el t a LOW VOLTAGE CABLE Note: Contents of that document is same as QGII specification QGX/20/00/EL/TS/NA/032-Rev.E1 FOR CONSTRUCTION T-(0203 1 _| issue for Construction ERR A Rado Okazaki |len.20.05 MARK DESCRIPTION BY__| cHKD | APVD_| DATE REVISIONS ‘CLIENT QATAR GAS 3&4 PROJECTS PROJECT : QATARGAS 3&4 ONSORE PROJECT JOB NO. DOC NO. _:_ QCS/SO/00/ELTSINA/032fr" Date : Jan. 23, 2005 LOW VOLTAGE CABLE QCS/SO/OD/ELTSINAIO32 Rev: Et Page 2 of 9 INTENTS, 1.0 SCOPE. 2.0 DEFINITIONS. 3.0 REFERENCES...... 4.0 GENERAL... 5.0 CONDUCTORS......... 6.0 INSULATION. 7.0 ARMOR 8.0 JACKETS... 9.0 INSTALLATION REQUIREMENTS .... 10.0 TESTING AND INSPECTION.. 14.0 SHIPPING 12.0 DOCUMENTATION...Ld Date : Jan. 23, 2005 LOW VOLTAGE CABLE QCS/S0/00/ELITS/NAI032 Rev: Ef Page 3 of 9 10 SCOPE 20 3.0 4.0 44 42 ‘This SPECIFICATION shall define the minimum technical requirements for Low Voltage Power and Control Cable rated less than 1000 V to be used on the Qatargas--LNG-Pisnt 3&4 Onshore Project, DEFINITIONS Preliminary Definitions Lv: Low Voltage REFERENCES INTERNATIONAL ELECTROTECHNIGAL COMMISSION (IEC) ‘The Low voltage power end Control cables shall referred to the latest following IEC standards. The latest edition and addenda up to Year 2003 shall apply without updating edited year, litle and number. 1EC 60028 _Internationel standard of resistance for copper IEC 60228 Conductors of insulated cables. 1EC 60287 _Ellectic cables - Caloulation of the current rating IEC 60331 Tests for electric cables under fire conditions - Circuit integrity IEC 60332 Test on electrical and optical fibre cables under fire conditions (with part 1 and part 36) IEC 60446 Colour identification insulated and non-insulted core IEC 60502 Power cables with extruded insulation and their accessories for rated voltages from 4 KV (Um = 4,2 KV) up to 30 kV (Um = 36 KV) 1EC 60540 Test method for the insulation and sheaths of electric cables and cords (elastomer and thermoplastic compound) IEC 60754 —_Test on gases evolved during combustion of materials from cables IEC 80811-1 fo 4Common test methods for insulating and sheathing materials of electric cables ‘and optical cables 1EC 60885 _Electrical test methods for electric cables, PROJECT DOCUMENTS QGX/20 QCS/SOIOVIELITSINAI003 Electrical Design Criteria QGX/20 QCS/SQINUIELITSINAIO51 Testing and Commissioning of Electrical System GENERAL, The references and requirements of Q@GX20 QCS/SO/OO/ELITSINA/O03 shall apply to this specification. ‘The construction and testing of cables shall comply with IEC 60331, 60502, 60754, 60811 and 60885. The more stringent requirements of either document shall apply, unless otherwise approved by COMPANY.aa a lh Ge aa Date : Jan. 23, 2005. LOW VOLTAGE CABLE QCS/SO/OD/ELITS/NAIO32, Rev: Et Page 4 of © 43. Sie Conditions 44 45 48 Ar 48 5.0 64 52 a. For outdoor locations Maximum ambient air temperature: 49°C Minimum ambient air temperature: 4°C Maximum relative humidity: 100% at all temperatures In addition, windbiown send, dust storms and salt laden air will be present. For indoor locations Maximum ambient air temperature: 40°C Minimum ambient air temperature: 10°C Maximum relative humidity: 90% at all temperatures Prior to operation, the equipment may be subject to the conditions described for outdoor locations. The design life of cable shall be for a 30 years plant operating life. The selection of types of wire and cable to be installed shall be based upon the following considerations; a Conductor material Voltage level and earthing of the syster Atmospheric conditions, ambient temperatures, and physical exposure in which the wire and cable will be applied Availability Code requirements Available types of cable terminators Method of installation Quality and degree of importance of service i. Classification of area in which the wire and cable willbe installed ‘The sizing of wire and cable for load and voltage drop considerations shall be in accordance with document No.-Q&X/29 QCS/S0/00IELITSINA/O03. Where portions of wire and cable runs are exposed to temperatures in excess of the design ambient temperalure, or where raceway or cable tray runs have been fireproofed, the wire and cable ampacities shall be derated. Critical relaying, and control cables shall be flameproof where there is a possibilty that a cable failure may damage other cables. conpucToRS Copper, stranded class 2 (IEC 60228) conductors shall be used for all LV cable. ‘The minimum conductor size for 240V lighting and receptacle circuits shell be 2.5mm* stranded copper. For precautions to be taken when using stranded conductors for lighting and receptacle wiring, see paragreph 9.1.7. Power cable conductors shall be made up of annealed stranded high conductivity copper wires in concentric layers. Smaller sizes may be circular in profile but larger conductors shail be shaped oroT Date 1 dan. 23, 2005, LOW VOLTAGE CABLE QCS/SO/00/ELITSINAIO32 Rev EI Page 5 of 9 62 63 64 65 66 66.4 66.2 663 a7 70 TA 12 tightly compacted to reduce their physical size. Unless otherwise approved by the COMPANY, cables up to 185mm? conductor size shall be 3 cores (3/c) and cables larger than 185mm? shall be single core (1/c). ‘The minimum conductor size for single-conductor general control wiring is 2.5mm* stranded copper. ‘The recommended minimum conductor size in mult-conductor cables for low-energy control wiring shall be 4.5mm? stranded copper. For supervisory control wiring, the conductor shall be sized to meet the requirements of the connected ‘equipment and shall be in accordance with the vendor's recommendation. ‘The minimum conductor size for low-voltage power wiring shall be 4mm? stranded copper. ‘Conductors 1.5mm? and larger shall be stranded to facilitate installation and to resist damage from vibration. INSULATION The cable insulation shall be extruded thermosetting cross-linked polyethylene (XLPE), rated for 90°C continuous operating conductor temperature and 250°C temperature under short circuit conditions. To avoid atmospheric contamination the insulating extrusion process shall use cleanest grade of XLPE conveyed from sealed boxes to sealed extruder hopper. ‘The LV cabie insulation shall be rated for the following voltage levels. Insulation shall meet or ‘exceed the electrical and physical requirements of the applicable standard. System voltage Voltage Rating Uo/U Applicabie standard atv 0.6/1.0KV IEC 60502 Cores to be identified by color up to and including 4 cores and by number for 5 or more cores. ‘The cores of 3 cores power-cable shall be color coded red, yellow and blue for phase identification. The fourth core shall be color coded black or green. Single core cable insulation shall be black or red. Multi Core Cable Assembly The interstices between the cores of muifi core cable shall be filled with @ non-hygroscopic filler devoid of air spaces and bound together with an inner sheath or tape wrapping and a layer of extruded PVC. The cores of all multi core cables having 2 or more cores shall be laid up with a right hand direction of lay, Alternate directions shall be used for successive layers of multi core control cables. Multicore contro! cables shall contain odd numbers of cores, made of 1.5mm? insulated copper conductors (seven strands of 0.6mm each). ‘The earthing conductor shall be colored green with yellow stripes. ARMOR Cables shall have a layer of galvanized steel wire (andlor braid) armor applied over the binder tape (6° the layer of PVC bedding) around the 3 cores. Mechanical protection for single core cables shall be provided with an armor of aluminum wires, applied over bedding of extruded PVC.LOW VOLTAGE CABLE QCSISOINU/ELITSINAIOS2 Page 6 of 9 8.0 84 82 83 84 9.0 94 944 942 913 91.4 94.5 916 JACKETS, Armored cabie shall be protected by @ PVC oversheath over the armor to prevent corrosion of the metallic armor. The oversheath shall be sunlight-esistent, oll and water-resistant, gas/vapor tight, black-coloured and flame-retardant (Cat-B in IEC 60332-3-23), ‘Armored cable shall have an overall thermoplastic jacket under the armor. Where the highest degree of protection from solvents and other materials deleterious to the cable insulation is required, the use of a lead sheath instead of the overall thermoplastic jacket under the ‘armor, as noted in paragraphs 8.2 should be considered. Following information shall be stamped or embossed on the over-sh cable, at intervals of not more than 1m; + Cable insulation type = Voltage level - Number and size of conductors along the length of the - Remaining length meter - Manufacturer's name - Year of manufacture INSTALLATION REQUIREMENTS: General All wire and cable installations shall be in accordance with the requirements of IEC and with local codes and regulations. The radii of cable bends shell equal or exceed the minimum values, specified by the vendor. Pulling tensions and sidewall pressures for wire and cable shall not exceed the maximum values specified by the vendor. The vendor's limitations on pulling cable at low ambient temperatures shall not be compromised ‘Taps and splices of LV wire and cable shall conform with the following specific requirements; 2, Taps and splices in branch-circuit wiring for lighting and convenience receptacles shall be minimized, especially in areas of high moisture content. Where unavoidable, wire connectors consisting of an insulator cap with a spring or set-screw insert may be used for this application. These connectors shall be taped to prevent entry of moisture. b. _ Pigiailtype taps and splices shall be made only in accessible ebovegrade locations and in boxes and conduit outlet bodies sized in accordance with IEC. c. Generally, power conductors shall be installed without splices between terminating points. Where splices are deemed unavoidable and are approved by COMPANY, straight (in-line) splices using two-way compression connectors shall be used. d. Power conductor splices shall be accessible for inspection, and their locations shall be recorded. e. The joining of more than 2 control conductors shall be made only at terminal boards, preferably those that are located on equipment or panels. These connections shall be accessible and identified for checking individual conductors, ‘Where conductors for control wiring and instrumentation power supply wiring are fo be connected toDate LOW VOLTAGE CABLE QCSISOIOOIELITSINAIO32 : Ef Page 7 of 9 922 9.23 924 925 926 binding-screw terminal boards, the conductors shall be provided with self-insulated, ring or forkec-tongue pressure terminals. The terminals shall be attached with a compression too! recommended by the terminal manufacturer. ‘The use of stranded conductors for wiring receptacles, lighting switches, and related devices requires special attention to the terminations. Receptacles and switches shall have extemal back-wiring clamps with an antrotational strand containment feature that bundles the conductor strands to ensure reliable connections. Circuit separation for different circuits and classes of services shall conform to the following specific requirements; a. The installation of motor power and control conductors in raceways shall be in accordance with the requirements of document No.-QGX/20 QCS/S0IOOIEL/TSINA003. b. The installation of direct burial armored cable for different services shall be in accordance with the requirements of document No.-@GX/20 QCS/S0I00/ELITS/NA/O03. Conductors for one or more lighting branch circuit may be run in common raceway. d. Power system control, metering, instrument, alarm, and relaying circuits associated with a particular piece of electrical equipment rated GOOV or less (such as a transformer or motor) may be routed in @ common raceway, enclosure, or cable. However, all conductors shall have an insulation voltage rating equal to or higher than the highest circuit voltage rating of any conductor within the common raceway, enclosure, or cable. Furthermore, noise interference between circuits shall not be a problem. fe. Substation contro! circuits associated with @ single power source may be routed in a ‘common raceway or cable, Station control circuits associated with primary-selective, secondary-selective, or spot-network substations that have alternate power sources shall be separated according to their related power source. Differential relay circuits be kept separate from other circuits. f. Telephone circuits shall be routed in separate raceways. Subject fo COMPANY approval and the specific requirements of IEC, telephone and power-limited signal circuits may be routed in the same raceway or cable support. Cables and splices shall be arranged and supported to allow visual inspection and to prevent excessive tension and pressure on the cable sheath and insulation. Special Consideration of Wiring Design When planning cable routes, consideration shall be given to possible interference with piping and other equipment and to cable damage that may occur through normal facility operations, such as traffic, maintenance, and the release of corrosive materials. Cabies shall be run between terminating points in one continuous length, wherever practical A minimum 305mm spacing shall be maintained between cables and high-temperature surfaces. Where necessary to route cables closer to such surfaces, a high-reflectance thermal barrier shall be installed between the cables and the surface. Where practical, cables shall enter outdoor boxes end equipment enclosures from below to prevent entrance of water into the enclosures. Cables entering outdoor boxes or enclosures from above shall be provided with terminators specifically designed to prevent entrance of water. ‘Armored cables that are to be direct buried shall be installed in accordence with the requirements of document No-OGX20 QCS/S0/DO/ELITSINA/03, Conductors and cables trenches containing multiple circuits shall be securely tagged with permanent markings for circuit identification,aa me Gu Saw aS Date: Jan. 23, 2005 LOW VOLTAGE CABLE QCS/SOIOOIELITSINAIO32 Rev: Et Page 8 of 9 10.0 TESTING and INSPECTION 10.1 Routine Tests 40.1.1 Routine tesis shell be performed on every crum of completed cable to ensure that the cable complies with the requirements of IEC 60502, 60811 and 60885. 10.1.2 Asa minimum, the following tests on complete cables shall be carried out, - Conductor resistance measurement = Voltage test on insulation - Partial discharge test 10.1.3 Manufacturing tolerance on drum cable length shall be -0%. 10.2 Sample Tests 10.2.1 Tests shail be carried out on samples of completed cable to verify that the finished cable meets the design specification, 10.2.2 Sample tests required are; = Hot set test for the insulation ~ Shrinkage fest on insulation 11.0 SHIPPING 11.1. The cable shall be supplied in non-returnable reals, lagged with wood, with suitable export packing 11.2. The cable ends shall be sealed and capped with heat-shrinkable caps. 44.3 Cable reels shall camry stainless steel labels securely attached to both flanges of the reel and plainly stating the following information; - CONTRACTOR's purchase order number and item No. ~ Shipping length of cable on reel - Number, type and size of conductors = Voltage rating ~ Shipping weight of the reel - Cable weight in kgimeter - CONTRACTOR's Drum No. ‘Additionally, cable wind direction and end mark shall be indicated on outer flange faves of the reel 12.0 DOCUMENTATION A data sheet for each type of cable shall be submitted by the manufacturer. “The vendor shall submit the following data with the proposal as minimum; 2. Weights and dimensions for cable (overall, over armor, under armor, conductor and thickness of insulation) b. Shipping weights and dimensions c. Recommended bending and training radius for each size and voltage classLOW VOLTAGE CABLE QCSISOINO/ELTSINAJO32 Page 9 of 9 Maximum pulling tension Electrical Characteristics = AC resistance at max. operating temperature (ohm/km) ~ Reactance at 50Hz (ohm/kmn) = Current rating direct in ground at 20°C = Current rating in free air at 30°C Recommended sealing-end data ‘Storage and installation details Termination details Maximum cable length on a reel for each size of cable