CABLE ENGINEERING SPECIFICATION

CABLE ENGINEERING SPECIFICATION FOR MEDIUM VOLTAGE POWER CABLE, LOW VOLTAGE POWER AND CONTROL CABLE, FOR RUSTIMIYAH AND KERKH WWTP TABLE OF CONTENTS Page PART 1 – GENERAL 3 1.1 Work Included 3 1.2 Related Work 3 1.3 Codes and Standards 3 1.4 Quality Standards 4 1.5 Submittals 5 1.6 Shipping, Handling, and Storage 5 1.7 Service Requirements/Site Conditions 6 PART 2 – PRODUCTS 6 2.1 Materials – General 6 2.2 Conductors 7 2.3 Insulation 7 2.4 Shielding 7 2.5 Jacketing 7 2.6 Armoring 8 2.7 Assembly 8 2.8 Conductor Identification 8 2.9 Cable Identification 9 PART 3 – EXECUTION 9 3.1 Inspection and Testing 9 PART 1 – GENERAL 1.1 WORK INCLUDED Furnish medium voltage (5 kV) power cable in single or multiconductor nonshielded power cable, low voltage (600 volt) power and control cable, armored (metal clad) in the sizes and quantities stated in the Rustimiyah/Kerkh cable requisition sheet. 1.2 RELATED WORK 1.2.1 Delivery to jobsite, unloading, and site storage at location determined by representative. 1.3 CODES AND STANDARDS Furnish cable in accordance with the applicable portion of the latest revision of the following standards: AEIC CS5-94 Specifications for Cross-Linked Polyethylene Insulated Shielded Power Cables Rated 5 Through 46 kV AEIC CS6-96 Specifications for Ethylene Propylene Rubber Insulated Shielded Power Cables Rated 5 Through 69 kV ASTM B3 Standard Specification for Soft or Annealed Copper Wire ASTM B8 Standard Specification for Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft ASTM B33 Standard Specification for Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B496 Standard Specification for Compact Round Concentric-Lay-Stranded Copper Conductors ICEA P-32-382 Short Circuit Characteristics of Insulated Cable ICEA S-61-402 Thermoplastic-Insulated Wire and Cable for the Transmission and (NEMA WC 5) Distribution of Electrical Energy ICEA S-66-524 Cross-Linked-Thermosetting-Polyethylene-Insulated Wire and Cable (NEMA WC 7) for the Transmission and Distribution of Electrical Energy ICEA S-68-516 Ethylene-Propylene-Rubber-Insulated Wire and Cable for the (NEMA WC 8) Transmission and Distribution of Electrical Energy ICEA S-73-532 Standard for Control Cables (NEMA WC 57) ICEA S-82-552 Instrumentation Cables and Thermocouple Wire (NEMA WC 55) ICEA T-30-520 Guide for Conducting Vertical Cable Tray Flame Tests with Theoretical Heat Input Rate of 70,000 Btu/Hour IEEE-1202 Standard for Flame Testing of Cables for Use in Cable Tray in Industrial and Commercial Occupancies ISA MC96.1 Temperature Measurement Thermocouples NEC National Electrical Code, NFPA 70 NEMA C84.1 Electric Power Systems and Equipment Voltage Ratings (60 Hertz) NEMA WC 26 Wire and Cable Packaging UL 13 Standard for Safety – Power Limited Circuit Cables UL 44 Standard for Safety – Thermoset-Insulated Wire Cables UL 83 Standard for Safety – Thermoplastic-Insulated Wires and Cables UL 1072 Standard for Safety – Medium voltage (5 KV) Power Cables UL 1277 Electrical Power and Control Tray Cables UL 1569 Metal Clad Cables UL 1581 Vertical Tray Flame Test, 70,000 Btu/Hr UL 2250 Standard for Safety for Instrumentation Tray Cable 1.4 QUALITY STANDARDS 1.4.1 Control the quality of items and services to meet the requirements of this specification, referenced codes and standards, and other contract documents. 1.4.2 The Suppliers and their subsuppliers, as applicable, for this specification shall have a Quality Management System that complies with industry standards and that controls the manufacturing, testing, and inspection of their product. 1.4.3 Provide cables accepted by a recognized testing laboratory, unless otherwise noted in the material requisition or purchase order. 1.5 SUBMITTALS 1.5.1 Furnish cable design information, which shall include a description of cable construction (including generic chemical names of insulation materials, fillers, tapes, shields (if applicable), and jackets) and dimensions for all components. Provide cable construction drawings showing all dimensions. Dimensions for all components shall be given in both English and metric units. Provide guaranteed maximum outside diameter, and the weight per foot for each cable. Provide a description of the marking/ identification printed on the jacket for the cables being provided. A separate supplier drawing/cable data sheet shall be provided for each construction. 1.5.2 Provide recommendations for cable installation, including minimum bend radius (pulling and training), maximum pulling tension, maximum sidewall pressure, compatible pulling lubricants, and any other installation information which would aid in ensuring that cables are installed properly. Minimum training bend radius shall also be provided for individual single conductors. 1.5.3 Provide cable termination procedures and splicing details for medium/low voltage power cable. 1.5.4 Furnish instructions for handling, short-term storage (up to and including 6 months), and long-term storage (longer than 6 months) for use at the jobsite. 1.5.5 Furnish a certificate or statement of conformance which states that all type tests and production tests, as required by applicable standards, have been performed and that the cable supplied fully meets all requirements. 1.5.6 Furnish a statement of the design life of the cable and service conditions upon which this design life is based. 1.5.7 Furnish cable test reports and certifications that the cable meets the appropriate vertical tray flame test and that the cable is free of water. 1.6 SHIPPING, HANDLING, AND STORAGE 1.6.1 Prepare the cable for shipment and protect it from corrosion, dampness, reel breakage, etc. during transportation, handling, and storage. 1.6.2 Place continuous lengths of cable with no splices on individual reels. Shipping lengths shall be as noted in the Rustimiyah/Kerkh cable requisition sheet. Size the reel drums to maintain the minimum bending radius of cable. Cable shall be placed on reels so that both ends are accessible for inspection and testing upon receipt at the jobsite. Exposed portions of inner cable end shall be protected from damage by using wooden framing or equivalent. 1.6.3 Seal both ends of each cable with a weathertight seal (e.g., shrink caps) to prevent moisture from entering the conductor, insulation, jacketing, or interstices. 1.6.4 Protect each reel with weather-resistant covering to meet the requirements for Class 4, extra heavy-duty physical protector for medium voltage (5 KV) cable, and Class 3, heavy-duty physical protector for all other cable types, in accordance with NEMA WC‐26. If specified in the material requisition or purchase order, provide export lagging per Class 5 of NEMA WC-26. 1.6.5 Mark each side of each cable reel with a permanent tag bearing the Buyer's purchase order number, manufacturer's unique reel number, length of cable, size of conductors, number of conductors, Buyer's cable code, insulation voltage rating, and sequential length marking (if applicable). Embossed metal (aluminum) or plastic tags are acceptable. Paper tags are not acceptable. 1.6.6 Mark reels on each side with the following or equivalent words: STAND REEL ON RIM ONLY DO NOT LAY ON SIDE ROLL REEL IN THIS DIRECTION ONLY 1.7 SERVICE REQUIREMENTS/SITE CONDITIONS 1.7.1 Cables shall be suitable for use indoors or outdoors in open or covered trays, conduit, underground ducts, or directly buried in wet and dry locations. Cables shall be suitable for exposure to direct sunlight and a corrosive atmosphere that may be found in fossil, cogeneration, industrial, refinery, or chemical plants. 1.7.2 Medium voltage (5 kV) power cables shall be suitable for use on 3-phase 50 Hz ac systems rated at 5 kV, under operating conditions, including voltage variations specified in NEMA C84.1. 1.7.3 Medium voltage (5 kV) power cables shall be suitable for continuous use at conductor temperatures not exceeding 90 °C for normal conditions, 130 °C for emergency loading conditions, and 250 °C for short circuit conditions in accordance with applicable ICEA Standards. Cables shall also be rated for 90 °C wet or dry conditions. Medium voltage (5 kV) power cable rated for 105 °C is acceptable in lieu of cable rated for 90 °C. 1.7.4 Low voltage (600 volt) power, control, and instrument cables shall be suitable for use on 50 Hz ac systems rated 600 V or less and on dc systems rated 250 V or less between conductors specified in ANSI C84.1. 1.7.5 Low voltage (600 volt) power and control cables shall be rated for 90 °C wet or dry, unless otherwise specified in the material requisition or purchase order. PART 2 – PRODUCTS 2.1 MATERIALS – GENERAL 2.1.1 Asbestos or any other material deemed to be hazardous to health by the Occupational Safety and Health Administration (OSHA) shall not be used in any part of the cable. 2.1.2 Only flame-retardant, nonhygroscopic filler materials shall be used in construction of the cable. 2.2 CONDUCTORS 2.2.1 Only copper conductors that meet the requirements of Part 2 of the applicable ICEA Standard shall be used for all cable except thermocouple extension wire, fiber optic cable, and other specialty cable. 2.2.2 Class B or Class C, compressed concentric, or compact round stranded bare or coated annealed copper conductors that meet the requirements of applicable ASTM Standards (B3, B8, B33, or B496, as applicable) shall be used. 2.3 INSULATION 2.3.1 Cable insulation shall be thermosetting insulating compounds that meet the requirements of ICEA Standard S-66-524 (XLPE). All insulation materials shall meet the requirements of ICEA and UL standards. 2.3.2 Insulation shall be flame-retardant, and resistant to heat, moisture, ozone, oil, chemicals, and ultraviolet (sunlight). For nonshielded cable, the insulation shall also be resistant to electrical discharge and surface tracking. Insulation shall be suitable for the site conditions and service requirements specified in the material requisition or purchase order. 2.3.3 Wall thicknesses and tolerances shall be as specified in applicable ICEA Standards, with the minimum wall thickness no less than 90 percent of the average thickness. 2.3.4 For medium/low voltage power cable, an insulation level of 133 percent shall be provided unless otherwise specified in the material requisition or purchase order. 2.3.5 Nonshielded medium voltage (5 kV) power cables shall have insulation wall thickness which complies with NEC Table 310-63. 2.4 SHIELDING Medium voltage (5 kV) and low voltage (600 volt) cable will be nonshielded. 2.5 JACKETING 2.5.1 Provide a heavy-duty, overall jacket on each cable in accordance with Part 4 of the applicable ICEA Standard. Jackets such as chlorinated polyethylene (CPE), chlorosulfonated polyethylene (CSPE or hypalon), or flame-retardant PVC are acceptable. The manufacturer shall provide evidence that all cable passes the vertical tray flame tests of IEEE‐1202, UL 1072, UL 1581, or ICEA Standard T‐30-520, in addition to meeting all other specification and standard requirements. 2.5.2 Jackets shall be flame-retardant, and resistant to heat, moisture, ozone, oil, chemicals, and ultraviolet (sunlight). Jackets shall be suitable for the site conditions and service requirements specified in the material requisition or purchase order. 2.5.3 Wall thicknesses and tolerances shall be as specified in applicable ICEA Standards, with the minimum wall thickness no less than 80 percent of the average thickness. 2.5.4 Nonshielded medium voltage (5 KV) power cables shall have jacket wall thickness which complies with NEC Table 310-63. The jacketing shall also be resistant to electric discharge. 2.5.5 Low voltage (600 volt) power (both single and multiconductor), control, and instrument cable shall have a black flame-retardant, ultraviolet light resistant, overall jacket. 2.6 ARMORING Provide a protective armor between an inner and outer jacket. Armoring shall be either galvanized steel type, aluminum interlocked type, or continuously welded aluminum type. The armoring shall comply with the ICEA and UL Standards (e.g., UL 1072 and UL 1569). 2.7 ASSEMBLY 2.7.1 Low voltage (600 volt) power and control multiconductor cables are to be helically assembled with compatible fillers, as needed, and binder tape to present a substantially circular cross section. 2.7.2 Ground wires, when provided, shall be within the interstices of the cable, and shall be sized per UL 1072 Table 20.1 for medium voltage (5 kV) power cable and per NEC Table 250-122 for low voltage (600 volt) power cable. 2.8 CONDUCTOR IDENTIFICATION 2.8.1 For single conductor cables, identification shall be determined and marked in the field by the Buyer. 2.8.2 For multiconductor medium voltage (5 kV) power cables, individual conductor identification that meets the requirements of ICEA Standard S-66-524 or S-68-516 shall be provided. 2.8.3 For multiconductor low voltage (600 volt) power cable, size AWG #8 (8 mm2) and larger, conductor identification shall be per ICEA Standard S-73-532, Table E-2, Method 4. 2.8.4 Low voltage (600 volt) power cable sizes smaller than AWG #8 (8 mm2)and control cable, conductor identification shall meet the requirements of ICEA Standard S-73-532, Table E-2, Method 1 or 3. 2.9 CABLE IDENTIFICATION 2.9.1 Mark the cable jacket at a maximum of 3-ft intervals with the manufacturer's standard identification which meets the marking requirements of both NEC and UL standards. The marking shall be durable enough to remain legible for the life of the plant. PART 3 – EXECUTION 3.1 INSPECTION AND TESTING 3.1.1 Electrical tests on completed cables shall be made after manufacturing to verify quality. 3.1.2 Finished cable shall be free of water. The manufacturer shall certify that the cable is free of water. Evidence of water within the cable shall be grounds for rejection. 3.1.3 The manufacturer shall certify that the cable has passed the vertical tray flame test (70,000 Btu) per the requirements of IEEE-1202, UL 1072, UL 1581, or ICEA Standard T‐30‐520, as applicable. Cable Engineering Specification for Rustimiyah and Kerkh WWTP PAGE Page PAGE 9 of NUMPAGES 9