SECTION 16912 CONTROL, & INSTRUMENT CABLES

PART 1 - GENERAL 1.1 A. DESCRIPTION OF WORK Scope of work includes the design, manufacture, test and installation of control and instrument cables. The cable system shall be installed in ducts, in cable trays or in conduits. The supply of materials shall include the following: 1. 2. Manufacture of cables and all their respective accessories. Implementation of manufacturer's standards and otherwise specified quality control program for inspection and testing of products. Preparation of design and shop drawings, cable schedule and lists. Certification of compliance of all products with specification and test certificates. Delivery of all material and equipment to installation site.

B. C.

3. 4.

5. D.

The installation of the cable system shall include the following: 1. All electrical and telecommunication work required for installation of the cable system. Implementation of all manufacturer's standards and otherwise specified quality control, inspection and testing procedures.

2.

1.2 A.

QUALITY ASSURANCE Except as otherwise stated herein, all cables furnished in accordance with this specification shall comply with the following applicable Codes and Standards: 1. 2. 3. 4. 5. Insulated Cable Engineer's Association (ICEA) Institute of Electrical and Electronics Engineers (IEEE) National Electrical Manufacturers Association (NEMA) MARAFIQ Electrical Code (RCEC) National Electrical Safety Code (NESC)

P.O. Number : 7200018725

6. 7. 8. B.

American Society for Testing and Materials (ASTM) International Electrotechnical Commission (IEC) Saudi Arabian Standards Organization (SASO).

As a minimum, the latest edition of the following individual standards shall apply: 1. ICEA Standard No. S-68-516, as applicable (NEMA) Standard No. WC8, Ethylene Propylene rubber -insulated wire and cable for the transmission and distribution of electric energy ICEA Standard No. S-66-524, as applicable (NEMA Standard No. WC7), Crosslinked-thermosetting-polyethylene-insulated wire and cable for the transmission and distribution of electric energy. ICEA Standard No. P-32-382, Short Circuit Characteristics of Insulated Cables. IEC 93 -Methods of Test for Volume Resistivity and Surface Resistivity of Solid Electrical Insulating Materials. IEC 228 -Conductors of Insulated Cables Guide to the Dimensional Limits of Circular Conductor. IEC 540 -Test Methods for Insulation and Sheaths of Electric Cables and Cords (Elastomeric and Thermo-plastic Compound).

2.

3.

4.

5.

6.

C.

Any conflict between this Specification and the referenced standards shall be brought to MARAFIQ's attention for written resolution. This specification is based on the standards and publications referenced herein. Contractor may, upon the approval of MARAFIQ, use other standards and publications, the use of which will result in cables of comparable or better quality than that specified. The Contractor shall submit a copy of the applicable sections of the other standards in the English language for review by MARAFIQ.

D.

PART 2 - PRODUCTS 2.1 A. Cables shall be of the following types: 1. Control cables: Single or multi-conductor cables with 600 V, 90C crosslinked polyethylene or EPR insulation and copper conductor. Flame retardant jackets shall be used as the overall jacket for multi-conductor cables and for single conductor cables where required. Instrument cables: Cross-linked polyethylene or EPR insulated 300 V, 90C copper conductor pair, triad or quads with individual shield and overall

2.

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flame-retardant jacket. Multi-core cables shall have both individual and overall shields. 3. Thermocouple extension wire: Cross-linked polyethylene or EPR insulated 300 V, 90C chromel-constantan conductor pair with individual shield and overall flame-retardant jacket. Multi-core cables shall have both individual and overall shields.

B.

Minimum conductor size of the cables shall be: 1. 2. 3. 4. 5. Control : 2.5 mm2 single or multi-conductor PT Leads : 4.0 mm2. CT leads (1A sec.) : 4.0 mm2 CT leads (5A sec.) : 6.0 mm2 Instrument : 1.5 mm2 for pair, triad or quad, and 1.0 mm2 for multi pairs, triads and quads

6. Thermocouple extension : 1.0 mm2 for pair and multi-pairs

2.2 A.

CONTROL CABLES Control Cables: The cable shall be 600 V rated, single conductor or multi conductor 6mm2, 4mm2 or 2.5 mm2. Conductors shall be tin-coated stranded copper, insulated with a thermosetting, fire-retardant, oil-and heat-resistant compound. Cable shall be suitable for installation in conduits or ducts above and below ground and for exposed installation in cable trays. Cables shall be suitable for operation in wet or dry locations with alternatively wet and dry conditions. If exposed installations in cable trays are used, cable shall be suitable for operation in a sandy and salty atmosphere without affecting its physical and electrical characteristics. Outdoor cable trays shall be covered. Conductors: Conductor shall be Class B (7 strand) concentric-stranded copper, in accordance with ICEA S-66-524 (NEMA WC 7) or S-68-516 (NEMA WC 8). Conductor wire shall be annealed tin-coated wire, in accordance with ASTM B33 for tin-coated conductors. Concentric lay of the conductors shall conform to ASTM B 8. Insulation: 1. Insulation shall be heat-, oil-, ozone-, and moisture-resistant thermosetting compound rated for 90 C maximum conductor temperature under normal operating conditions, 130 C under emergency operating conditions, and 250 C under short-circuit conditions. The insulation shall be applied directly to

B.

C.

D.

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the surface of the conductor and shall fit tightly to that surface. Special fireretardant construction incorporating fire-resistant tapes may be used. 2. The average insulation thickness shall not be less than that specified in ICEA S-68-516, or ICEA S-66-524 based on the rated circuit voltage, cable insulation level, and conductor size. The minimum thickness at any point shall not be less than 90 percent of the average thickness. The electrical and physical properties of the insulation shall be in accordance with ICEA S-68-516, or ICEA S-66-524, as applicable to the insulation used.

3.

E.

Conductor Identification: Each conductor shall be color coded in accordance with Method 1 of ICEA S-66-524 Section 7.7.5. Cable Assembly: 1. The proper number of insulated conductors shall be cabled together in sequence, in accordance with ICEA S-68-516 or S-66-524 Fillers shall be used where necessary to assure a round cable. Filler material shall be non-hygroscopic, fire retardant, and shall not adhere to the conductors. A non-hygroscopic, fire-retardant binding tape shall be applied over the cable assembly.

F.

2.

G.

Outer Jacket: 1. Overall jacketing shall be a thermosetting, fire-retardant, heat-, oil-, ozone, and moisture-resistant material. The average jacket wall thickness shall not be less than that specified in ICEA S-68-516 or S-66-524. The minimum thickness shall not be less than 80 percent of the average thickness. The properties of the jacket shall be as indicated in ICEA S-68-516 or S66524, and ASTM D752. Cable shall carry the manufacturer's identification, voltage rating, number of conductors, type of cable, and size and sequential meter marker stamped on the outer jacket along the entire length of the cable. Cable identification shall be repeated along the cable at regular intervals of not more than 0.6 meter.

2.

3.

4.

5.

H.

Tests: 1. Cable shall be tested in accordance with the latest requirements of ICEA S68-516, or S-66-524.

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2.

Cable shall be tested to determine its capability of preventing the propagation of fire, and to determine that it has self-extinguishing characteristics. a) The flame-retardant capability of the cable shall be demonstrated by subjecting samples of the cable to be furnished to the vertical cable tray flame test as described in IEEE 383, paragraph 2.5. The sizes of the test samples shall be in accordance with IEEE 383, paragraph 2.2, Table 1. Individual insulated conductors of the multi-conductor cable shall satisfactorily pass the Underwriters' Laboratories, Inc. (UL) vertical flame test as described in UL 83 and the flame test as described in ICEA S-19-524, Section 6.12.5.

b)

2.3 A.

INSTRUMENTATION CABLE Instrumentation Cable: The instrumentation cables shall be suitable for use on thermocouple extension wire and cable and electronic instrument wire and cable systems. 1. Thermocouple Extension Wire and Cable: a) Thermocouple extension cable will be used to provide interconnection between remote thermocouples and the recorders, indicators, and plant computers. Thermocouple extension cable shall be 300-V insulation class, single-twisted and multiple-twisted pairs, individually shielded. Conductor material shall be chromel-constantan, insulated with a thermosetting compound with flame-retardant characteristics, and provided with an overall jacket of thermosetting compound.

b)

2.

Electronic Instrument Wire and Cable: a) Electronic instrument cable will be used to transmit low-energy signals from remote sensors to the plant computer and analog control systems, as well as to indicators and recorders. Electronic instrument cable shall be 300-V insulation class, singletwisted and multiple-twisted pairs, triads or quads, individually shielded. The conductor material shall be copper, insulated with a thermo-setting compound with flame-retardant characteristics, and it shall be provided with an overall jacket of thermosetting compound such as, but not limited to, neoprene or Hypalon.

b)

B.

Conductors: 1. Conductors for thermocouple extension wire shall be a solid alloy. Conductors shall be matched and calibrated in accordance with ANSI C96.1, and shall meet standard limits of error for temperature.

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2.

Conductors for electronic instrument wire and cable shall be Class B (seven-strand) concentric-stranded copper in accordance with IPCEA S68516 (NEMA WC-8) or S-66-524 (NEMA Wc-7). Part 2. Conductor wire shall be annealed coated wire in accordance with ASTM B 33 for tin-coated conductors or ASTM B 189 for lead-or lead-alloy-coated conductors. Concentric-stranded copper conductors shall conform to ASTM B 8.

C. Insulation: 1. Insulation shall be a thermosetting, fire-retardant, heat-, oil-, ozone-, and moisture-resistant compound, and shall be rated for 90C maximum conductor temperature under normal operating conditions. Insulation shall be applied directly to the surface of the conductor and shall fit tightly to that surface. Special fire-retardant construction incorporating fire-resistant tapes may be used. The average insulation thickness shall not be less than that specified in Part 3 of ICEA S-68-516, or ICEA S-66-524, based on the rated circuit voltage, cable insulation level, and conductor size. The minimum thickness at any point shall not be less than 90 percent of the average thickness. The electrical and physical properties of the insulation shall be in accordance with S-68-516, or ICEA S-66-524, as applicable to the insulation used.

2.

3.

D.

Conductor Jacket: Each insulated conductor shall be jacketed with a thermosetting compound. The average jacket wall thickness shall not be less than that specified in ICEA S-66524. The minimum thickness shall not be less than 80% of average thickness. The properties shall be as indicated in ICEA S-68-516 or S-66-524 and ASTM D 752.

E.

Lay of Twist: Insulated conductors shall be twisted in pairs, triads, or quads as indicated in ICEA S-68-516 or S-66-524. Conductor Identification: 1. Thermocouple extension wire shall be color coded by impregnating the conductor insulation in accordance with the color code requirements of ANSI C96.1. Where multiple-twisted pair cable is required, the group shall be identified by printed numbers on the conductor insulation. Electronic instrument twisted-pair cable shall be color coded according to Method 1 of ICEA S-66-524. Where twisted triad cable is required, the conductor insulation shall be impregnated black, white, and red; for twisted quad cable, the conductor insulation shall be impregnated black, white, red, and green. Multiple-twisted triad or quad cable groups shall be identified by printed numbers on the conductor insulation.

F.

2.

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G.

Shielding System: A continuous individual shield of aluminum-coated Mylar tape shall be provided on each twisted pair, triad, and quad. Shielding tape shall have a minimum thickness of 1.5 mils and shall be applied with a minimum of 25% overlap. A 0.82 mm bare stranded-copper drain wire, running the entire length of the cable in continuous physical contact with the aluminum coating on the mylar tape, shall be provided.

H.

Cable Assembly: 1. The conductors, pairs, triads, or quads, shall be assembled in accordance with ICEA S-68-516 or S-66-524 Fillers shall be used where necessary to assure a round cable. Filler material shall be non-hygroscopic and fire retardant, and it shall not adhere to the jacketed conductors. A non-hygroscopic, fire-retardant, binding tape, providing a barrier to direct flame, shall be applied over the cable assembly.

2.

I.

Outer Jacket: 1. Overall jacketing shall be of a thermosetting fire-retardant, heat-, oil-, ozone-, and moisture-resistant material. The average jacket wall thickness shall not be less than that specified in ICEA S-68-516 or S-66-524. The minimum thickness shall not be less than 80% of the average thickness. The properties shall be as indicated in ICEA S-68-516 or S-66-524 and ASTM D 752. The cable shall carry the manufacturer's identification, voltage rating, number of conductors, type of cable, size, and sequential meter marker stamped on the outer jacket along its entire length. Cable identification shall be repeated along the cable at regular intervals of not more than one meter.

2.

3.

4.

5.

J. Tests: 1. The cable shall be tested in accordance with the latest requirements of ICEA S-68-516, or S-66-524. The cable shall be tested to determine the capability of preventing the propagation of fire and to determine that it has self-extinguishing characteristics. a. The flame-retardant capability of the cable shall be demonstrated by subjecting samples of the cable to the vertical cable tray flame test as described in IEEE 383, section 2.5. The sizes of the test samples shall be in accordance with IEEE 383, Section 2.2, Table 1.

2.

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b.

Individual insulated conductors of multiple conductor cable shall satisfactorily pass the Underwriters' Laboratories, Inc. (UL) vertical flame test described in UL 83, and the flame tests described in ICEA S-68-516 or S-66-524.

PART 3 - EXECUTION 3.1 A. CABLE INSTALLATION Each cable shall be pulled into the particular conduit and/or cable tray designated for it on Contractor's Drawings and in his Cable and Raceway Schedule. Where cable on reels is provided with end seals, when portions of cable are pulled, and cut made, end seals shall be established on cut ends. ++ END OF SECTION 16912 ++

P.O. Number : 7200018725