Revision A Page 2
CONTENTS 1.0
Introduction
2.0
Custodian
3.0
Purpose
4.0
Application
5.0
Scope of Supply
5 .1 5 .2 5 .3 5 .4
Power, control and earthing cables Cable glands Equipment not included in the scope of supply Definition of non-technical terms
6.0
Service and Environmental Conditions
6 .1 6 .1 .1 6 .1 .2 6 .2 6 .3 6 .4
Ambient temperature for design purposes Air temperature Ground temperature Thermal resistivity of the ground or soil Rating of cables for site conditions Short circuit current withstand capability
7.0
International Reference Standards
8.0
General Re Requirements
8 .1 8.2 8.3 8 .4 8 .5
The Supplier’s product range Origin of materials Project management Abbreviations of of so some te technical te terms us used he herein Supplier’s drawings and documents
9.0
Design and Performance Requirements
9 .1 9 .2 9.3 9.3 9.4 9.4 9 .5 9 .6 9 .7 9 .7 .1 9 .7 .2 9 .7 .3 9 .7 .4 9.8 9.8 9 .8 .1 9.8. 9.8.2 2 9 .8 .3 9 .9 9.10
Voltage and frequency variations The electrical power system Conductor maximum continuous operating temperature Conductor maximum shortrt-circu rcuit operating temperature Short-circuit K values for co copper co conductors De-rating factors for cables laid in air De-rating factors for cables laid in ground Direct burial Use of ducts Pre-formed concrete trenches The use of lead sheathing Flam lame pr propagation, sm smoke pro prod duction an and to toxic ga gas em emission Flame propagation Smoke production and toxic gas emission Oxygen index Fire resistance Resistance to hot oils
Revision A Page 3 10.0
Construction Requirements
10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.10.1 10.10.1.1 10.10.1.2 10.10.2 10.10.2.1 10.10.2.2 10.11 10.11.1 10.11.2 10.12 10.12.1 10.12.1.1 10.12.1.2 10.12.2 10.12.2.1 10.12.2.2 10.12.3 10.12.4 10.13 10.13.1 10.13.2 10.13.3 10.14 10.14.1
Notation used in this document Conductors Conductor screening Conductor insulation Insulation screening Insulation screening tape Bedding between multi-cores Inner sheathing Armour General requirements Land-based installations Normal use in the air or in the ground Abnormal use in the air or in the ground Platform-based installations Normal use in the air LV cables in accommodation areas Outer sheathing Power distribution cables Earthing cables Other components Fire survival in non-accommodation areas HV cables LV cables Fire survival in accommodation areas HV cables LV cables Earthing cables Special applications Colours of components Conductors Outer sheathing colour Outer sheathing marking Cable glands Cable dimensional tolerances
11.0
Inspection
12.0
Testing
12.1 12.2
General Type tests, sample tests and routine tests
13.0
Packing
13.1 13.2
General Drum marking
14.0
Approval to Deviate
15.0
Revision History Log
16.0
Bibliography
Revision A Page 4 1.0
Introduction
This is an engineering standard that gives details of power, control and earth cables and associated glands for high voltage and low voltage systems. Note that any changes to this document from its last revision are highlighted by a bold vertical bar to the left of each area of change. Should there be a need to consult this document’s change history log, refer in the first instance to its custodian (EE). References made throughout this guideline are numbered inside square brackets [ ] and may be found in the Bibliography of section (16). 2.0
Custodian
The Custodian of this standard guideline is EE, who is responsible for the accuracy and quality of its contents and for its future revisions, where these are required to reflect industry trends or changes to QGPC business practices. 3.0
Purpose
The purpose of this standard is to provide guidance to QGPC, their Consultants and Contractors on the cables and accessories utilised by QGPC for voltages up to 33000 Volts. This specification is based on QGPC Engineering Design Philosophy ES.2.03.0001 and QGPC Electrical Installation Practices ES.2.06.0001. 4.0
Application
This standard shall be applied to the design, manufacture and testing of 33kV, 11kV, 6.6kV, 3.3kV, and low voltage power, control and earthing cables to be installed for various projects of Qatar General Petroleum Corporation (QGPC). 5.0
Scope of Supply
5.1
Power, control and earthing cables
This specification details the requirements for industrial type, power distribution cables, control cables of the single and multi-core type and single core earthing cables. The cables will normally be installed indoors, outdoors, in air and in the ground at QGPC oil and gas processing plants, refineries, chemical plants, LNG plants, off-shore platforms, industrial sites, and the like. This specification shall be used to purchase equipment for both existing and new plants. As a rule the requirements of this specification shall be adhered to. However, national and local regulations may exist in which some of their requirements are more stringent. The Supplier shall inform the Principal in writing of any deviation from the technical requirements of this specification, preferably at the tendering stage, but certainly before the manufacturing commences. Otherwise the Principal will consider that the Supplier complies with these technical requirements and will be manufacturing the cable accordingly.
Revision A Page 5 This specification covers the design, manufacture and testing of 33 kV, 11 kV, 6.6 kV, 3.3 kV and low voltage power, control and earthing cables for various projects of Qatar General Petroleum Corporation (QGPC) in Qatar, Arabian Gulf The requirements for drawings and documentation are given in section 8.5. 5.2
Cable Glands
Industrial type cable glands are recommended for terminating cables of single and multicore type for all QGPC operations. Zone 2 classified areas may require the use of barrier type glands. The Principal shall specify these on the data sheets. Reference should also be made to Engineering Philosophy ES.2.03.0001 Appendix H table H3.A and Installation Specification ES.2.06.0001 Section 16.4. 5.3
Equipment not included in the Scope of Supply
The following equipment shall be excluded from the scope of supply of cables and glands of the SUPPLIER unless specified in other documents of the requisition.
5.4
•
Submarine cables.
•
Cable jointing equipment and splices.
•
Heat-shrink termination kits and equipment.
•
Terminating lugs and tools and test equipment.
•
Racking and trays.
•
Underground cables at a voltage higher than 33 kV.
Definition of Non-Technical Terms
For the purposes of this document the following definitions of terms and interpretations shall apply regardless of any other meaning the words may have in other respects. Shall.
The word shall is to be understood as mandatory.
Should.
The word should is to be understood as being strongly recommended.
Principal.
Is the party, which initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include an agent or consultant to act for the Principal.
Contractor(s).
Is the party, which carries out all aspects or part of the design, engineering, procurement, construction and commissioning of the plant. The Principal may sometimes undertake all or part of the duties of the Contractor.
Manufacturer or Supplier.
Is the party which manufactures or supplies equipment and services to perform the duties specified.
End-user.
A third party that has already purchased the same equipment as that being offered by the manufacturer, or supplier.
Revision A Page 6
6.0
Inspection.
This shall be taken to mean a visual inspection of the equipment and installation.
Testing.
This shall be taken to mean the routine tests normally carried out at the factory of the Supplier.
Commissioning.
This shall be taken to mean energisation and the final tests and checks at the Principal’s site subsequent to the energisation necessary to ensure that each circuit satisfactorily performs its function.
Land-based installations
All plants installed on the mainland of Qatar. All plants installed on Halul Island. Abbreviated to LBIs.
Platform-based installations
All plants installed on elevated platforms or moored installations vessels located in the sea or waters around Qatar. Abbreviated to PBIs.
Service and Environmental Conditions
The atmosphere and ground throughout all QGPC plants shall be considered to be corrosive, as normally associated with oil and gas processing plants, refineries, chemical plants, LNG plants, off-shore platforms, industrial sites, and the like. In addition, for offshore and coastal locations, the atmosphere shall be considered as salt laden and the ground as having a corrosive water table near its surface. High humidity is experienced in all areas and condensation will occur on all equipment during some period of its lifetime. 6.1
Ambient Temperature for Design Purposes
6.1.1
Air Temperature The ambient air temperature shall be considered as a maximum of 50 °C. The Supplier shall take this into account in the design and selection of materials for his cables, and when calculating and quoting de-rating factors for normal rated currents and fault currents of the cables. The Supplier shall quote his nominal temperature for which his de-rating factor for ambient temperature is 1.0 in his tender documentation.
6.1.2
Ground Temperature The ambient ground temperature shall be considered as a maximum of 40 °C.
6.2
Thermal Resistivity of the Ground or Soil
The thermal resistivity of the ground or soil shall be taken as 2.5 K m/W for general guidance. Soil tests should be taken at all sites to identify areas where the thermal resistivity is likely to be higher than 2.5 K m/W e.g. well-drained sand where heavily loaded cables are to be buried and operated continuously in the summer.
6.3
Rating of the Cables for Site Conditions
Revision A Page 7
The cable manufacturer shall not be responsible for sizing the cables for normal current conditions for a particular project. 6.4
Short Circuit Current Withstand Capability The Supplier shall provide detailed information in his tender documents for the Isquared-t short circuit current withstand capability which is applicable over the time range of 0.2 to 10.0 seconds. This information shall be given in the form of equations or graphs for: -
7.0
a)
The conductors.
b)
The armouring wires or braid.
International Reference Standards
The following standards and specifications shall be used unless the Principal approves another national standard: (Add to all references e.g. IEC 34 becomes IEC )60034 Standard Compliance IEC 43
Recommendations for alternating current watt-hour meters.
IEC 92-3
Electrical installations in ships. Part 3: Cables (construction, testing and installation) wires or cables.
IEC 183
Guide to the selection of High Voltage Cables
IEC 189
Copper conductors.
IEC 331
Fire resisting characteristics of electric cables.
IEC 332
Tests on electric cables under fire conditions.
IEC 502-1
Extruded solid dielectric insulated power cables for rated voltages from 1 kV up to 30 kV.
IEC 540
Test methods for insulations and sheaths for electric cables and cords (elastomeric and thermoplastic compounds).
IEC 754
Tests on gases evolved during combustion of electric cables.
IEC 885
Electrical test methods for electric cables.
BS 2621
Mechanical cable glands.
BS 2782
Methods of testing plastics.
BS 5467
Armoured cables with thermosetting insulation for electricity supply.
BS 5468 BS 6004
Cross-linked polyethylene insulation systems of electric cables. PVC insulated cables (non-armoured) for electric power and lighting.
Revision A Page 8
BS 6346
PVC cables for electricity supply as relevant to the contract cables with XLPE insulation.
BS 6360
Copper conductors in insulated cables and cords.
BS 6425
Test on gases evolved during the combustion of materials from cables.
BS 6746
Specification for PVC insulation and sheath of electric cables
BS 7211
Non armoured cables for power and lighting with low emission of smoke/gases
8.0
General Requirements
8.1
The Supplier’s Product Range
It is a general requirement that the supplier offers only cable that is within his standard range of cables. Any cable that is ‘bought-in’ from a third party shall also be from a standard range of products from the third party, but subject to the approval of the Principal. The cable shall not be a new product-line that has not been sold in reasonable quantities to similar end-users as QGPC. The Supplier shall include in his quotation a list of end-users in the Middle East region that have purchased the same cable being offered. 8.2
Origin of Materials
The Supplier shall offer all the cables in the purchase order from his own factory in one country; preferably the country where the purchases order will be managed by the Supplier. Type Test certificates shall be in the name of the Supplier for the cable, and not in the name of a third party manufacturer or vendor. The Supplier shall confirm this paragraph in his quotation. 8.3
Project Management
The Supplier shall nominate a single person to manage the project and this person shall be the single ‘focal point’ for all discussions, meetings, communications, correspondence, and the like, between the Supplier and the Principal. 8.4
Abbreviations of Some Technical Terms Used Herein
The definitions for some technical words and abbreviations used in this specification and the QGPC M.E.S.C. system are: DATA SHEETS
This includes all relevant data sheets, diagrams and drawings issued with the enquiry or purchase order package.
AWA
Aluminium wire armour
CSP
Chloro-sulphonated polyethylene
COR CU
Corrugated copper
CU
Un-tinned copper
CUWB
Copper wire braid
Revision A Page 9 EMA
Ethylene methyl acrylate
EPDM
Ethylene propylene diene monomer
EPR
Ethylene propylene rubber
EVA
Ethylene vinyl acetate
FLEX
Flexible
GSWA
Galvanised steel wire armour
GSWB
Galvanised steel wire braid
HCL
Hydrochloric acid or gas
HOFR
Heat and oil resisting, flame retardant
IS
Intrinsically safe
LDF
Low density foam
LSLH
Low smoke low halogen
MI
Mineral insulated
MT
Mica glass tape
NBR
Nitrile butadiene rubber
PBWB
Phosphor bronze wire braid
Pb
Lead sheathing
PbCU or TCU
Tinned copper
POL
Polyethylene
PTP
Polyethylene terephthalate
PTFE
Polytetra fluoro ethylene
PVC
Polyvinyl chloride
PVDF
Polyvinyldiene fluoride
SCR
Screened
SOL CU
Solid copper
STR CU
Stranded copper
SWA
Steel wire armour
XLPA
Cross linked polyalkylene
XLPE
Cross linked polyethylene
M.E.S.C
Material and Equipment Stores Catalogue (Shell)
IEC
International Electrotechnical Commission.
BSI
British Standards Institution.
S.I.
System International.
RMS
Root mean square value of current or voltage.
Pk
Peak value of instantaneous current or voltage.
A.C. or a.c.
Alternating current or voltage.
D.C. or d.c.
Direct current or voltage.
Revision A Page 10 Hz
Frequency of alternating current or voltage in cycles per second.
FAT
Factory acceptance testing.
HV
High voltage, above 600 volts.
LV
Low voltage, 51 volts to 599 volts.
C
8.5
°
Degrees Celsius
SCADA
System control and data acquisition.
DCS
Distributed control system
Supplier’s Drawings and Documents
All drawings and documents shall be expressed in the English language and units of measure shall be generally in accordance with the S.I. system. The Supplier shall submit with his tender documents cross-sectional area drawings to illustrate the proposed construction of all the types of cables being offered. These drawings shall also indicate the dimensions and diameters of the main components e.g.: -
* * * * * * * *
Outside diameter of the outer sheathing. Inside diameter of the outer sheathing. Outside diameter of the armouring. Inside diameter of the armouring. Outside diameter of the inner sheathing. Inside diameter of the inner sheathing. Outside diameter of the conductor insulation including the semi-conductor screening if provided. Outside diameter of each conductor.
The dimensions, and their tolerances, may be shown in tabular form instead of in the drawings. 9.0
Design and Performance Requirements
9.1
Voltage and Frequency Variations
The cables shall operate correctly, continuously and without being overloaded when the Principal’s nominal system voltages deviate by plus or minus 10 % for long periods of time. Likewise when Principal’s nominal system frequency deviates by plus or minus 5%. The worst cases of simultaneous variation of voltage and frequency shall be withstood by the cables. 9.2
The Electrical Power System
The Principal shall state the rated power system voltage and frequency on the data sheets. 9.3
Conductor Maximum Continuous Operating Temperature
The conductor maximum continuous operating temperature shall be no greater than that given by the Supplier of the cables when the current has been reduced by the appropriate de-rating factors for the project, see 9.6, 9.7. The Supplier shall clearly state the value of the conductor maximum continuous operating temperature in his tender
Revision A Page 11 documentation. This temperature should not exceed the value given below for typical designs of power cables: -
Insulation material
Maximum continuous conductor temperature ° C
Paper PVC EPR XLPE 9.4
65 70 90 90
Conductor Maximum Short-Circuit Operating Temperature
The conductor maximum short-circuit operating temperature shall be no greater than that given by the Supplier of the cables. The Supplier shall clearly state the value of the conductor maximum continuous operating temperature in his tender documentation. This temperature should not exceed the value given below for typical designs of power cables: Insulation material
Maximum short-circuit conductor temperature ° C
Paper (compression connections) Paper (lead solder connections) PVC < 300 mm2 PVC > 300 mm2 PVC > 6600 V EPR XLPE 9.5
250 160 160 140 140 250 250
Short Circuit K Values for Copper Conductors
The short circuit K values for use in I-squared-t calculations, for copper conductors surrounded by different insulation materials, armouring and sheathing, shall be taken as guidance to be: Insulation material Paper (compression connections) Paper (lead solder connections) 2 PVC < 300 mm PVC > 300 mm2 PVC > 6600 V EPR XLPE
Short-circuit K value 0.5 2 A-secs /mm 250 160 150 130 130 250 250
The time duration of the full fault current shall normally be no less than one second, unless the cable is protected by fast acting fuses in which case the fusing time shall be taken into account. 9.6
De-rating Factors for Cables laid in Air
Revision A Page 12
The cables may be laid on racks, trays or ladders in the vertical or horizontal plane and with various bunching arrangements. The Supplier shall provide de-rating factors for his cables for these laying situations, preferably in the form of numerical tables. 9.7
De-rating Factors for Cables laid in Ground
9.7.1
Direct Burial The cables may be laid directly in the ground at various depths and with various bunching arrangements. The Supplier shall provide de-rating factors for his cables for these laying situations, preferably in the form of numerical tables.
9.7.2
Use of Ducts The cables may be laid inside ducts in the ground at various depths and with various bunching arrangements. This is normally needed for road crossings. The Supplier shall provide de-rating factors for his cables for these laying situations, preferably in the form of numerical tables.
9.7.3
Pre-Formed Concrete Trenches The cables may be laid in pre-formed concrete trenches in the ground at various depths and with various bunching arrangements. These trenches will be filled with still air and may be provided with racking and supports, and concrete lids will be used to close the trench. The Supplier shall provide de-rating factors for his cables for these laying situations, preferably in the form of numerical tables.
9.7.4
The Use of Lead Sheathing For special situations e.g. tank farms, chemical plants, the Principal shall specify a lead outer sheathing for the cable to protect the cable from chemical attack. The effect of the lead sheathing should be taken into account in the de-rating factors for buried cables.
9.8
Flame Propagation, Smoke Production and Toxic Gas Emission
9.8.1
Flame Propagation All cables shall be constructed with materials that are of the Reduced Propagation of Fire type. The method of test and test configuration used to demonstrate the capability should be as defined by IEC 332 “Tests on electric cables under fire conditions”.
9.8.2
Smoke Production and Toxic Gas Emission The cable materials shall be chosen such that the hazard of smoke and toxic gas emission (e.g. Hydrochloric acid gas, halogens) during a fire shall be minimised. The data to be used shall be taken from IEC 332-2.
9.8.3
Oxygen Index
Revision A Page 13
The oxygen index of all non-metallic materials except the insulation shall be not less than 30 as described in BS 2782 or IEC 754. 9.9
Fire Resistance
Specified cable circuits and routes will utilise cables that shall have a continued electrical performance under fire conditions, e.g. emergency shutdown systems and their power supplies. The method of test to be used to demonstrate this capability should be as defined by IEC 331-1. This will be achieved by means of glass mica tape applied over the conductors in the form of a helix. Mineral Insulated Copper Cables (MICC) are prohibited for use for vital services. 9.10
Resistance to Hot Oils
Cables that are required to operate where there is oil present shall be certified for oil immersion test recommended by the Supplier 10.0
Construction Requirements
10.1
Notation Used in This Document
The generally accepted construction of the cable components is defined in this document as follows in a LHS to RHS format: *
Conductor / insulation / armouring / outer sheathing
An example of which is: -
CU / XLPE / SWB / CSP
There will be other components for particular applications e.g. system voltages above 3300 volts where semi-conducting screening may be needed for electric stress relieving. 10.2
Conductors
The conductors shall be made of high purity electrolytic copper in accordance with BS 6360. The Principal shall specify that the conductors shall be tin-coated where this is necessary for special situations. Aluminium shall not be used. The Principal shall specify that the conductors shall be finely stranded where this is necessary for special situations. The conductors shall be circular in section, stranded, annealed copper conductors. Sector shaped conductors shall not be used. The conductors of multicore cables shall be laid up with solidly extruded non-fibrous, nonhygroscopic fillers to form a compact circular cable. 10.3
Conductor Screening
The conductors for cables in which the phase-to-ground operating voltage is greater than 3600 volts RMS for PVC or XLPE insulation or 6000 volts RMS for EPR insulation shall be provided with a semi-conductor screen, which shall be bonded to the inner surface of the insulation.
Revision A Page 14
The Supplier shall confirm the need for this screening and describe how it is bonded to the insulation. 10.4
Conductor Insulation
The insulation material shall be extruded over the conductor and be PVC, XLPE or EPR as stated in the data sheets for the project. EPR shall only be used for operating line-to-line voltages up to 6600 volts RMS. Insulation grades for various service voltages shall be as follows: -
System Voltage (U) 33kV system 11kV system 6.6kV system 3.3kV system 440V system 415V/240V system 380V/220V system 10.5
Rated Voltage/Nominal System Volts (U0/U) 18kV/30kV 6kV/10kV 3.6kV/6kV 1.8kV/3kV 600V/1000V 600V/1000V 600V/1000V
Highest Voltage (Um) 36kV 12kV 7.2kV 3.6kV
Insulation Screening
The insulation of conductors for cables in which the phase-to-ground operating voltage is greater than 3600 volts RMS for PVC or XLPE insulation or 6000 volts RMS for EPR insulation shall be provided with a semi-conductor screen, which shall be bonded to the outer surface of the insulation. The Supplier shall confirm the need for this screening, and describe how it is bonded to the insulation and how it should be removed during the termination of the cable e.g. stripping. 10.6
Insulation Screening Tape
A copper tape wound in an over-lapped helical manner shall cover the insulation screening. Aluminium shall not be used. The Principal shall specify that the copper tape shall be tin coated where this is necessary for special situations. 10.7
Bedding Between Multi-Cores
Bedding shall be included in the design of the cable to ensure that the cable is robust and firm, and that passages are not present that could allow gases to be transmitted along the cable. The bedding shall also ensure that the overall diameter of the finished cable is constant (subject to the tolerances given in the appropriate IEC standard) throughout the periphery of the cable. Good “roundness” is an essential requirement. 10.8
Inner Sheathing
Revision A Page 15 An inner sheath shall be provided over the bedding and insulation. For HV cables it shall be resistant to ozone, electric discharge and surface tracking. The inner sheath and fillers shall provide a good longitudinal seal against humidity, gas and vapours. 10.9
Armour
Armouring shall be provided except for special applications. The Principal shall clearly state on the data sheets whether armouring is not required. The Principal shall clearly state on the data sheets type of armouring that is required, e.g. wires in single or double layers, braid, galvanised steel, tinned copper, aluminium, bronze, stainless steel. See 10.9.1 and 2. Aluminium, tinned copper or bronze wires or braid shall be used for single cables, as stated on the data sheets. The armouring shall be highly conductive for fault currents and the addition of some copper wires or strands in the armouring may be necessary to reduce the armouring impedance for long lengths of cables in sensitive situations. The Principal should call for this requirement if it is needed in the project documentation. a) Armour shall provide mechanical protection (except those specified in the data sheet). The armour shall be of single galvanised steel wire. b) Galvanised steel wire braid shall be used for flexible cables and cables up to and including 10 mm2. c) The thickness of steel wire shall comply with IEC 502. d) Particular consideration shall be given to the problem of armour becoming embedded in the inner sheath making separation for termination difficult. e) A stick-proofed tape shall be provided between the inner sheath and the braid. 10.10
General Requirements
Cables shall have Oxygen Index greater than 30 and acidic emission less than 17%. Maximum cross–sectional area for multicore cable shall be limited to 240 mm 2. Cables for offshore installations shall be low smoke low halogen types (LSLH). Cables to be used on HV circuits shall be cross-linked polyethylene (XLPE) insulated, steel wire armoured, UV stabilised, PVC oversheath, construction having flame retardant design in accordance with IEC 332 – 3 Cat. A. LV cables for use on vital circuits shall be of fire resistant design in accordance with IEC 331. Cables meeting this requirement will be of cross-linked polyethylene (XLPE) insulated, steel wire armoured or braided, UV stabilised, PVC oversheath construction.
10.10.1
Land-Based Installations
Revision A Page 16 10.10.1.1
Normal use in the air or in the ground The cable construction shall be: For multi-cores cables CU / XLPE / GSWA / PVC
or
CU / XLPE / GSWA / XLPE
For single-core cables CU / XLPE / PBWB / PVC
or
CU / XLPE / PBWB / XLPE
For single-core cables in air (not in ground) CU / XLPE / AWA / PVC or CU / XLPE / AWA / XLPE 10.10.1.2
Abnormal use in the air or in the ground In abnormal situations (e.g. where oil spillage is expected) the cable construction shall incorporate a lead sheath: For multi-cores cables CU / XLPE / PVC / Pb/ PVC or CU / XLPE / XLPE / Pb / XLPE For single-core cables CU / XLPE / PVC / Pb / PVC or CU / XLPE / XLPE / Pb / XLPE Due considerations shall be given while using Lead Sheathed Cables. These cables shall be used only for those locations where spillage of oil/hydrocarbons/chemicals is expected.
10.10.2
Platform-Based Installations
10.10.2.1
Normal use in the air LV cables shall be cross-linked polyethylene (XLPE) insulated, galvanised steel wire armoured (or braided for < 10 mm2.), UV stabilized, PVC oversheath construction having flame retardant design in accordance with IEC 332-3 Cat A. Ethylene Propylene Rubber (EPR) with Chloro-sulphonated Polyethylene (CSP) oversheath is also acceptable. The cable construction shall be: For multi-cores cables where flexibility or oil resistance is required CU / XLPE / CSP / GSWB / CSP or CU / EPR / CSP / GSWB / CSP For multi-cores cables in general use CU / XLPE / PVC / GSWA / PVC or CU / EPR / PVC / GSWA / PVC For single-core cables where flexibility or oil resistance is required CU / XLPE / CSP / PBWB / CSP or CU / EPR / CSP / PBWB / CSP For single-core cables in general use CU / XLPE / PVC / AWA / PVC or CU / EPR / PVC / AWA / PVC
10.10.2.2
LV Cables in Accommodation Areas
Revision A Page 17 The EPR insulation shall be covered with an inner sheath of EMA or an acceptable alternative material. The armouring shall be covered with an outer sheath of EMA or an acceptable alternative material. The cable construction shall be: For multi-cores cables CU / EPR / EMA / GSWB / EMA For single-core cables CU / EPR / EMA / PBWB / EMA 10.11
Outer Sheathing
10.11.1
Power Distribution Cables An outer sheath shall be extruded over the armouring, and lead sheathing if used. The oversheath shall be PVC with the necessary additives to obtain the following characteristics: a) Flame retardant (IEC 332-3 Category A) b) Minimum production of noxious gases and fumes in the event of fire (less than 17% release of acidic emissions). c) Proof against aliphatic hydrocarbons
10.11.2
Earthing Cables Earthing cables shall be insulated as described in 10.12.3 and the insulation material shall be coloured green and yellow.
10.12
Other Components The Supplier shall describe in his tender documentation any other components that form part of the cable design, and their purpose, for example mica tape for fire resistance.
10.12.1
Fire Survival in Non-Accommodation Areas
10.12.1.1
HV Cables HV cables should be considered to have sufficient material in their insulation to withstand fire conditions for the short period of time during which the HV system will shut down and the emergency systems start-up and supply the essential and vital services.
10.12.1.2
LV Cables The conductors shall be wrapped with mica tape.
Revision A Page 18 The insulation shall be covered with an inner sheath of EPDM or an acceptable alternative material. The cable construction shall be: For multi-cores cables where fire resistance is required CU / MT / XLPE / EPDM / GSWB / CSP or CU / MT / EPR / EPDM / GSWB / CSP For single-core cables where fire resistance is required CU / MT / XLPE / EPDM / PBWB / CSP or CU / MT / EPR / EPDM / PBWB / CSP 10.12.2
Fire Survival in Accommodation Areas
10.12.2.1
HV Cables As for 10.12.1.1
10.12.1.2
LV Cables The conductors shall be wrapped with mica tape. The insulation shall be covered with an inner sheath of EMA or an acceptable alternative material. The armouring shall be covered with an outer sheath of EMA or an acceptable alternative material. The cable construction shall be: For multi-cores cables where fire resistance is required CU / MT / EPR / EMA / GSWB / EMA For single-core cables where fire resistance is required CU / MT / EPR / EMA / PBWB / EMA
10.12.3
Earthing Cables For cables used for earthing and bonding structures, frames, vessels etc., Their construction shall be: For general use CU / PVC For increased flexibility and resistance to oil is required CU / EPR / CSP
10.12.4
Special Applications The Principal should be consulted for special applications, e.g. drilling rigs, down hole pumps, drag chains, where the working conditions require flexible conductors, oil and mud
Revision A Page 19 resistance, chemical contamination, extra protection against mechanical damage, prolonged exposure to high temperatures, extra large conductor sizes, submarine cables, cables with voltages in excess of 100 kV where special cross-bonding of armouring is necessary, etc. 10.13
Colours of Components
10.13.1
Conductors Number of phase and neutral cores
Colour
Numbering
1
Black (or natural)
Not applicable
2
Red, Black
1 and 2
3
Red, Yellow, Blue
1, 2 and 3
4
Red, Yellow, Blue, Black
1, 2, 3 and 4
White with black numbers
1, 2, 3, 4, 5, etc.
more than 4 10.13.2
Outer Sheathing Colour Service voltage Volts 33000
Red
11000
Red
6600
Red
3300
Red
600/1000 Power control cables 10.13.3
Colour
Black Grey preferred, black acceptable
Outer Sheathing Marking The manufacture’s name and voltage grade shall be permanently marked or embossed on the surface of the outer sheathing at intervals of approximately 3 metres along the total length of the cable. For the earthing cables in 10.12.3 this requirement is unnecessary.
10.14
Cable Glands
Cable glands shall be manufactured and tested to the requirements of BS6121 as EExd, EExe and Industrial glands shall be nickel plated brass.
Revision A Page 20 Entry threads shall be metric x 1.5mm pitch as standard. The length of entry thread into EExd II flameproof equipment, which must be threaded, shall be as detailed in BS EN 50018. Cadmium plated brass glands are not acceptable throughout QGPC. 10.14.1
Cable Dimensional Tolerances Cable gland selection shall be done in accordance with cable dimensions supplied by the cable manufacturer. The corresponding gland sizes are selected from the Gland manufacturer selection charts. Glands are manufactured to cover a range of cable sizes. The gland selected should be based on the following procedure: a) Determine the requirements, i.e. EExd, EExe, or Industrial b) Choose appropriate gland type, i.e. indoor, outdoor, armoured or unarmoured. c) Check armour size and type. d) Select gland size using inner sheath diameter of cable. e) Check outer seal will accept cable outside diameter f) Check entry thread size.
11.0
Inspection
The Principal or his nominated representative shall inspect cables. The Supplier shall allow the Inspector all reasonable access to his factory and documentation at any times during manufacture of the cables. The Inspector shall give no less than 10 days notice for pre-planned inspection visits. The scope of Inspection shall be agreed in advance between the Principal and the Supplier. Approval of the Inspector shall not relieve the Supplier of his responsibilities under the terms of the purchase and this specification and its accompanying documents. 12.0
Testing
12.1
General
The manufacturer shall have a QA/QC system based on ISO 9000 – 9004 controlling the quality of design and assembly work during all stages of the production process. A test program shall be established to demonstrate that each cable types will perform satisfactorily in service. Testing shall be performed in accordance with written test procedures prepared by the Supplier and reviewed by the Principal. These procedures shall include provisions for assuring that the pre-requisites for a given test have been met and that the test is performed under suitable environmental conditions by appropriately trained personnel using recently calibrated instrumentation. 12.2
Type Tests, Sample Tests, Routine Tests
The material supplied shall be subject to full works tests in accordance with the relevant sections of the Standards as applicable to the material supplied
Revision A Page 21 The following tests shall be effected: 12.2.1
Type Tests Tests which are required to be carried out by the manufacturer to prove compliance with the quoted specifications and standards. Witnessing of these tests is not normally required, but certification of proof is to be provided for the tests, which are as follows: -
12.2.1.1
Oil Immersion Test Utilising “Cleanspot” and the existing Sterling Test Rig, in addition to a normal immersion test.
12.2.1.2
Ageing Test
12.2.1.3
Water absorption
12.2.1.4
Tinning Tests on Conductors
12.2.1.5
Galvanising Tests on Armouring
12.2.1.6
Material Tests – Insulation and Sheath
12.2.1.7
Ozone Resistance
12.2.1.8
Resistance to Abrasion
12.2.1.9
Stripping Test
12.2.1.10
Bend Test
12.2.1.11
Full witnessed tests to IEC 502 for the High Voltage 33kV /6.6kV/3.3kV screened cables
12.2.2
Sample Tests
12.2.2.1 12.2.2.2 12.2.2.3
Reduced Propagation to IEC 332 Part 3, Category ‘A’. Fire withstand test to IEC 331. Smoke Emission to Appendix 1 of Sterling Report No. 117, which is based on the IEC 332 Part 2.
12.2.2.4
Oxygen Index.
12.2.2.5
Temperature Index.
12.2.3
Routine Tests Tests to be carried out at regular intervals on each cable. Tests and records will be witnessed during inspection visits.
Revision A Page 22 12.2.3.1
Visual Examination
12.2.3.2
Marking
12.2.3.3
Dimensions
12.2.3.4
Conductor Resistance
12.2.3.5
HV Test
12.2.3.6
Partial Discharge
12.2.3.7
Insulation Resistance
12.2.3.8
‘IS’ Cable Tests (including check of capacitance, inductance, and L/R ratio)
12.2.3.9
Bending Test
13.0
Packing
13.1
General
The Supplier shall deliver the cables on wooden drums. Each wooden drum shall be in very good condition before the cable is wound onto it. The drum shall fully protect the cable, both radially and peripherally. Only one cable shall be wound on a drum. The smallest drum shall be used to contain the cable. The drum shall be returnable to the Supplier after the Principal has finished using it. The Supplier shall make all the necessary arrangements for the removal of drums from the QGPC site. The drum shall be protected to give adequate protection during shipment to the QGPC site, in accordance with the particular requirements of QGPC the details of which will be found in the purchase order documentation. 13.2
Drum Markings
The Supplier shall mark the drums with at least one indelible label. The label shall be secured inside a waterproof but transparent plastic pocket. The pocket shall be nailed or screwed to the face of the drum at a place where it can be easily seen. The language to be used on the label shall be English. At least the following information shall be printed on the label: * * * * * * * * * * *
Manufacturer’s name, address, telephone number, fax number, and telex number. Manufacturer’s purchase order number and details. Manufacturer’s cable type details. QGPC’s purchase order number and details. QGPC’s M.E.S.C reference number. Date of manufacture. Voltage grade. Cable cross-section construction abbreviations, see 10.1. Total length of the cable. Total weight of the cable. Unique drum number.
Revision A Page 23
14.0
Approval to Deviate
Strict compliance with this standard guideline is required. Any deviation must obtain prior written approval from its custodian. 15.0
Revision History Log
A record or log shall be kept of the revision history of each engineering document, and be incorporated in the document’s accompanying electronic “readme” file [5]. In this way, there should be no need for a history log to be included in a document - only details of its latest approved revision need be shown (note that the readme file will contain information about the particular operating system + application software versions which were used to create the document’s electronic file; it can also include “help pages” in the form of background notes and explanations, where such details are considered of benefit to its reader). The following is recommended for the contents of a document’s revision history log:Revision Number Prepared By/Date Checked By/Date Approved By/Date Reason For Change Release/Date 16.0
0,1,2,3, etc. Name or reference indicator and date (ddmmmyy) Name or reference indicator and date (ddmmmyy) Name or reference indicator and date (ddmmmyy) Short description, with “change request reference” if available Release/transmittal reference and date (ddmmmyy)
Bibliography st
[1] ISO216: 1989, 1 Edition [2] [3] [4] [5]
ES.0.10.0001, Rev 0 ES.0.10.0002, Rev 0 ES.0.07.0010, Rev 0 ES.0.06.0021, Rev 0
Writing Paper and Certain Classes of Printed Matter Trimmed Sizes - A and B Series Standard Database - Key Words & Phrases Standard Database - Acronyms Engineering Document Classifications Electronic “ReadMe” Files
At the time of publication of this standard the revision of each of the above references, , were valid. As all references are as they cross-r elate to th e revision of thi s document subject to change from time to time, the reader is required to first check with the custodian of this document to find out the latest “cross-revision” status with respect to the above bibliographic list.
