. The outer sheath
material shall be semiconducting PE (MDPE) with all required properties for tensile strength, robustness,
installation-bending radius etc. Cables shall meet the requirements of IEC 60332. The outer sheath shall
be of UV resistant and Termite resistance properties. The oxygen index shall be of 30 or a numerically
higher value. The outer sheath shall have a graphite smear layer applied to enable sheath testing.
22.2.1 Underground Onshore Installations (in process areas subjected to hydrocarbons contamination):
Cables shall be to IEC 62067, Single Core, with the following construction
Cu / XLPE / PVC / PB* / PVC / AWA / HDPE
Or
Cu / XLPE / PVC / CCA / PVC / AWA / HDPE
Or
Cu / XLPE / AL/HDPE/PA / AWA / HDPE
Where:
PB* : Lead sheath cables or equivalent eco-friendly sheathing shall be used subject to
COMPANY approval for underground cables in hydrocarbon contaminated soil
Conductors
The conductor shall consist of plain segmental annealed high conductivity copper wires of 99.99% purity,
complying with the class 2 requirements of IEC 60228. The conductor shall be clean and free from
metallic and foreign particles, which may contaminate the insulation or cause high stress points.
The copper wire before shaping shall be smooth, uniform in quality, and free from scale, inequalities,
spills, splits and other defects.
The term “annealed” signifies that the wire can stand elongation of at least 15 percent without fracturing
before stranding, the test piece being not shorter than 150mm and not longer than 300mm.
When made up from shaped wires the conductor shall be clean and uniform in size and shape and its
surface shall be free from sharp edges and unless otherwise approved shall be taped with a layer of
conductive or semi-conductive material.
Not more than two joints shall be allowed in any of the single wires forming each length of conductor,
and no joint shall be allowed within 300mm of any other joint in the same layer. The jointing of wires shall
be made by brazing, silver soldering or electrical welding. No joint shall be made in the wire after it has
been formed up into the required length.
The cable and conductor shall be watertight both in axial and radial direction because of water table.
Provision shall be made to prevent the longitudinal passage of water. This shall be achieved by the
application of water swelling tapes around each layer of conductor wires to form a water barrier to prevent
water penetration along the conductor in case the cable is damaged. A radial water barrier over the
finished conductor alone is not acceptable.
b. Insulation
The insulation shall consist of homogeneous extruded super-clean cross-linked polyethylene (XLPE)
complying with the requirements as specified in the relevant latest IEC Standard.
The insulation shall be free from micro voids, contaminants, protrusions and moisture as specified in the
above standard.
The insulation raw material should be of super clean class.
The insulation shall also be explicitly resistant to the formation of water trees.
The thickness of the insulation shall be as specified in the Technical Data Sheets.
The average thickness of the insulation, when determined by the method described in Section 11
“Inspection and Tests” shall not be less than the minimum value stated in the data sheet. The thickness
at any place may however be less than the specified nominal value provided that the difference does not
exceed 10 percent of the specified nominal value.
The thickness of the semi-conductive screen or any separator on the conductor or over the insulation
shall not be included in the thickness of the insulation.
Particular attention shall be given to insulation, voltage stress with particular reference to installation
conditions and ingress and migration of moisture so as to ensure a long service life.
c. Insulation Screen (non-metallic)
The insulation screen shall consist of an extruded layer of black thermosetting super-smooth semi-
conducting compound applied directly over the insulation.
The thickness of the insulation screen shall be as specified on the Technical Data Sheets.
The inner surface of the insulation screen shall be smooth and free of protrusions and irregularities.
The inner surface of the insulation screen shall be firmly and continuously bonded to the outer surface
of the insulation and shall have no tendency to separate from the insulation due to the effect of bending
during installation, load cycling and short-circuit under service conditions.
The volume resistivity of the extruded insulation screen shall not exceed 500 Ω-m at 90ºC.
d. Manufacturing Process of Conductor Screen, Insulation and Insulation Screen
The conductor screen, the insulation and the insulation screen shall be mutually compatible and shall be
continuous triple extrusion and completely dry cured by a common head in a common manufacturing
process. For cooling after vulcanization, dry cooling is preferred. Details of the characteristics of the
material and the curing process shall be set out in the data sheet.
To reduce the methane content of XLPE a heat treatment shall be carried out after curing for minimum
7days at 75ºC. The Cable Manufacturer shall provide evidence to have degassed the cable.
The extruded conductor screen, insulation and insulation screen shall be manufactured to the highest
standard of concentricity, diameter roundness and longitudinal diameter, stability.
The Cable manufacturer shall provide a detailed description on the extrusion, curing, cooling and heat
treatment processes.
Bedding Tape
The core shall be taped overall with semi-conducting tape(s) to prevent mechanical damage to the cable
core during manufacture and in service.
Cable fillers of polypropylene (PP) or equivalent shall be used to fill the voids in the cable and ensure a
well-rounded finished product.
Metallic Sheath
The water impervious metallic sheath shall preferably consist of a seamless and continuously extruded
tube of lead alloy, which shall meet the requirements of BS EN 12548 and BS 3909 standards. A thin
layer of bitumen shall be applied over the sheath. Other alternatives such as Continuous Corrugated
Aluminium or Poly-Al Laminate Sheath may be proposed for acceptance by COMPANY provided the
alternative is supported by good technical and commercial considerations.
The metallic sheath shall be of best quality and shall be tightly extruded over the water-blocking layer.
The metallic sheath shall be impervious to moisture and free from defects and impurities such as oxides
that could give rise to failure under working conditions.
Lead alloy sheaths shall also have good creep ductility to provide the necessary mechanical strength for
the cable due to the effects of bending during installation, load cycling, and short circuit under service
conditions.
The minimum thickness of the sheath when determined by the appropriate method described in the IEC
test standards shall not be less than the appropriate value stated in the data sheet.
When carrying the specified short-circuit current the integrity and performance of any part of the cable
shall not be deteriorated due to the rising temperature. The sheath temperature shall neither exceed the
allowable temperature of the insulation nor of the outer sheath covering, whichever is the lower.
The metallic sheath thickness and its composition shall be sufficient to ensure adequate mechanical
strength and to resist fatigue caused by vibration.
The minimum thickness of the lead or Aluminium sheath shall not fall below 5%+0.1mm of the nominal
thickness.
The sheath and screen shall be capable of carrying, without damage, the fault current for one second
under the most severe fault condition. The current density for the type of sheath used shall also be stated
in the data sheet.
The Cable manufacturer shall prove by calculation that the metallic sheath and the insulation screen
copper wires can withstand the short circuit current rating specified in the data sheet.