Guideline-Estimation of Cables

Document Number PEC-EN-GDE
GDE-E-08359
Revision 1
Applicability ALL
Document Type Guidelines
Guidelines - Estimation of Cables, Lighting, Earthing and

Bulk Material
REVISION / APPROVAL HISTORY
G.Jilani
Approved, Generally
enerally revised;
revised Girish K
1 19-May-2014 V.Neerathilingam Tushar Pase
hence revision not marked Ramesh SS
Vineet M
Girish K
Ramesh SS
0 11-Aug-2013 Approved G. Jilani R. Savardekar
Bambang H
Vineet M
Rev Date Description of Change Originator Reviewer Approver
Records of approval are retained in the QMS
Page 1 of 17
This document is an uncontrolled copy when printed or saved. Viewed by:
Periyanayaki Gurusamy 05-Nov-2014
Document Number Document Title Revision
Guidelines - Estimation of Cables, Lighting,
PEC-EN-GDE-E-08359 Earthing and Bulk Material 1
CONTENTS
1.0 PURPOSE................................
........................................................................................
........................ 3
2.0 SCOPE ...........................................................................................

................................ ........................... 3
2.1 DATE OF APPLICABILITY ................................................................

..................................... 3
3.0 DEFINITIONS ................................................................

................................................................................... 3
4.0 REFERENCES ................................................................

................................................................................... 4
5.0 RESPONSIBILITY & AUTHORITY .............................................................

............................. 4
6.0 DESCRIPTION................................
................................................................
................................................... 4
6.1 CABLES - HV / LV POWER, CONTROL – Sizing & Selection ................................
............................................. 4
6.2 CABLE LENGTH ESTIMATION ................................................................
................................................. 4
6.3 CABLE CARRIER SYSTEM - CABLE TRAYS, LADDERS, COVERS, SUPPORTS ............................ 8
6.4 EARTHING AND LIGHTNING PROTECTION MATERIAL................................
MATERIAL....................................................10
6.5 LIGHTING FIXTURES, LIGHTING DISTRIBUTION BOARDS ................................
...............................................10
6.6 LIGHTING POLE ...............................................................................................
................................ ...............................10
6.7 LOCAL CONTROL STATIONS (RCU), POWER RECEPTACLES,JUNCTION BOXES ......................12
6.8 TERMINATION KITS, JOINTING KITS ................................................................
....................................... 14
6.9 CABLE GLAND ................................................................................................
................................ ................................. 14
6.10 CABLE TIES, CLEATS & STRAPS ................................................................
.............................................15
6.11 CABLE MARKERS, FERRULES AND ROUTE MARKERS ................................
.....................................................15
6.12 CABLE TRANSIT SYSTEMS ................................................................
....................................................................................16
6.13 CONDUITS AND ACCESSORIES ................................................................
...............................................16
6.14 CABLE LUGS ................................................................................................
................................ ................................... 17
6.15 Sunshades................................
................................................................................................
...................................... 17
7.0 RECORDS................................
.......................................................................................
.......................17
8.0 Flow Chart................................

......................................................................................
......................17
Page 2 of 17
1.0 PURPOSE
This guideline include

lude estimation
tion of bulk material and consumable electrical items
such as cables, cable trays, Earthing & lightning Protection material, Lighting
System etc., where quantities required for procurement are dependent on specific
project requirements such as layouts, systems etc. and are required to be estimated
without full inputt data at the time of issue of inquiry requisition.
This guide does not include Tagged items such as transformers, switchgear etc.
which are easily identifiable and where quantity estimates are not difficult. The
intent of this guide is to suggest methods that will
will help in making the estimates of
quantities as accurate as possible.
possible
While using this guide, which is general and broad based,, caution must be exercised
to take care of specific project requirements.
requirements
2.0 SCOPE
Following equipment & material are included in this

t guide:
 Cables - HV / LV Power,
Pow Control and Instrumentation
 Cable carrier system-
system cable Ladder & trays, supporting structural steel, tray
covers
 Earthing and Lightning protection Material
 Lighting fixtures, Lighting distribution boards
 Lighting Pole
 Junction boxes
 Local Push Button stations & Power receptacles
 Termination kits, Jointing kits and cable gland
 Cable clamps and cable ties
 Cable markers and cable ferrules
fer
 Cable Transit System
 Rigid and Flexible Conduits
 Cable Lugs
 Sunshades
2.1 DATE OF APPLICABILITY

BILITY
From approved date
3.0 DEFINITIONS
Hazardous area
An area in which an explosive gas atmosphere is or may be expected to be present
in such quantities as to require special precautions for the construction, installation
and use of electrical apparatus
Page 3 of 17
4.0 REFERENCES
PEC-EN-FRM-E-11190 : Bill of Material (MTO) - Earthing & Lightning Protection

PEC-EN-FRM-E-11191 : Bill of Material (MTO) – Lighting
PEC-EN-FRM-E-11192 : Bill of Material (MTO) - RCU, Socket-outlets,
outlets, JBs, Isolators
Other references are provided under respective sections.
Standards
EN 10025-3 Hot rolled products of structural steels. Technical delivery conditions

for normalized/normalized rolled weldable fine grain structural steels
IEC 60309 Plug, socket-outlets

socket outlets and couplers for industrial purposes
IEC 61537 Cable management-

management Cable tray systems and cable ladder systems
BS EN 61386-1 Conduit systems for cable management. General requirements
BS EN 61386-21 Conduit systems for cable management. Particular requirements. Rigid

conduit systems
BS EN 61386-24 Conduit systems for cable management. Particular requirements.

Conduit systems buried underground
ISO 1461 Hot dip galvanized coatings on fabricated iron and steel articles –
Specifications and test methods
ISO 14713 Zinc coatings – Guidelines and recommendations for the protection
against corrosion of iron and steel in structures – Part 1: General
principles of design and corrosion resistance
NEMA VE 1 Metal Clad Tray Systems
NEMA VE 2 Cable Tray Installation Guidelines
NEMA FG1 Fiberglass Cable Tray Systems
5.0 RESPONSIBILITY & AUTHORITY

AUT
As indicated in the document.
6.0 DESCRIPTION
The various bulk equipment & material are covered under various sections below.
6.1 CABLES - HV / LV POWER, CONTROL – Sizing & Selection

For Selection and sizing of cable refer QMS Doc. No. PEC-EN-GDE
GDE-E-2185 Design
Guide-Cable
Cable Selection and Sizing.
S
6.2 CABLE LENGTH ESTIMATION

This section presents only the guideline to measure cable length. The purpose of
this guideline is to define the basic considerations used for cable length
measurement, ensure uniformity across various users and benchmark the cable
Page 4 of 17
length. The cases illustrated with sample drawings are for reference only. It is the
responsibility
bility of the user to define the actual length based on actual laying patterns
(including rise/drops, crossing, straight though joints, any loops etc.,) applicable
project codes, standards and specifications.
6.2.1 CABLE ROUTED INSIDE SUBSTATION BUILDINGS - Refer Fig.-A
FIG.-A
 TERMINATION LENGTH WITHIN PANEL / EQUIPMENT FROM GLAND PLA PLATE (‘Y’)
(a) FOR LV CABLES TO BE CONSIDERED AS 3M AT EACH END ; TOTAL= 6M
(b) FOR HV CABLES TO BE CONSIDERED AS 1.5M AT EACH END ; TOTAL= 3M
 ROUTE LENGTH FROM POINT A TO B = ‘X’ M

(- Route length from the gland plate of Start Panel/Equipment upto the gland plate
of End Panel/Equipment
-Above
Above Ground or Under Ground route length including the laying pattern, rise
/drops, crossings, straight through joints, any loops etc.,)
 (Z) = LENGTH SHALL BE CONSIDERED ALONG WITH LENGTH ESTIMATED

ES IMATED “A” TO “B”,
IF CABLES ARE LAID IN CABLE LADDER/TRAY OR BURIED INSIDE CABLE CELLAR
 ADDITIONAL CONTINGENCY
GENCY ON EACH CABLE LENGTH LAID INSIDE SUBSTATION
BUILDING ONLY
= 3M (FOR SUBSTATION LENGTH UP TO 30M)
= 6M (FOR SUBSTATION LENGTH BETWEEN 31M TO 60M)
= 9M (FOR SUBSTATION LENGTH ABOVE 61M)
Page 5 of 17
6.2.2 CABLE ROUTED FROM SUBSTATION TO FIELD (REFER FIG.- B)
FIG.-B
 TERMINATION LENGTH WITHIN PANEL / EQUIPMENT FROM GLAND PLATE (‘Y’)

(a) FOR LV CABLES TO BE CONSIDERED AS 3M AT PANEL END AND 2M AT LOAD END;
TOTAL= 5M
(b) FOR HV CABLES TO BE CONSIDERED AS 1.5M AT EACH END ; TOTAL= 3M
 ROUTE LENGTH FROM POINT A TO B = ‘X’ M

(- Route length from the gland plate of Start Panel/Equipment upto the gland plate
of End Panel/Equipment
-Above
Above Ground or Under Ground route length including the laying pattern, rise
/drops, crossings, straight through joints, any loops etc.,)
 (Z) = LENGTH SHALL BE CONSIDERED ALONG WITH LENGTH ESTIMATED “A” TO “B”,
IF CABLES ARE LAID IN CABLE LADDER/TRAY OR BURIED INSIDE CABLE CELLAR
 ADDITIONAL CONTINGENCY
GENCY ON EACH CABLE LENGTH ROUTED FROM SUBSTATION TO
FIELD
* 3% on each
ach Cable length upto 600m
* For cable lengths above 600m the additional contingency shall be finalized based
on balanced approach to get cost effective solution.
* For DC cables of long lengths,
lengths, the additional contingency shall be finalized based
on balanced approach considering impacts on the cable size.
Page 6 of 17
6.2.3 CABLE LENGTH ESTIMATION FOR FIELD LIGHTING CABLE (RFER FIG.
FIG.- C)
TERMINATION LENGTH 0.5M AT EACH END WITHIN JB = 1M
ROUTE LENGTH FROM POINT A TO B = ‘X’
‘ M (route in cable ladder or directly buried
as per project)
MARGIN TO TAKE CARE OF LAYING PATTERN AT SITE :-
:
DB TO 3Ph JB = 9M
3Ph JB TO 1Ph JB = 3M
M
M
POLE JB TO FIXTURE = Pole height x 1.5 times (i.e.;; MARGIN = half of pole height)
FIG.-C
6.2.4 CABLE LENGTH ESTIMATION FOR BUILDING LIGHTING

LI CABLE (REFER
REFER FIG.-D)
X= STRAIGHT LENGTH
MARGIN TO TAKE CARE OF LAYING PATTERN AT SITE :-
:
M
JB(1Ph JB) TO FIXTURE = 0.5M
FIG.-D
Page 7 of 17
PEC-EN-GDE-E-08359 Earthing
rthing and Bulk Material 1
6.2.5 CABLES ROUTED AT 90° BENDS

(REFER FIG.- E)
At 90°bends, the actual cable length of the bending radius portion (1022mm) is less
than straight measured lengths
length (1300mm). Hence at bends additional margin need
not be considered.
However, for routing of trefoil arrangement and at loops, bending radius depend
depends on
the diameter of the cable.
cable
FIG.-E
6.3 CABLE CARRIER SYSTEM - CABLE TRAYS, LADDERS, COVERS, SUPPO

SUPPORTS
Cable Carrier Systems are of following types:
 Cable ladders
 Perforated Cable Tray
 Cable Trunking
6.3.1 Material of construction

Material of construction shall be as specified in the Project Specification. In case
not specified by client,, following to be considered while selecting the material.
 Ambient Temperature (Minimum / Maximum ambient).
 Climatic Condition (Rain / Snow fall).
 Atmospheric Condition (Corrosive / Salty atmosphere)
Normally Cable trays, cable ladders and associated
associated accessories shall be
manufactured from steel material, hot dip galvanized in accordance with ISO 1461
Table-2.
Page 8 of 17
For climatic conditions with low temperatures less than –10ºC,, the cable trays,
ladders and associated accessories shall be manufactured from low temperature
grade steel (e.g:- S355J2G3) material, hot dip galvanized in accordance with ISO
1461 Table-2.The
The minimum galvanization thickness requirement depends on the
corrosion factor in the environment and the design life expectancy.
For highly corrosive/salty
alty atmosphere,
atmosphere cable trays, ladders & associated accessories
shall be manufactured from stainless steel or Fiber Glass, if recommended by
project specification.
6.3.2 Construction
truction Requirements
Cable ladder and tray system include a range of standard fittings (internal/external
risers, flat bends, reducers, tees, 4-way Crosspieces,, hold down clamps
clamps, Straight
Coupler plates,
tes, Adjustable Coupler plates for Vertical/ Horizontal bends/risers,
solid covers with clamp etc.)) and installation accessories such that complete cable
support systems can be assembled and installed with minimum of drilling and
cutting.
Cable ladders
Ladder rungs shall be fabricated steel,
steel slotted type. Spacing of rungs shall not
exceed 300mm.
Minimum loading depth for cable ladder shall be 100 mm.
SWL (safe working load) and midpoint deflection criteria 1/100th
1/100 of the span as per
IEC 61537 and NEMA VE-2
VE
For material, thickness, Loading requirement, support
supp etc. refer Doc. PEC-EN-STN-
E-08350 Specification for Cable Tray and Ladder system.
system
Cable Tray
Cable trays shall be perforated heavy duty, return flanged, having a min minimum
material thickness as per specification. Perforation slit orientation shall preferably
be along the length of tray as this is least harmful with respect to EMC requirement,
as per IEC 61000-5-2
Minimum loading depth for cable tray shall be 50 mm. Cable tray width shall be as
per NEC section 392.9 or as specified in project specification.
For material, thickness, Loading requirement, support etc. refer Doc. PEC-EN-STN-
E-08350 Specification for Cable Tray and Ladder system.
system
The Cable ladder and Tray are standardized as part of Frame Agreement. For details
of each type of Cable ladder and Tray, refer to the relevant drawings /documents
part of the Frame Agreement.
6.3.3 Supports for Cable Ladder & Tray

Design and Supply of supports for Cable Ladder & Tray is usually by Civil discipline.
In order to design the support the following information to be provided to Civil
discipline :
 Size of the cable ladder / tray.
 Mounting
nting or Hold down clamp detail.
 Spacing or the clearance between different voltage grade of the ladder /
tray.
 Ladder / Tray loading data.
Page 9 of 17
 Ladder / Tray support spacing.

 Refer to NEMA VE-2
VE 2 : Cable Tray Installation Guidelines, for details of
supports for Cable tray/ladder
Refer Doc. PEC-EN-GDEGDE-G01-12512– Cable ladder loading data, for the civil and
structural design of pipe racks and other steel structures.
6.4 EARTHING AND LIGHTNING PROTECTION MATERIAL

For selection, Design and sizing of Earthing and Lightning Protection material refer
Doc. No. PEC-EN-GDE-E E-08404 Guide - Safetyty Earthing and Lightning protection.
For typical MTO refer document number: PEC-EN-FRM-E-11190 : Bill of Material
(MTO) - Earthing & Lightning Protection.
Protection
The Earthing and Lightning protection material are standardized as part of Frame
Agreement. For details of Earthing and Lightning protection material, refer to the
relevant drawings /documents part of the Frame Agreement.
6.5 LIGHTING FIXTURES, LIGHTING DISTRIBUTION BOARDS

For selection, Design and Calculation of Lighting Fixture and Lighting Distribution
Boards refer Doc. No. PEC-EN-GDE-E-08402
PEC Guide - Lighting and small power system.
For typical MTO for lighting fixtures refer document number:
PEC-EN-FRM-E-11191 : Bill of Material (MTO) - Lighting
For the purpose of inquiry requisition, the first MTO may be issued after completion
of 60% of modeling.
The Lighting Fixtures are standardized as part of Frame Agreement. For details of
each type of lighting fixture, refer to the relevant drawings /documents part of the
Frame Agreement.
6.6 LIGHTING POLE

Selection of lighting pole depends upon requirement & application listed below:
 High Mast
 Flood Lighting Pole
 Street Lighting Pole
 Security / Fence Lighting Pole
 Platform / Stanchion Mounted lighting pole
While designing a lighting pole,
pole following need to be considered.
 Dead weight of pole
 Lighting fixture weight and surface area
 Wind loading on the pole and fixture due to a wind velocity as specified in
the project specification.
specification
6.6.1 High Mast Lighting Pole

High Mast Pole are 20 /25
/25 meter high, Polygonal / Circular construction or Lattice
Structure Lighting tower made up of Hot dip galvanized steel.
High Mast Polygonal / Circular pole shall have raising and lowering head frame
system comprising of Double drum winch mounted in the base
base compartment of the
Page 10 of 17
mast complete with Portable power tool consisting of motor, socket, junction box
and other accessories along with 10m m cable with reverse switch to allow remote
raising and lowering of the system, coupler to attach to the winch mechan
mechanism. For
construction detail of High mast refer DWG No. PEC-EN-SDR-E-46654665. Selection of
electrical components for high mast pole shall be based on Hazardous Area
Classification
ation Drawing.
6.6.2 Flood Lighting Pole

Flood Lighting Poles are 12 / 10 /8 meter high made up of Hot dip galvanized steel.
The Flood lighting pole are of two types:
type fixed and Hinged type. The hinged pole are
to two type: Middle Hinged or Bottom Hinged.Hinged. The hinged pole installed in
Hazardous area shall be provided with insulated bushing to avoid sparking. The
requirement of type of Flood Lighting Pole shall be as per Project specification
specification.
The flood lighting pole shall have extended bracket to fit junction box. This junction
box will be used for looping of lighting cables at the time of installation. The
Lighting pole shall be complete with cross arm bracket for mounting flood light and
hot dip galvanized steel pole cap.
cap
The poles shall be suitable for flange mounting and shall be supplied complete with
foundation anchor bolts, template and flange plates.
The lighting pole shall be installed in such a way that minimum gap shall be
maintained between the pole base plate and to the foundation.
For construction
truction detail of Flood Lighting Pole,
Pole refer DWG No.PEC-EN
EN-SDR-E-4657 and
PEC-EN-SDR-E-4658.
6.6.3 Street Lighting Pole

Street Lighting Poles are 10 /8 meter high made up of Hot dip galvanized steel. The
requirement of type of Street Lighting Pole shall be as per Project specification
specification.
The Lighting pole shall be complete with cross arm bracket for mounting Street light
fixture and hot dip galvanized steel pole cap.
cap
foundation anchor bolts, template and flange plates.
The lighting pole shall be installed in
i such a way that minimum gap shall be
For construction detail of Street Lighting Pole, refer Dwg. PEC-EN--SDR-E-4662
6.6.4 Security / Fence Lighting Pole

Fence Lighting Poles are 8 /6 meter high made up of hot dip galvanized steel or 2”
dia hot dip galvanized steel pole mounted on fence post. The requirement of type
of Security /Fence Lighting Pole shall be as per Project specification
specification.
The Lighting pole shall be complete with cross arm bracket for mounting Street light
fixture and hot dip galvanized steel pole cap.
cap
foundation anchor
chor bolts, template and flange plates.
The lighting pole shall be installed in such a way that minimum gap shall be
For construction detail of Fence Lighting Pole, refer Dwg. PEC-EN--SDR-E-4663
Page 11 of 17
6.6.5 Platform lighting poles / Stanchion pole

2.5M/3M long, 2” dia. galvanized steel tubular handrail mounted / ground mounted
lighting pole with accessories
access for mounting Lighting Fixture.
The Pole top shall be covered by suitable Hot-dip
Hot galvanized steel end
end-cap.
For construction detail of Platform lighting / Stanchion Pole refer DWG No. PEC-EN-
SDR-E-4655, PEC-EN-SDR
SDR-E-13056 & PEC-EN-SDR-E-13057
6.7 LOCAL CONTROL STATIONS (RCU), POWER RECEPTACLES,JUNCTION

JUNCTION BOXES
6.7.1 Local Control Station

Local control Station (RCU – Remote Control Unit) includes Start / Stop Push button,
Selector Switch, Indicating Lamp and Ammeter as per project specification.
Local Control Station enclosures shall be supplied in one of the following materials
as defined in the requisition:-
requisition:
 Glass reinforced Plastic (GRP)
 Copper-free die cast aluminium alloy
 Cast Iron
 Stainless steel
Enclosures for outdoor installation shall be rated minimum IP 555 and designed for
the environmental temperature specified in the project specification
Local Control Station enclosures shall be equipped with threaded cable entries as
appropriate to standards and hazardous area regulations. All pre pre-drilled cable
entries shall be fitted with proprietary blanking plugs, hazard certified according to
enclosure certification.
Non-metallic
metallic enclosures shall have factory installed integral earth continuity plates
at cable entry positions, complete with internal and externalrnal earthing connection
studs. Metallic enclosures will have internal and external earthing connection studs.
The Local Control Station is standardized as part of Frame Agreement. For details of
each type of Local Control Station, refer to the relevant drawings /documents part
of the Frame Agreement.
6.7.2 Power Receptacles

Welding Outlets or receptacles
Outlets shall be provided for portable welding supplies and other power
requirements on the basis of a maximum 50m extension lead, unless spe
specified
otherwise in project philosophy. These are provided generally at grade level,
installed on pipe rack columns or dedicated support structure as per typical
installation details.
These sockets shall be of the switched interlocked type, rated for low vvoltage
application with IEC 60309 colour and 5-pin
5 configuration.
A maximum of three welding outlets connected to each circuit circuit, unless specified
otherwise in project philosophy. Separate terminals shall be provided inside the
welding socket outlet for loop-in
lo and loop-out
out facility. Based on the cable size and
size of socket outlet, if separate Junction Box is envisaged, then separate JB shall
also be considered. Residual current devices with 30mA setting shall be used to
protect circuits against earth faults.
fa
Page 12 of 17
Only when specifically requested for in the project specifications or required as per
project ESD cause &effect diagram,
diagram the feeders
eeders supplying power to the welding
outlets shall include a contactor circuit to cut-off
cut off power to the sockets on receipt of
an ESD signal. The ESD circuit shall be fail-safe
fail safe type (normally closed contact under
healthy condition, open to trip).
trip)
Welding Socket outlets shall be of Industrial Type suitable for safe area or hazardous
area certified type suitable for classified area.
area. The selection shall be based on
Hazardous Area Classification drawing, unless specified otherwise in project
philosophy.
Convenience Outlets
General purpose, convenience socket outlets shall be provided on the basis of 25m
extension lead, unless specified
specified otherwise in project philosophy. These sockets shall
be of the switched interlocked type, rated for low voltage with IEC 60309 colour
and 3-pin
pin configuration.
General purpose, convenience Socket outlets shall be of Industrial Type suitable for
safe area or hazardous area certified type suitable for classified area. The selection
shall be based on Hazardous Area Classification drawing, unless specified otherwise
in project philosophy.
Non-industrial,
industrial, convenience socket outlets shall be provided in all administrative
buildings, control rooms and offices. They shall be of two pin and earth type,
suitable for low voltage application.
These socket outlets shall be supplied from lighting & small power distribution
boards with outgoing circuits incorporating 2 pole circuit breakers, each with 30mA
earth leakage protection.
protection Maximum of eight convenience socket outlets shall be
connected per circuit, unless specified otherwise in project philosophy
The Welding Outlets/ Convenience Outlets are standardized as p part of Frame

Agreement. For details, refer to the relevant drawings /documents part of the
Frame Agreement.
6.7.3 Junction boxes (JBs)

Junction box enclosures shall be of following material as defined in the requisition
and as per project requirement:
 Glass
lass reinforced plastic (GRP)
 Copper-free die cast aluminium alloy
 Cast Iron
 Stainless steel
The junction boxes shall be of Industrial type suitable for safe area or hazardous
area certified type suitable for classified area.
area The selection shall be based on
Hazardous Area Classification drawing, unless specified otherwise in project
philosophy.
Junction box enclosures shall be adequately sized to allow for maintenance and
replacement of individual terminals without major disassembly. Enclosures shall
have
e adequate spacing around terminal blocks for ease in termination of conductors
and for routing and bending cables without crossing over terminals.
Junction box enclosures shall have either removable un-drilled
drilled gland plates or
Page 13 of 17
threaded cable entries as appropriate to standards and hazardous area regulations.

All pre-drilled
drilled cable entries shall be fitted with proprietary blanking plugs, hazard
certified according to enclosure certification.
Non-metallic
metallic enclosures shall have factory installed integral Bra
Brass nickel plated
earth continuity plates at cable entry positions, complete with internal & external
earthing connection studs. Metallic enclosures shall ll have internal & external
earthing connection terminal.
terminal
Terminal sizes and quantities shall be in accordance
accordance with the project requirement.
The minimum size of terminal used will be suitable for a 2.5mm² stranded copper
conductors. Terminals shall be suitable for terminating conductors with or without
the use of crimped wire pins, lugs or equivalent.
For typical MTO refer to document number: PEC-EN-FRM-E-11192 : Bill of Material
(MTO) - RCU, Socket-outlets,
outlets, JBs, Isolators
The junction box is standardized as part of Frame Agreement. For details of each
type of Junction box, refer to the relevant drawings /documents part of the Frame
Agreement.
6.8 TERMINATION KITS, JOINTING KITS

Cable Termination kits are of Elastimold or heat shrinkable type depending upon the
terminal available in the Equipment. Termination kit shall be suitable for the
required voltage grade, cable type and Indoor/outdoor application.
The termination kit shall contain cable preparation kit (i.e. abrasive paper, string,
cleaning tissues and plastic gloves
gloves etc.) cable breakout, core insulation sleeves,
control tubing, solderless earth connection,
connection armour earthing kits and skirt (for
outdoor).
The type of insulating boot / sleeve (Straight or Right angle) and the tail length
depend upon the type of termination.
termina
The termination kits and jointing kits are standardized as part of Frame Agreement.
For details of termination kits and jointing kits, refer to the relevant drawings
/documents part of the Frame Agreement.
6.9 CABLE GLAND

Cable glands shall be of the nickel plated brass for multi core cable and stainless
steel 316 glands / Aluminum glands for single core cable. Double
D compression types
are used for armored cable and single compression type are used for unarmored
cable.
All cable glands used in hazardous
haz and non-hazardous area shall be dual certified
type (Ex‘d’ / Ex ‘e’) & IP65 degree of protection.
Cable glands shall be provided with inner/outer seal, entry thread seal, serrated
washer, earth tag and locknuts. The Cable glands shall be provided w with shrouds if
specified in the project specification. Each Gland shall be packed
ed separately in kit
form including all the accessories.
Cable glands shall have ISO metric threads of pitch 1.5 mm or as specified in the
project specification.
The sizing of cable
able gland depends on outer diameter and under armour diameter.
For selecting cable gland use cable manufacturer actual data and also consider the
impact of manufacturing tolerance.
Page 14 of 17
If project specification mentions the requirement of displacement type cab cable

glands, Deluge protection for cable glands and Insulated adaptors (application with
single core power cables) for cable glands, then these shall be specifically inquired
in the requisition.
In case the cable is not gas tight or the cable filler is loose and there is chance of
Hazardous gas travel for hazardous area to the panel. The barrier gland can be used
at one end of the termination.
Adaptor and Reducer with sealing washers , NPT to Metric Adaptor and Reducer with
sealing washers shall be considered wherever there is non-availability
availability of suita
suitable
size of the gland.
Note :
There had been cases where cable glands were supplied by vendor to site with
Gland main body, sealing washers, Locknuts and Earth Tags in separate packets
causing difficulties at site to assemble them, misplacement and shortages
shortages. Hence it
is recommended to specify in requisition to supply complete set of each gland
assembled.
The Cable glands are standardized as part of Frame Agreement. For details of cabl
cable
glands, refer to the relevant drawings /documents part of the Frame Agreement.
6.10 CABLE TIES, CLEATS & STRAPS

ST
Unless otherwise specified in the project specification; Tie-wraps
T wraps for outdoor shall
be 316 grade non-magnetic
magnetic stainless steel, PVC or nylon coated and UV resistant
resistant;
Tie-wraps
wraps for Indoor application shall be of Polypropylene or Nylon.
Normally, one
ne tie wrap per meter for horizontal runs and three wraps per meter for
vertical runs shall be provided to secure cables to the tray.
Stainless
ss steel (grade 316) cable cleats shall be 2 holes fixing bolted saddle clamp
type suitable for cable diameter.
diameter
Single core power cables fixed in trefoil formation shall be secured by means of
stainless steel (grade 316) banding; on epoxy coated cast iron bases (cable cleats).
These
ese trefoil clamps shall be non-magnetic
non magnetic & shall be complete with tensioning clip,
securing pin and binding key. Cable cleats for single-core
core cables shall be fully fault
rated.
Cable ties, cleats and straps shall be sufficient in size and number to guarantee
cable rigidity for the design duty.
6.11 CABLE MARKERS, FERRULES AND ROUTE MARKERS

All cables shall be identified at each termination and each side of any obstacle (e.g.
cable transit, ducting extremities, etc.) if any, by their
their respective numbers, as
indicated on the cable schedule. Cable markers are of following type:
 Printable flame retardant heat shrink sleeves
 Polyamide
olyamide carrier strips with slotted ends for fixing to cable by means of
cable ties
 Stainless steel cable tag plates
plates with slotted ends for fixing to cable by means
of cable ties
 Lad strips
For detail refer Drawing No. PEC-EN-SDR-E-4683.
Page 15 of 17
Lighting
For control cables, core ferrules shall be fitted

fitted at every termination. These ferrules
shall be of engraved plastic slip on, interlocked and self-grip type. Cable core
markings shall be permanent black characters on a yellow background.
Cable route markers shall be installed every 30 meters inside plant
nt battery limits
limits, at
every 100 meters outside plant battery limits,
limits at the cable entries to building and at
change of direction in cable trenches. Project specification shall be followed.
Cable marker pedestal shall be made of concrete. These markers shal shall have
Stainless steel (SS316) identification plates. Cable route markers shall be provided
as per typical cable marker installation drawing PEC-EN-SDR-E-4684
4684.
6.12 CABLE TRANSIT SYSTEMS

Cable entry (transit) systems for sealing cable passing through buildings shall be of
the modular, gas tight, compression type, utilizing neoprene type sealing blocks
held in a Galvanized steel frame or as specified the Project specificati
specification.
Frames shall be rectangular, single or multi-way,
multi way, with mounting flange, for bolting /
welding into building civil work, concrete structures or metallic frames/structures.
The material of Frames, stay plates, compression plates and Insert blocks shall b
be as
per Project specification.
Cable transit assemblies shall be suitable for use indoors and outdoors under the
environmental conditions specified in the project specification.
When located in outdoor safe non-hazardous area, cable transit system shall b
be
Industrial type having ingress protection of IP55.
6.13 CONDUITS AND ACCESSORIES

The conduits shall be of the following types in accordance with the project
specification/documents
 Rigid hot-dip
dip galvanized steel
 Rigid Polyvinyl chloride (PVC)
 Electricall Metallic Tubing (EMT)
 Flexible conduits
Minimum diameter of conduits shall be 20mm.
Rigid hot-dip
dip galvanized steel:
Conduit installed exposed (E.g., not embedded in walls) above ground in outdoor,
shall be threaded, rigid steel, hot dip galvanized.
Each piece of conduit shall be straight, free from blister and other defects; internal
surface shall be of smooth finish and covered with capped bushings at both ends.
Rigid hot dip galvanized steel conduits installed above ground in severe co
corrosive
environments shall be factory PVC coated.
Rigid Polyvinyl Chloride (PVC):
(PVC)
Wires in PVC conduit systems shall be used only for lighting, communication and
convenience outlets in closed buildings in non-hazardous
non areas.
Conduit installations shall be made with rigid PVC conduit and non
non-metallic conduit
boxes. Conduit box covers shall remain accessible.
Page 16 of 17
Electrical Metal Tubing (EMT):

(EMT)
Electrical Metal Tubing (EMT) made from coated steel or aluminium is acceptable
only in non-hazardous
hazardous indoor locations.
locations
Flexible Conduits:
Flexible
ble conduits shall be made with,
with cold-rolled,
rolled, annealed and electro
electro-galvanized
mild steel strips. Flexible
lexible conduits shall be used between embedded conduits/pipes
and the motor terminals,
terminals and for suspended Lighting;; wherever require
required. Flexible
conduits shall also be used between fixed conduit and any equipment terminal
boxes where vibration is anticipated or equipment that require regular removal.
Cable protection pipe sleeve shall be galvanized iron (GI) or PVC as per project
specification.
6.14 CABLE LUGS

Cable lugs shall be suitable for termination of different cross cross-sections of
HV/MV/LV/Control/instrumentation
MV/LV/Control/instrumentation cables and shall be of following types:
 Tinned Copper tubular
tubular terminal end for solder less crimping to
copper conductors. The cable lugs shall suit the type of terminals
provided on the equipment. Lugs for control/instrumentation cables shall be
PVC insulated/sleeved type.
type
 Cable lugs for control
co cable termination shall be insulated. These lugs shall
be either Pin
in type/
type Fork type / Ring type/ Blade type/ Hooked blade type to
suit the terminals provided in the panels.
panels
 For selection of lug type and number of holes on the lug refer terminal
details
ils provided by equipment vendor.
6.15 Sunshades
All electrical components such as Local Control Station (LCS), welding socket
outlets, convenience socket outlet etc., shall be suitable for the exposure
temperature and intense ultra violet radiations of desert environment and shall be
protected by sunshades where needed, to achieve an adequate temperature and UV
resistant rating. Material shall be GRP or sheet metal as per the project
specification.
7.0 RECORDS
Not applicable
8.0 FLOW CHART
Not applicable
Page 17 of 17

Guideline-Estimation of Cables

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Guideline-Estimation of Cables

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Document Number PEC-EN-GDE

Document Type Guidelines

Guidelines - Estimation of Cables, Lighting, Earthing and

REVISION / APPROVAL HISTORY

Records of approval are retained in the QMS

2.0 SCOPE ...........................................................................................

2.1 DATE OF APPLICABILITY ................................................................

3.0 DEFINITIONS ................................................................

4.0 REFERENCES ................................................................

5.0 RESPONSIBILITY & AUTHORITY .............................................................

8.0 Flow Chart................................

This guideline include

Following equipment & material are included in this

2.1 DATE OF APPLICABILITY

From approved date

PEC-EN-FRM-E-11190 : Bill of Material (MTO) - Earthing & Lightning Protection

EN 10025-3 Hot rolled products of structural steels. Technical delivery conditions

IEC 60309 Plug, socket-outlets

IEC 61537 Cable management-

BS EN 61386-1 Conduit systems for cable management. General requirements

BS EN 61386-21 Conduit systems for cable management. Particular requirements. Rigid

BS EN 61386-24 Conduit systems for cable management. Particular requirements.

NEMA VE 1 Metal Clad Tray Systems

NEMA VE 2 Cable Tray Installation Guidelines

NEMA FG1 Fiberglass Cable Tray Systems

5.0 RESPONSIBILITY & AUTHORITY

As indicated in the document.

6.1 CABLES - HV / LV POWER, CONTROL – Sizing & Selection

6.2 CABLE LENGTH ESTIMATION

6.2.1 CABLE ROUTED INSIDE SUBSTATION BUILDINGS - Refer Fig.-A

 ROUTE LENGTH FROM POINT A TO B = ‘X’ M

 (Z) = LENGTH SHALL BE CONSIDERED ALONG WITH LENGTH ESTIMATED

6.2.2 CABLE ROUTED FROM SUBSTATION TO FIELD (REFER FIG.- B)

 TERMINATION LENGTH WITHIN PANEL / EQUIPMENT FROM GLAND PLATE (‘Y’)

 ROUTE LENGTH FROM POINT A TO B = ‘X’ M

6.2.4 CABLE LENGTH ESTIMATION FOR BUILDING LIGHTING

6.2.5 CABLES ROUTED AT 90° BENDS

6.3 CABLE CARRIER SYSTEM - CABLE TRAYS, LADDERS, COVERS, SUPPO

6.3.1 Material of construction

6.3.3 Supports for Cable Ladder & Tray

 Ladder / Tray support spacing.

6.4 EARTHING AND LIGHTNING PROTECTION MATERIAL

6.5 LIGHTING FIXTURES, LIGHTING DISTRIBUTION BOARDS

6.6 LIGHTING POLE

6.6.1 High Mast Lighting Pole

6.6.2 Flood Lighting Pole

6.6.3 Street Lighting Pole

6.6.4 Security / Fence Lighting Pole

6.6.5 Platform lighting poles / Stanchion pole

6.7 LOCAL CONTROL STATIONS (RCU), POWER RECEPTACLES,JUNCTION

6.7.1 Local Control Station

6.7.2 Power Receptacles

The Welding Outlets/ Convenience Outlets are standardized as p part of Frame

6.7.3 Junction boxes (JBs)

threaded cable entries as appropriate to standards and hazardous area regulations.

6.8 TERMINATION KITS, JOINTING KITS

6.9 CABLE GLAND

If project specification mentions the requirement of displacement type cab cable

6.10 CABLE TIES, CLEATS & STRAPS

6.11 CABLE MARKERS, FERRULES AND ROUTE MARKERS

For control cables, core ferrules shall be fitted

6.12 CABLE TRANSIT SYSTEMS

6.13 CONDUITS AND ACCESSORIES