Wire and Cable Installation

Technical Specification

Document: SECO-10-024-0-TS-16120
Revision: A
Date: December 2010

SECO-10-024-0-TS-16120
Rev A (December 2010)

Page 1

CONTENTS
PART 1 SCOPE......................................................................................................................................... 5
1.1

Specification Includes................................................................................................................... 5

1.2

Related Specifications.................................................................................................................. 5

1.3

References................................................................................................................................... 5

1.4

Submittals..................................................................................................................................... 6

1.5

Design Requirements................................................................................................................... 7

1.6

Performance Requirements.......................................................................................................... 7

1.7

Marking and Identification............................................................................................................. 7

1.8

Packing and Delivery.................................................................................................................... 7

1.9

Handling, Storage and Protection................................................................................................. 8

PART 2 PRODUCTS................................................................................................................................. 9
2.1

Acceptable Manufacturers............................................................................................................ 9

2.2

Materials....................................................................................................................................... 9

2.3

Mixes and Processes................................................................................................................... 9

2.4

Fabrication and Assembly Requirements.....................................................................................9

2.5

Personnel Requirements.............................................................................................................. 9

2.6

Inspection and Test Requirements............................................................................................... 9

2.7

Cleaning....................................................................................................................................... 9

2.8

Corrosion Protection/Coatings...................................................................................................... 9

PART 3 EXECUTION.............................................................................................................................. 10
3.1

Inspection and Preparation......................................................................................................... 10

3.2

Installation.................................................................................................................................. 10

3.3

Personnel Requirements............................................................................................................ 19

3.4

Inspection and Test Requirements.............................................................................................20

3.5

Adjustment and Cleaning........................................................................................................... 20

3.6

CorrosionProtection/Coatings..................................................................................................... 20

3.7

Protection................................................................................................................................... 20

3.8

Extra Stock/Spare Parts............................................................................................................. 20

SECO-10-024-0-TS-16120
Rev A (December 2010)

Page 2

3.9

Schedule and Attachments......................................................................................................... 20

Section Break - Do not delete this line

SECO-10-024-0-TS-16120
Rev A (December 2010)

Page 3

PART 1
1.1

Specification Includes
A.

1.2

1.3

SCOPE

This Specification covers the technical requirements for the handling, installation,
inspection, storage and handling, and testing of the following:
1.

Medium-voltage power cables, 15-kV and below

2.

600-Volt power cables

3.

600-Volt control cables

4.

300-Volt instrumentation cables

Related Specifications
A.

07270 - Firestopping

B.

16080 - Electrical Equipment Installation

C.

16111 Conduit

D.

16113 Embedded Conduit, Underground Ductbanks and Trenches

E.

16114 - Cable Trays

References
A.

The latest edition and publishing addenda of the following publications in effect on the
date of Contract Award are a part of this Specification and, where referenced to by title or
basic designation only, are applicable to the extent indicated by the specific reference:
1.

NFPA 70, "National Electrical Code"

2.

IEEE C2, NESC, National Electrical Safety Code

B.

Where the above referenced codes and standards contain recommendations in addition
to the requirements, the recommendations shall be considered requirements and shall be
followed unless stated otherwise by this Specification.

C.

In the event of any conflict between codes, or Specifications and codes, the more
stringent regulation shall apply.

SECO-10-024-0-TS-16120
Rev A (December 2010)

Page 4

1.4

Submittals
A.

After Contract Award:

1.

SECO-10-024-0-TS-16120
Rev A (December 2010)

Procedures covering all aspects of cable penetrations, including the following:

a)

Pre- and post-installation cleaning procedure.

b)

Seal forming procedure and materials.

c)

Foam installation procedure.

d)

Ventilation requirements.

e)

Hydrogen detection and protection procedures.

f)

Test reports of silicon foam subjected to fire testing.

Page 5

1.5

1.6

Design Requirements
A.

24-Volt digital inputs shall use shielded, 600-volt insulated, #16 AWG (1.0 mm squared)
cable run in instrument level tray unless otherwise directed by the control system
Manufacturers requirements. (Note that 300-volt cable is non-standard in this
configuration. Therefore, 600-volt insulation shall be used).

B.

48-Volt digital inputs shall use non-shielded, 600-volt insulated, #16 AWG (1.0 mm
squared) cable run in control level tray.

C.

Digital inputs and outputs for 125-volt dc shall be non-shielded, 600-volt insulated, #12
AWG (2.5 mm squared) cable run in control tray. Digital inputs and outputs for 120-volt
ac shall be non-shielded, 600-volt insulated, #14 AWG (1.5 mm squared) run in control
tray.

D.

Analog input and output circuits shall use shielded, 300-volt insulated #16 AWG (1.0 mm
squared) cables run in instrument level tray. Multi-pair or multi-triad shielded cable shall
be provided with an overall shield.

E.

Voltages shall not be mixed in a cable.

F.

Low-voltage cable ampacity shall be based on 75 degrees C cables and adjusted for site
maximum average temperature and if routed in tray, trench or underground duct bank.
Medium voltage cable ampacity is to be based on 90 degrees C cable and adjusted for
site maximum average temperature and if routed in tray, trench or underground duct
bank.

Performance Requirements
Not used.

1.7

Marking and Identification

Not used.

1.8

Packing and Delivery

Not used.

SECO-10-024-0-TS-16120
Rev A (December 2010)

Page 6

1.9

Handling, Storage and Protection

A.

The cables shall be stored in areas or buildings designated for that purpose. Cables
shall be protected form damage both while being handled and while in storage.

B.

The cable reels shall be kept in a secure storage area outside the work area until the
cable is to be pulled. Empty reels shall be returned promptly to the storage area. The
Contractor is responsible for returnable reels and their return to the cable Manufacturer.

C.

The Contractor shall visually inspect the cable and reels for shipping damage and
manufacturing defects at the time of delivery of the cable and report any problems to the
Company. Additional visual inspections shall be done each time the cable reel is to be
used for installation.

SECO-10-024-0-TS-16120
Rev A (December 2010)

Page 7

PART 2
2.1

PRODUCTS

Acceptable Manufacturers
As approved by the Company.

2.2

Materials
In accordance with the requirements in this Specification.

2.3

Mixes and Processes

Not used.

2.4

Fabrication and Assembly Requirements

Not used.

2.5

Personnel Requirements
Not used.

2.6

2.7

Inspection and Test Requirements

A.

In accordance with the Contractors standard requirements.

B.

The Contractor shall employ a quality plan.

Cleaning
Not used.

2.8

Corrosion Protection/Coatings
Not used.

SECO-10-024-0-TS-16120
Rev A (December 2010)

Page 8

PART 3
3.1

3.2

EXECUTION

Inspection and Preparation

A.

Complete installation of raceways and supports before installing cables.

B.

Clean and test conduits for obstructions or dirt by pulling a mandrel or Companyapproved object through the conduit. Clear obstructions with a cutting mandrel or
Company-approved means. Clean and inspect any other raceway such as cable tray or
wireway prior to cable installation.

Installation
A.

General Cable Installation Requirements:

1.

Handle cables carefully when unreeling to avoid damage due to kinking or

otherwise bending to radius less than the Manufacturers recommended bending
radius.

2.

Do not lay cables on rough ground; drag them over sharp objects or drive over
them with any equipment or vehicle.

3.

Cables shall not be installed when the ambient temperature is lower than 10
degrees F or as directed by the cable Manufacturer.

4.

Set cable reels as close as practical to the raceway entrance, and train the cable
as directly as possible to the entrance with minimal bending.

5.

Use a protector at the raceway entrance to protect the cable jacket.

6.

For installations of multiple cables in a conduit pull all cables simultaneously.

7.

Cable installation shall be performed so that no undue stress is placed upon the
insulation and coverings when they are drawn through conduits or otherwise
handled.

8.

For circuits using single conductor cables whose cables are on more than one
reel, the cables shall be pulled from reels designated for that specific circuit
number.

9.

Attachment of Cable to Pulling Line:

SECO-10-024-0-TS-16120
Rev A (December 2010)

Page 9

a)

Use woven basket grips or attach directly to conductors. Do not use

rope hitches.

b)

Use a swivel conductor connection for conductors of size 250 MCM (120
mm squared) or larger.

c)

Seal the cable ends for installations where moisture could enter the cable
during pulling.

10.

Use cable lubricant as recommended by the cable Manufacturer. If Low Smoke

Zero Halogen cable is specified, Polywater LZ lubricant or equal must be used.

11.

Pulling Tension:
a)

Use a calibrated dynamometer for observing pulling tensions. Provide

certification of the calibration and how often the dynamometer is
calibrated.

b)

Report recorded tensions to the Company.

c)

Maximum allowable pulling tension is the lower of either of the following:

i)

The cable Manufacturer's recommended value.

ii)

1000 lbs. if pulled with a basket grip.

12.

Cable splices in general shall not be used. Where a splice is needed, it shall be
brought to the Company's attention. The method of splicing shall be approved by
the Company.

13.

Cable Penetration Sealing:

SECO-10-024-0-TS-16120
Rev A (December 2010)

a)

Where cable raceways pass through areas of widely different

temperatures, or where area isolation is critical, the raceways and
electrical openings shall be sealed to prevent condensation and/or
passage of air from one area to another.

b)

Conduit in these areas requires sealing to prevent any propagation of

fire, and prevent possible passage of gas. Sealing may be accomplished
by using appropriate sealing fittings or by applying a filler compound, as
approved by the Company, around the conductors at the termination or
another accessible point in the run. Conduits passing through walls and
floors shall be encased in concrete.

Page 10

B.

c)

Cable tray openings in the walls and floors shall be sealed with silicone
foam or similar Company-approved material.

d)

Where cable raceways enter or exit areas containing active fire

protection systems, all conduit and cable tray openings shall be
temporarily sealed at the end of each work period in order to maintain the
active fire protection boundary. Openings shall be sealed with a bag seal
or an Company-approved temporary sealing system.

e)

Where cables leave conduits outdoors that are not terminated to an

enclosure (i.e. cable tray) the conduit shall be sealed after the cables are
installed to prevent water or moisture from entering the conduits.

14.

Do not bend the cable either temporarily during installation or permanently to a

radius less than the Manufacturer's recommended minimum bending radius.

15.

Low level instrument cables shall each be installed in their own separate totally
enclosed galvanized steel raceway throughout the plant except in corrosive
environments where PVC conduit shall be used above grade.

16.

Fire protection and data highway cables shall each be installed in their own
separate totally enclosed galvanized steel raceway in exposed locations
throughout the plant except in corrosive environments where PVC conduit shall
be used above grade.

17.

The Contractor may utilize his standard cable routing/management system,

however must strictly follow as designed route strings to ensure the proper fill
requirements and circuit lengths are maintained.

Additional Installation Requirements for Cables in Trays:

1.

In pulling, laying and training cable and wire, the Contractor shall minimize
damage, maintain neat and orderly groups, and providing maximum ventilation to
minimize heat problems.

2.

Install cables neatly avoiding crosses as much as practical.

3.

Use guide rollers at each change in tray direction.

a)

SECO-10-024-0-TS-16120
Rev A (December 2010)

Guide Roller Radius: At least 50 percent greater than the Manufacturer's

recommended bending radius of the cable.

Page 11

C.

D.

4.

Support cables clear of the tray lip where they exit the tray.

5.

Anchor cables in place at 6-foot (1.8 m) maximum intervals vertically, and at each
bend within 12 inches (300 mm) of the change in direction at both sides of the
bend with T & B Ty-Rap fasteners.

6.

Install a bushing on the tray end of the conduit and anchor the conduit to the tray.

7.

Use mineralite-insulated clamps or Company-approved equal to support cables

exiting the tray where trays are subject to significant vibration.

8.

For non-metallic sheathed cable from a tray to equipment, the cable shall be
supported if over 6 feet (1.8 m) in length.

Additional Installation Requirements for Cables in Manholes:

1.

Use cable racks to support cables passing through manholes with a minimum of
interlacing.

2.

Provide a minimum of one linear foot (300 mm) of cable slack for each cable in
each manhole through which the cable passes.

3.

Permanently and effectively separate medium voltage conductors from the

conductors of other systems and securely fasten to racks.

4.

Suitable insulating supports or cradles to be provided where necessary to ensure

adequate cable support, in particular for the single conductor power cables.

5.

Low level instrument, fire protection and data highway cables shall each be
installed in its own separate totally enclosed galvanized steel raceway through
the manhole.

Additional Installation Requirements for Cables in Boxes and Cabinets:

1.

Arrange open wiring in a neat orderly manner.

2.

Use T & B Ty-Rap fasteners to couple together single conductors belonging to

the same cable.

3.

Space and individually support groups of cables.

SECO-10-024-0-TS-16120
Rev A (December 2010)

Page 12

4.

E.

Provide slack in the cable in all junction boxes, pull boxes, and other places so
that the cables are not drawn tight against conduit and bushings or short radius
corners and the insulation eventually damaged by being squeezed between
conductor and other objects.

Requirements for Cable Terminations:

1.

Each conductor of control and instrument cables shall be long enough to reach
the most distant terminal point in the equipment being installed. Loop and tie the
conductors in a bundle.

2.

Strip cable jackets only as far back as needed to accommodate the termination
of the conductors. For cabinets with a high density of cable the jackets may be
stripped to the point of entry of the cabinet.

3.

Control and instrument cable terminal connections shall not stress the terminal
studs and other connections. Power cable terminations shall be installed such
that stress on the bus connections is minimized.

4.

Medium-Voltage Cable:

5.

SECO-10-024-0-TS-16120
Rev A (December 2010)

a)

Use prefabricated stress cones to terminate shielded medium voltage

cables.

b)

Ground the shielding tape at each end and at any splices.

c)

Route the ground lead through the zero sequence CT before connecting
to the ground bus.

d)

Unless directed otherwise by the prefabricated stress cone Manufacturer

instructions, solder the ground conductor to the shield. Use minimum
size #10 AWG (4 mm squared) to ground the shields.

Control and Instrumentation Cables:

a)

Neatly arrange and fan out the cables entering control boards and
switchgear, and secure them in position at the terminal blocks with nylon
cord or approved plastic ties.

b)

Attach conductors to terminals using solderless locking fork type

pressure connectors with insulated ferrules. Conductor insulation shall
be stripped from the end of the wire, inserted into the insulated end of the
ferrule, crimped using manufacturers designated crimping tool, inserted
into the terminal block and tightened with the terminal compression
Page 13

screw. Do not terminate wires by wrapping them around the screw

terminals except for thermocouples.

F.

c)

All instrument cable shields, including the overall shield on multipair or

multitriad cables, shall be kept floating (not-grounded) at the transducer
and final control element ends (thermocouples, transmitters, analyzers,
etc.) and shall be terminated and grounded in the DCS or PLC cabinets.
Shield braids shall be taped or insulated with sleeves to prevent
accidental grounds or touching of shields. The overall shield on multipair or multi-triad cables shall be terminated on the instrument ground
bus.

d)

Shields shall have continuity maintained from the primary sensor to the
DCS or PLC termination cabinets. Each shield shall be separately
terminated in any intermediate terminal box.

6.

No soldering of wires is permitted.

7.

Self-insulated, locking fork type lugs to be used on wiring terminations on

terminal strips and at motor terminal boxes. Crimping tool used must be
approved by the terminal lug manufacturer and shall crimp both the conductor
and insulating sleeve.

8.

Motor lead terminations shall be bolted together with the ring tongue type
terminals and tin plated bolts of the appropriate size. Cover terminations with UL
approved insulating tape or heat shrinkable caps suitable for the cable insulation
and voltage level.

9.

A ratcheting type crimping tool shall be used that will not release until the proper
size crimp has been completed.

10.

Removal of insulation from cables size #10 AWG (4 mm squared) and smaller to
be performed using Company-approved stripping tools. For cable sizes larger
than #10 AWG (4 mm squared) the removal of insulation may be by hand. In
baring conductors, care to be taken to avoid nicking strands.

Tagging Requirements for Installed Cables:

1.

The Contractor may utilize his standard tagging procedure for cables providing,
as a minimum, the following voltage levels are easily identifiable within the tag
numbering sequence:
a)

SECO-10-024-0-TS-16120
Rev A (December 2010)

VOLTAGE LEVEL IDENTIFICATION

Page 14

i)

The following are the voltage level identification levels required

for raceways and cables;
Medium voltage, single lay power Single conductor.
Low voltage, single lay power - Single conductor (480VAC) (#2/0
AWG (70 mm squared) and larger).
Low voltage, random lay power - Multi-conductor (480VAC,
240VAC, 208VAC, 120VAC, and 125VDC) (#1/0 AWG (50 mm
squared) and smaller).
Control, random lay - Digital Inputs (48VDC), Digital Outputs
(120VAC, 125VDC) and Control Power (120VAC and 125VDC)
(Non-shielded cable).
Instrumentation - Digital Inputs (24VDC and lower), TC, RTD, 420mA analog I/O (Shielded cable).
Data highway - coax or fiber optic.
Fire protection.
Telephone.
Spare.

SECO-10-024-0-TS-16120
Rev A (December 2010)

Page 15

G.

H.

2.

Affix cable identification tags at each termination as close to the termination as

possible, and at pull boxes, manholes or other points of access.

3.

Fabricate cable identification tags from either strong non-conducting fiber,

approximately one inch in size, with a hole for attaching it with a cable tie to the
cable on both ends of the tag, or with a slip-on or heat shrink type cable tag.
Stamp or print the cable number to the tag with a non-fading waterproof ink.

4.

Identify all cables in accordance with the drawings and the Contractors standard
Cable and Raceway Management Program. Cables shall be identified at each
end.

Tagging Requirements for Individual Conductors

1.

Individual conductors identification products may be slip-on or heat shrink.

Identification information to be typed or printed with non-fading waterproof ink.

2.

If a conductor is used as a ground wire, it shall have green tape applied at each
end to signify it is used as a ground conductor.

3.

If a conductor is used as a neutral wire, it shall have white or gray tape applied at
each end to signify it is used as a neutral conductor.

4.

Each cable and individual conductor marking shall be done using Brady
Identification Solutions system or Company-approved equal.

Raceway and Cable Separation Spacing Requirements

1.

3.3

Raceway and cable separation spacing distances shall be in accordance with

Attachment A of this specification.

Personnel Requirements
Install all wires and cable in a neat manner using competent individuals in complete accordance
with the drawings, the Cable and Raceway Management Program if provided and the cable
Manufacturer's instructions and recommendations.

SECO-10-024-0-TS-16120
Rev A (December 2010)

Page 16

3.4

3.5

Inspection and Test Requirements

A.

All tests or inspections normally employed either in installation or construction processes,

or as called for in the applicable codes and standards, are required.

B.

Inspect installed medium voltage power cables and perform megger and high potential
testing and a phase check in accordance with applicable codes and standards.

C.

Inspect installed low voltage power cables and perform megger testing and a phase
check as required in accordance with applicable codes and standards.

D.

Control and instrument cables shall have a continuity check performed.

E.

Field testing shall include continuity and insulation testing of all shields and conductors,
between conductor and conductor, and conductor and ground for all cables.

Adjustment and Cleaning

Not used.

3.6

CorrosionProtection/Coatings
Not used.

3.7

Protection
Seal the cut ends of cables remaining on the cable reel and either prior to installation or as soon
thereafter as possible to prevent the entrance of moisture or water.

3.8

Extra Stock/Spare Parts

Not used.

3.9

Schedule and Attachments

See Appendix 1.

SECO-10-024-0-TS-16120
Rev A (December 2010)

Page 17

Appendix 1

Wire and Cable Installation Tables

The following voltage classes apply to the separation tables that follow:
L
- Instrumentation - Digital Inputs (24VDC and lower), TC, RTD, 4-20mA analog I/O
(Shielded cable).
C
- Control, random lay - Digital Inputs (48VDC), Digital Inputs and Outputs (120VAC,
125VDC) and Control Power (120VAC and 125VDC) (Non-shielded cable)
P
- Low voltage, random lay power - Multi-conductor (480VAC, 240VAC, 208VAC, 120VAC,
and 125VDC).
M & S - Medium voltage, single lay power and Low Voltage, single lay power
D

- Data highway - coax or fiber optic.

SECO-10-024-0-TS-16120
Rev A (December 2010)

Page 18

FPL - MARTIN AND MANATEE ESP

WIRE AND CABLE INSTALLATION
TECHNICAL SPECIFICATION

CABLE TRAY SEPARATION

CONDUIT - TRAY SEPARATION

INCHES (MM)

INCHES (MM)

CLASS

M&S

CLASS

M&S

4(102)

20(508)

48(1219)

4(102)

20(508)

48(1219)

4(102)

12(305)

18(457)

4(102)

12(305)

18(457)

20(508)

12(305)

20(508)

12(305)

M&S

48(1219)

18(457)

M&S

48(1219)

18(457)

CONDUIT SEPARATION, INCHES (MM)

CONDUIT SEPARATION, INCHES (MM)

ABOVE GRADE

UGND DUCT & EMBEDDED

Conduits Class L Steel

CLASS

M&S

CLASS

M&S

3(76)

12(305)

12(305)

3(76)

12(305)

12(305)

3(76)

6(152)

3(76)

6(152)

12(305)

12(305)

M&S

12(305)

6(152)

M&S

12(305)

6(152)

SECO-10-024-0-TS-16120
Rev A (December 2010)

Page 19

FPL - MARTIN AND MANATEE ESP

WIRE AND CABLE INSTALLATION
TECHNICAL SPECIFICATION

CONDUIT - CABLE - SEPARATION, INCHES

(MM)

CABLE CABLE SEPARATION,

INCHES (MM))

CLASS

M&S

CLASS

M&S

4(102)

18(457)

18(457)

4(102)

12(305)

18(457)

12
(305)

18
(457)

18(457)

12(305)

12(305)

M&S

18(457)

18(457)

M&S

18(457)

DATA HIGHWAY SEPARATION, INCHES (MM)

CLASS

SECO-10-024-0-TS-16120
Rev A (December 2010)

M&
S

6(152)

36
(914)

36
(914)

Page 20