Contents 1.0 Introduction 2.0 Scope 2.1 Power, control and earthing cables 2.2 Cable glands 3.

0 Service and Environmental condition 3.1 Ambient temperature for design purpose 3.2 Thermal resistivity or ground or soil 3.3 Short circuit withstand capacity 4.0 General requirements 4.1 The supplier product range 4.2 Origin of materials 4.3 Drawings and documents 5.0 design and performance requirements 5.1 voltage and frequency variations 5.2 the electrical power system 5.3 conductor maximum continuous operating conditions 5.4 conductor maximum short circuit operating temperature 5.5 short circuit K values for copper conductors 5.6 de-rating factors for various methods of installation 5.7 flame propagation, smoke production and toxin gas emission 5.8 fire resistance 5.9 resistance to hot oils 6.0 Construction requirement 6.1 Notation used in this document 6.2 Conductors 6.3 Screening 6.4 Insulation 6.5 Insulation screening 6.6 Insulation screening tape 6.7 Bedding between multi-cores 6.8 Inner sheathing 6.9 Armouring 6.10 General requirements 6.11 Outer sheathing 6.12 Other components 6.13 Colour of components 6.14 Cable glands 7.0 Testing 7.1 General 7.2 Type Tests, sample test and routine test 8.0 Packing 8.1 general 8.2 drum marking

1.0 Introduction This specification standard gives details of power, control and earth cables and associated glands for high voltage and low voltage systems. 2.0 Scope 2.1 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 Shipyards and Ports. This specification covers the design, manufacture and testing of 11kV, 6.6kV, 3.3kV and low voltage power, control and earthing cables. 2.2 Cable Glands Industrial type cable glands are recommended for terminating cables of single and multi-core type. Zone 2 classified areas may require the use of barrier type glands.

3.0 Service and Environmental Conditions The atmosphere and ground throughout location of installation shall be considered to be corrosive, as normally associated within Shipyards and Ports. In addition, for offshore ad coastal locations, the atmosphere shall be considered as salt laden and the ground as having 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. 3.1 Ambient Temperature for Design Purpose 3.1.1 Air Temperature The ambient air temperature shall be considered as a maximum of 50 degree C. The Contractor 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 current of the cables. 3.1.2 Ground Temperature The ambient ground temperature shall be considered as a maximum of 40 degree C.

3.2 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 test should be taken at all sites to identify where the thermal resistivity is likely to higher than 2.5 k m/W e.g. well drained sand where heavily loaded cables are to buried and operated in the summer. 3.3 Short Circuit Current Withstand Capability The Contractor shall provide detailed information in his material requisition for the I-squared-t short circuit current withstand capability which is applicable over the time rand of 0.2 to 10.0 seconds. This information shall be given in the form of equations or graphs for: a. The Conductors b. The armouring wires or braid 4.0 General Requirements 4.1 The Suppliers Product Range It is a general requirement that the Contractor offers only cable that is within the manufacturer 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 Client/Consultant. The cable shall not be a new product line that has not been sold in reasonable quantities to similar end users as the Client. The Contractor shall include in his quotation a list of end-users in the Middle East region that have purchased the same cable being offered. 4.2 Origin of Materials The Contractor shall offer all the cables in the purchase order from a manufacturer factory in one coutry; preferably the country where the purchase orders will be managed by the Contractor. Type Test certificates shall be in the name of the Contractor for the cable, and not in the name of a third party manufacturer or vendor. 4.3 Drawings and Documents All drawings and documents shall indicate units of measure in accordance with the S.I system. The Contractor shall submit with his material requisition documents cross-sectional area drawings to illustrate the proposed construction of all the types of cables being offered. These drawings shall indicate the dimensions and diameters of the main components e.g. Outside diameter of the outer sheating Inside diameter of the outer sheating Outside diameter of the armouring

Inside diameter of the armouring Outside 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 drawing.

5.0 Design and Performance Requirements 5.1 Voltage and Frequency Variations The cables shall operate correctly, continuously and without being overloaded when the Principals nominal system voltages deviate by plus or minus 10% for long period of time. Likewise when Principals nominal system frequency by plus or minus 5%. The worst cases of simultaneous variation of voltage and frequency shall be withstood by the cables. 5.2 The Electrical Power System The Principal shall state the rated power system voltage and frequency on the data sheets. 5.3 Conductor Maximum Continuous Operating Temperature The Contractor shall clearly state the value of the conductor maximum continuous operating temperature in his Material Approval Requests. This temperature should not exceed the value given below for typical design of power cables: Insulation Material Maximum Continuous Conductor Temperature (Degree C) 65 70 90 90

Paper PVC EPR XLPE 5.4 Conductor Maximum Short Circuit Operating Temperature

The conductor maximum short circuit operating temperature shall be no greater than that given in the Supplier of the Cables. The Contractor shall clearly state the value of the conductor maximum continuous operating temperature in his Material Approval Requests. This temperature should not exceed the value given for typical designs of power cables: Insulation Material Maximum Short-Circuit Conductor Temperature (Degree C)

Paper (compression connections) Paper (lead solder connections) PVC<300 mm2 PVC>300 mm2 PVC>6600V EPR XLPE 5.5 Short Circuit K Values for Copper Conductors

250 160 160 140 250 250 250

The short circuit K values for use in I2t calculations, for copper conductors surrounded by different insulation materials, armouring and sheathing, shall be taken as guidance to be: Insulation Material Short circuit K value A-secs/mm 2 250 160 150 130 130 250 250

Paper Paper (lead solder connections) PVC < 300 mm2 PVC> 300 mm2 PVC>6600V EPR XLPE

The time duration of the fault current shall normally be no less than one second, unless the cable is protected by fast acting fuse in which case the fusing time shall be taken into account. 5.6 De-rating Factors for various methods of cable installation The de-rating factors for various methods of cable installation shall be as per BS 7671 or as per the information provided by the manufacturer. 5.7 Flame Propagation, Smoke Production and Toxic Gas Emission 5.7.1 Flame Propagation All cables shall be constructed with materials that are of the Reduced Propagation of Fire tpe. The method of test ad test configuration used to demonstrate the capability should be as defined by IEC 60332 Tests on electric cables under fire conditions. 5.7.2 Smoke Production and Toxic Gas Emission The cable material shall be chosen such that the hazard of smoke and gas emission (e.g. Hydrochloric acid gas, halogens) during a fire shall be minimised. The data to be use shall be taken from IEC 60332-2.

5.7.3

Oxygen Index The oxygen index of all non-metallic except the installation shall not be less than 30 as described in BS 2782.

5.8 Fire Resistance Specified cable circuit 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 603311. This will be achieved by means of glass mica tape applied over the conductors in the form of helix. Mineral Insulated Copper Cables (MICC) is prohibited for use for vital services. 5.9 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. 6.0 Construction Requirements 6.1 Notation Used in This Document The generally accepted construction of the cable components is defined in the 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 3300V where semi-conducting screening may be needed for electric stress relieving. 6.2 Conductors The conductors shall be made of high purity electrolytic copper in accordance with BS 6360. The Aluminium shall not be used. The conductors shall be in 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 filters to form a compact circular cable. 6.3 Screening

The conductors for cables in which the phase-to-ground operating voltage is greater than 3600V RMS for PVC or XLPE insulation or 6000V RMS for EPR insulation shall be provided with a semiconductor screen, which shall be bonded to the inner surface of the insulation. 6.4 Conductor Insulation The insulation material shall be extruded over the conductor and be PVC, XLPE or EPR. EPR shall be used for operating line-to line voltages up to 6600 V RMS. Insulation grades for various service voltages shall be as follows: System Voltage (U) 11kV System 6.6kV System 3.3kV System 415/240V System 380V/220V System 6.5 Insulation Screening Rated V/Nominal System Volts (Uo/U) 18kV/30kV 6kV/10kV 1.8kV/3kV 660V/1000V 600V/1000V Highest Voltage (Um) 36kV 12kV 3.6kV

The insulation of conductors for cables in which the phase-to-ground operating voltage is greater than 3600V RMS for PVC or XLPE insulation or 6000V RMS for EPR insulation shall be provided with a semi-conductor screen, which shall be bonded to the outer surface of the insulation. 6.6 Insulation Screening Tape A copper tape wound in an over-lapped helical manner shall cover the insulation screening. Aluminium shall not be used. Where specified, copper tape shall be tin coated. 6.7 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 would 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. 6.8 Inner Sheathing

An inner sheath shall be provided over the bedding and insulation. For HV cables it shall be resistant to ozone, electric charge and surface tracking The inner sheath and filters shall provide a good longitudinal seal against humidity, gas and vapours. 6.9 Armouring Armouring shall be provided except for special applications. Tinned copper or bronze wires or braid shall be used for single cables. 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. Armour shall provide mechanical protection. The armour shall be of single galvanised steel wire. Galvanise steel wire braid shall be used for flexible cables and cables up to and including 10 mm2. The thickness of steel wire shall comply with IEC 60502. Particular consideration shall be given to the problem of armour becoming embedded in the inner sheath making separation for termination difficult. A stick-proofed tape shall be provided between the inner sheath and the braid. 6.10 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 mm2. Cables for offshore installation shall be low smoke low halogen types (LSLH). Cables to be used on HV circuits shall be of fire resistant design in accordance with IEC 60331. Cables meeting this requirement will be of cross-linked polyethylene (XLPE) insulated, steel wire armoured or braided, UV stabilised, PVC oversheath construction. 6.10.1 Land Based Installations a. Normal use in the air or ground The cable construction shall be:

For multi-core cables Cu/XLPE/GSWA/PVC For single core cables CU/XLPE/PBWB/PVC

or

Cu/XLPE/GSWA/XLPE

or

CU/XLPE/PBEB/XLPE

For single core cables in air (not in ground) CU/XLPE/AWA/PVC or CU/XLPE/AWA/XLPE b. Abnormal use in the air or in the ground In abnormal conditions (e.g. where oil spillage is expected) cable construction shall incorporate lead sheath: For multi-core cables CU/XLPE/PVC/Pb/PVC For single core cables CU/XLPE/PVC/Pb/PVC

or

CU/XLPE/XLPE/Pb/XLPE

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. 6.10.2 Platform based Installations a. Normal use in the air LV cables shall be cross linked polyethylene (XLPE), insulated, galvanised steel wire armoured (or braided for <10mm2), UV stabilised, PVC oversheath construction having flame retardant design in accordance with IEC 60332-3 Cat A. Ethylene Propylene Rubber (EPR) with Chloro-sulphonated Polyethylene (CSP) oversheath is also acceptable. The cable construction shall be For multi-core cables where flexibility or oil resistance is required CU/XLPE/CSP/GSWB/CSP or CU/EPR/CSP/GSWB/CSP For multi-core cables in general use 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 b. LV cables in accommodation areas

The EPR insulation shall be covered with an inner sheath of EMA or an acceptable alternative material The armouring shall be covered with an outter sheath of EMA or an acceptable alternative material The cable construction shall be: For multi-core cables CU/EPR/EMA/GSWB/EMA For single core cables CU/EPR/EMA/PBWB/EMA 6.11 Outer Sheathing

6.11.1 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 60332-3 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 6.11.2 Earthing Cables Earthing cables shall be insulated as described 6.12.3 ad the insulation material shall be coloured green and yellow. 6.12 Other Components

6.12.1 Fire Survival in Non-Accommodation Areas a. 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 start-up and supply the essential and vital services. b. LV Cables The conductors shall be wrapped with mica tape.

The insulation shall be covered with an inner sheath of EPDM or an acceptable alternative material The cable construction shall be: For multi-core cables where fire resistance is required CU/MT/XLPE/EPDM/GSWB/CSP OR CU/MT/EPR/EPDM/GSWB/CSP For single core cable where fire resistance is required CU/MT/XLPE/EPDM/PBWB/CSP or CU/MT/EPR/EPDM/PBWB/CSP 6.12.2 Fire survival in Accommodation Areas a. HV Cables As for 6.12.1 b. 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-core cable where fire resistance is required CU/MT/EPR/EMA/PBWB/EMA For single core cables where fire resistance is required CU/MT/EPR/EMA/PBWB/EMA c. 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 6.13 Colour of Components

6.13.1 Conductors Number of Phase and Neutral core 1 2 3 4 More than 4 6.13.2 Outer Sheathing Colour Service Voltage Volts 11000 6600 3300 600/1000 Power Control Cables 6.13.3 Outer Sheathing Marking The manufacturers name and voltage grade shall be permanently marked or embossed on the surface of the outer sheathing at intervals of approximately 3 meters along the total length of the cable. For the earthing cables this requirement is unnecessary. 6.14 Cable Glands Cable glands shall be manufactured and tested to the requirements of BS 6121 as EExd, EExe and Industrial glands shall be nickel plated brass. Entry thread 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. Colour colour Numbering

Black (or natural) Red, Black Red, Yellow, Blue Red, Yellow, Blue, Black White with black number

Not applicable 1 and 2 1, 2 and 3 1, 2, 3 and 4 1, 2, 3, 4, 5 etc.

Red Red Red Black Grey preferred, black acceptable

Cadmium plated brass glands are not acceptable.

6.14.1 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 industrical b. Choose appropriate gland type, i.e. indoor, outdoor 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. 7.0 Testing 7.1 General 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 procedures prepared by the Contractor and reviewed by Client/Consultant representative. These procedures shall include provision for assuring that the pre-requisites for a given test have been met an that the test is performed under suitable environmental conditions by appropriately trained personnel using recently calibrated instrumentation. 7.2 Type Test, 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 The following tests shall be effected: 7.2.1 Type Tests Tests which are required to be carried out by the manufacturer to prove compliance with the quoted specification 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:

a. b. c. d. e. f. g. h. i. j. k. l. m. n. o.

Oil Immersion test Ageing Test Water absorption Tinning tests on conductors Galvanising tests on armouring Material tests- Insulation and Sheath Ozone resistance Resistance to abrasion Stripping test Bend test Full witnessed test to IEC 60502 for the HV 11kV/6.6kV/3.3kV screened cables Sample test Reduced propagation to IEC 60332-3, category A. Fire withstand to IEC 60331. Smoke emission to appendix 1 or sterling report no 117, which is based on the IEC 60332-2. p. Oxygen index. q. Temperature index. r. Routine tests Tests to be carried out at regular intervals on each cable. Tests and records will be witnessed during inspection visits I. II. III. IV. V. VI. VII. VIII. 8.0 Packing 8.1 General The drum shall fully protect the cable, both radically 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 Contractor has finished using it. The drum shall be protected to give adequate protection during shipment to the site. 8.2 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 socket. The pocket shall be nailed or Visual examination Marking Dimensions Conductor resistance HV test Partial discharge Insulation resistance Bending test

screwed to the face of the drum at a place where it can be easily seen. At least the following information shall be printed on the label: Manufacturers name, address, telephone number, fax number, and telex number. Manufactures purchase order numbers and details Manufactures cable type details Clients purchase order number and details Date of manufacture Voltage grade Cable cross-section construction abbreviations Total length of the cable Total weight of the cable Unique drum number.