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KOC-E-023
KOC STANDARD FOR ELECTRICAL POWER CABLES AND WIRING DOC NO: KOC-E-023
lSSUlNG AUTHORITY:
DOC NO. KOC-E-023
KOC STANDARD F0.R ELECTRICAL POWER CABLES and WIRING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 . GENERALIAPPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REFERENCE DOCUMENTS & STANDARDS ENVIRONMENTAL CONDITIONS
TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MATERIAL DESIGN REQUIREMENTS
GENERAL Voltage Designation Conductors Insulation Filling and Bedding Laying Up Armour (Metallic Covering) Marking and Identification of Cores, Sheath & Drums CABLE TYPES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Flame Retardant Cables Fire Resistant Cables L o w Halogen and Smoke Emissions Oxygen Index Additional Tests for Fire Resistant Cables Special Cables - Flexible and Oil Resistant
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 4 QUALITYASSURANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I6
DATASHEETS Cable Data Sheet
This Standard describes KOC's minimum requirements for the Design, manufacture, testing and supply of electric power cables and wiring for use within the company facilities. '-his Standard does not include cables for instrumentation;
Cables shall conform t o the requirements of this standard, except as modified or supplemented by the project specification data sheet.
Abbreviations KOC: BS: IEC: Ex(d): XLPE: PVC: SWA: EPR: CSP: LC: GSWA: SWBA: MlCS PlCC Kuwait Oil Company(K.S.C.) British Standard International Electrotechnical Commission Explosion proof Cross-linked Polyethylene Polyvinyl Chloride Single Wire Armouring Ethylene Propylene Rubber Chlorosulphonated Polyethylene Lead Covered Galvanised Steel Wire Armour Steel Wire Braided Armouring. Mineral Insulated Copper Sheathed Paper Insulated Copper Conductors
In the event of conflict between this standard and the codes referenced herein, the most stringent requirement shall apply, unless otherwise specified. Any exceptions or deviations from this standard, along with their merits and justifications, shall be brought t o the attention o f KOC's Controlling Departmentlstandards Division for their review, consideration and amendment (if required) of the standard. International Standards
Fire resisting characteristics of electrical cables. Tests on electric cables under fire conditions.
IEC 754 Part 1 IEC 8 1 1
Extruded solid dielectric insulated power cables for rated voltages from 1 kV up t o 30kV. Tests on gases evolved during combustion of electric cables. Common test methods for materials of electric cables. insulating and sheathing
IEC 8 8 5 British Standards BS 8 0 1
Electric test methods for electric cables.
Specification for composition of lead and lead alloy sheaths for electric cables. Specification for galvanised mild steel wire for armouring cables.
BS 2782 Part 0
Methods of testing plastics Specification for armoured cables w i t h thermosetting insulation for electrical supplies. PVC-insulated cables (non-armoured)for electric power and lighting.
BS 6207: Part 1
Rubber-insulated cables for electric power and lighting. Mineral insulated copper-sheathed cables with copper conductors. PVC insulated cables for switchgear and controlgear wiring. PVC-insulated cables for electricity supply. Performance requirement for cables required t o maintain circuit integrity under fire conditions.
BS 6425 : Part 2 Tests on gases evolved during the combustion of materials
from cables. Specification for impregnated paper insulated lead or lead alloy sheathed electric cables o f rated voltages up t o and including 33kV. Specification for cables with extruded cross-linked polyethylene or ethylene propylene rubber insulation for rated voltages from 3.8/6.6kV up t o 19133kV. Specification for armoured cables for electricity supply having thermosetting insufation and l o w emission of smoke
and corrosive gases when affected by fire. (60011000V & 1900J3300V ratings).
Specification for elastomer insulated cables for fixed wiring in ships Rubber Insulation & Sheath of Electrical Cables Thermosetting insulated cables (non armoured) for electric power and lighting with l o w emission of smoke and corrosive gases when affected by fire. (450/750V rating.)
BS 721 1
U.K. Industry Standards
EEMUA 133 Underground Armoured Cable Protected against Solvent Penetration and Corrosive Attack.
ENVIRONMENTAL CONDITIONS The environment of Kuwait, is severe on all equipment and must be considered carefully before procurement of plant and equipment. It must be assumed that, unless otherwise specified, equipment may be subjected t o sand and fine particle dust storms, sand laden winds, thunderstorms, heavy rains, chemical contaminants and extreme temperatures. Humidity can pose a serious problem with long periods of relative humidity levels of 1 0 0 % being part of the normal weather pattern. Electrical components and materials shall be designed for continuous operation under ambient temperatures of 50C in the shade. For buried cables a design temperature of 40C shall be used. Specific attention shall be given t o the following environmental factors:
Exposure t o seawater or salt spray. Exposure t o intense heat radiation from the sun or from a flare. Excessively high or l o w ambient temperatures. Exposure t o oil contamination and water pressure.
MATERIAL DESIGN REQUIREMENTS GENERAL
6.1.1 Voltage Designation
Power cables and wiring shall be designated for rated voltages (Uo/U) of 4501750V, 0.6/1, 1.913.3 or 6.3511 1 k V rms or other voltages as detailed in the attached data sheet. 6.1.2 Conductors The conductors shall comply with IEC 228. For power cables the conductors shall be circular stranded or shaped stranded tinned copper. Plain annealed copper conductors shall be used where elastomeric insulation of conductors is not employed providing that the manufacturer confirms that the core insulation material will not corrode the conductors. 6.1.3 Insulation Insulation of the cores shall be suitable for the specified voltage designation and duty. The insulation shall be applied by an extrusion process t o form a compact homogeneous body. Standard products should be purchased PVC, EPR, PlCC or XLPE all being acceptable as insulation on condition that performance requirements are met. Use of PlCC is subject t o KOC approval as it is being phased out. XLPE should be used in preference.
6.1.4 Filling and Bedding
The cable shall be circular and shall be substantially compact t o meet the requirements for direct entry into Ex(d) equipment. Fillers shall be used in the interstices between each core or pair, and any central voids, where it is not possible t o achieve a substantially compact and circular cross section with the extruded bedding. 6.1.5 Laying Up The cores of all cables having t w o or more cores shall be laid with a right hand direction o f lay. Alternate directions shall be used for successive layers of multicore cables. Twisting of cables shall not be permissable.
6.1.6 Armour (Metallic Covering)
The armour specified in the Data Sheets shall be equal or an approved equivalent of that type which is detailed in IEC 92-3, clauses 10.19, 10.20 & 10.21. Single core cables shall have non-magnetic armouring such as aluminium.
Page 8 o f 18
6.1.7 Marking and ldentification of Cores, Sheaths and Drums.
a)CORES Armoured cable: T w o cores
- Red and Black - Red, Yellow and Blue.
Three cores Four cores
- Red, Yellow,
Five cores and Above: White with black lett.ering along the core. Non armoured: b)SHEATH Colour: Marking: All voltages - Black Earth cable - Yellow and Green T o be embossed where practicable approx every metre: Manufacturers Name National/lnternational Standard ldentification No of cores & core sizes Cable Designation: Voltage rating Sheath & Insulation type Earthing cable: Yellow and Green stripes.
All cable drums shall have their identification reference clearly stencilled on the outside of both flanges. Drum identification labels shall be attached on the outside and inside of the drum flange. Labels shall be robust and non-fading and give the following information.
Drum identification number. Voltage grade. Cable construction (eg XLPE/LC/PVC, PVCISWAIPVC). Number of cores and cross-sectional area. Cable quantity. Order number and item number. Total weight o f cable and drum.
Cables shall be drummed in maximum continuous lengths o n non returnable cable drums with cable ends sealed and fixed t o the drums. Cable drums shall be fitted with battens, fixed around the entire periphery of the drum.
6.2.1 Approved Cable Types
Cables shall have annealed stranded circular or shaped copper or tinned copper conductors and should normally be selected from the types listed below, subject to their being suitable for their operating environment and any special application. All PVC outer sheaths shall be formed from flame retardant PVC meeting the test requirements set out in IEC 332 Part 3 CAT,A. The use of paper insulated cables is subject t o KOC approval and should only be considered where they can be justified on a cost basis otherwise XLPE insulated cables are to be selected in preference. XLPE Insulated. PVC lnner Sheath, SWA, PVC Outer Sheath Power Cable t o IEC 5021BS 6622 (XLPE/PVCshth/SWA/PVC) Voltage grade: Conductor Screen: Insulation: Core Identification: Insulation Screen:
Extruded semi-conductive compound. Cross linked polyethylene. Coloured red, yellow, blue. Extruded semi-conductive compound, bedding of semi-conductive tape and earth screen of copper tape. Cores laid up with rubber filling t o form a circular cable. Plastic tape wrapping and bedding of extruded polyvinyl chloride. Galvanised steel wire. Extruded polyvinyl chloride.
Conductor Lay:
Armouring: Outer Sheath:
XLPE insulated. lead covered. PVC inner sheath. SWA. PVC outer sheath Power Cable to IEC 502lBS 6622 (XLPEILCIPVCshthlSWA/PVC
Voltage grade: Conductor Screen: Insulation: Core Identification:
6.35111 kV.
Extruded semi-conductive compound. Cross-linked polyethylene. Coloured red, yellow, blue.
Page 1 0 of 1 8
Extruded semi-conductive compound, bedding of semi-conductive tape and earth screen of copper tape. Cores laid up with rubber filling t o form a circular cable. Plastic tape wrapping and lead alloy sheath according t o EEMUA 133. Extruded polyvinyl chloride. Galvanised steel wires. Extruded polyvinyl chloride.
mer Sheath:
3edding: Armouring: Outer Sheath:
Paper Insulated, Lead Covered, Steel Wire or Tape Armour. PVC Outer Sheath Power Cable to BS 6480. Voltage grade: Conductor Screen: Insulation: Insulation Screen: Core identification: Inner sheath: 6.3511 1kV Semi conductor carbon paper. Paper tape, mass impregnated non-draining. Non-ferrous metallic tape. Coloured red, yellow, blue. Plastic wrapping with lead alloy sheath according t o EEMUA 133 or BS 801. Extruded polyvinyl chloride. Galvanised steel wires or tape. Extruded polyvinyl chloride.
Bedding: Armouring: Outer Sheath:
XLPE Insulated. Lead Covered. PVC Inner Sheath. SWA. PVC Outer Sheath Power Cable to IEC 5021BS 5467 (XLPE/LClPVCshth/SWA/PVC. Voltage grade: Insulation: Core Identification: 0.611 k V or 1.913.3 kV. Cross-linked polyethylene. Up t o four core colours (red, yellow, blue and black). Five cores and above coloured white with black numbers along the length o f cores.
Page 1 1 of 1 8
Cores laid up with extruded PVC filler for up t o five cores. For six cores or more wrapping of polyester tape. Plastic tape wrapping and lead alloy sheath according t o EEMUA 133. Extruded polyvinyl chloride. Galvanised steel wire. Single-core cables shall have aluminium wire armouring. Extruded polyvinyl chloride.
Bedding: Armouring:
PVC Insulated. Lead Covered, PVC lnner Sheath, SWA, PVC Outer Sheath Power Cable to BS 6346 (PVCILCIPVCISWAIPVC. Voltage grade: Insulation: Core Identification: Extruded polyvinyl chloride.
Up t o four core colours (red, yellow, blue and black). Five cores and above coloured white with black numbers along the length of cores.
Cores laid up with extruded PVC filler for up t o five cores. For six cores or more wrapping of polyester tape. Plastic tape wrapping and lead alloy sheath according to EEMUA 133. Extruded polyvinyl chloride. Galvanised steel wire. Single-core cables shall have aluminium wire armouring. Extruded polyvinyl chloride.
lnner Sheath:
EPR Insulated. CSP lnner Sheath. Steel or Comer Allov Braid. CSP Outer Sheath Power Cable t o BS 6883 or IEC 92-3 for Flexible and Oil Resistant Duties. Voltage grade: Insulation: 0.611 kV t o 6.3511 1kV. Ethylene Propylene Rubber or equivalent type OR1 t o
Chlorosulphinated polyethylene or equivalent as inner sheath and fillers of synthetic rubber compound type RS3 to BS 6899
Galvanised mild steel, tinned annealed copper or tinned bronze braiding. Chlorosulphinated Polypropyleneorequivalent - Heat, Oil and Fire retardant synthetic rubber compound to BS 6883 type A, B, C or D selection dependent on requirements.
XLPE Insulated. PVC lnner Sheath, SWA, PVC Outer Sheath Power Cable to IEC 502lBS 5467 (XLPEIPVCshthlSWAIPVC Voltage grade: Insulation: Core Identification: 0.611 kV or 1.913.3 kV. Cross-linked polyethylene. Up t o four core colours (red, yellow, blue and black). Five cores and above coloured white with black numbers along the length of cores. Cores laid up with extruded PVC filler for up t o five cores. For six cores or more wrapping of polyester tape. Extruded polyvinyl chloride. Galvanised steel wire. Single-core cables shall have aluminum wire armouring. Extruded polyvinyl chloride.
Inner Sheath: Armouring:
PVC Insulated, PVC lnner Sheath. SWA. PVC Outer Sheath Power Cable t o BS 6346 (PVCIPVCISWAIPVC Voltage grade: Insulation: Core Identification: 0.611 kV Extruded polyvinyl chloride. Up t o four core colours (red, yellow, blue and black). Five cores and above coloured white with black numbers along the length of cores. Cores laid up with extruded PVC filler for up t o five cores. For six cores or more wrapping of polyester tape. Extruded polyvinyl chloride. Galvanised steel wire. Single-core cables shall have aluminum wire armouring.
Page 1 3 of 1 8
Extruded polyvinyl chloride.
Mineral Insulated Comer Sheathed Cable (MICS) to BS 6207 Part 1 Heavy Putv with Moisture Resistant Insulation. Voltage grade: Insulation: 750 V Compressed powdered mineral, chemically stable and non-corrosive t o copper. A moisture resistant insulation version is n o w available (AEII. Annealed copper. Extruded polyvinyl chloride.
Sheath: Outer Sheath: (When required)
PVC insulated sinqle core cable for use in conduit and Earthinq cable to BS 6004. 6007 and 6231 Voltage grades: Insulation: TESTING Routine tests shall be carried out as per the applicable standard and certification provided t o demonstrate these and any additional requirements stipulated for special applications e.g. Flame Retardant and Fire Resistant cables or Low Smoke and HCL emission. SPECIAL APPLICATIONS Flame Retardant Cables For use in offshore environments. Cable constructed of materials which will not assist the spread of flame when the cable is exposed t o combustion, meeting the test requirements set out in IEC 332. Fire ~ e s i s t a n t Cables For use in essential circuits and accommodation in offshore environments. Cable constructed t o allow continued normal operation for a period of 3 hours while exposed t o a temperature of 750C in accordance with IEC 331. Low Halogen Acid and Smoke Emission For use in manned offshore environments. A sample of each constituent component of the insulation, bedding and sheathing of the cable shall be tested in accordance with IEC 7 5 4 part 1. and the manufacturer shall state the total mass of acidic product released in the 4501750 V or 600t1000V Extruded polyvinyl chloride (colour t o suit service).
Page 1 4 of 1 8
data sheet and provide an analysis of the gas in compliance with BS 6425 Pt 2.Where l o w smoke emission and acid evolution are a requirement cables shall be specified t o comply with the requirements of BS 6724, 721 1 & 6883 type D. Oxygen lndex For use in offshore environments. All non metallic material components of the cable shall be tested for Oxygen lndex according t o the requirements of a National Standard such as BS 2782 P t l , Method 1410. The manufacturer shall state the value achieved and the standard used. A value of 2 8 or greater is required. Additional tests for Fire Resistant Cables Fire and Impact Resistance Fire resistant cable shall be capable of operating when exposed t o a source of heat as detailed in IEC 331 and sustaining a degree of mechanical impact as detailed in BS 6387. Water Resistance During a Fire Fire resistant cables shall be capable of operating when exposed t o a water spray during a fire as detailed in BS 6387. Cable ends are t o be sealed t o prevent ingress of moisture during the test. The insulation resistance of the cable during the test shall be not less than 1 megohm. All tests are to be carried out on the same piece of cable. Special Cables Special cables for use in marine environments, as trailing cables or for submersible pump applications require additional features such as flexibility, resistance t o pressure, heat and oil and flame retardancy. These should be selected from cables with synthetic rubber insulation and sheaths t o suit the particular application.
The information detailed on the data sheets (Appendix 1.) shall be provided for each type and size of cable. Sheet 1 is for completion by the purchaser and the remaining sheets are for completion by the manufacturer.
All correspondence, drawings, instructions, catalogues, data sheets, design calculations or any other written information shall be i n the English Language. All dimensions, units of measurements, physical constants, etc. shall be in'the SI units, unless otherwise specified.
The manufacturer shall operate a quality system t o ensure that the requirements o f this Standard are achieved. The quality system shall be preferably based on I S 0 9000. Certification may be done by internationally reputed inspection agencies. Verification of a Vendor's quality system is normally part o f the prequalification procedure, and is therefore not detailed in the core text of this standard.
Page 1 6 of 18
APPENDIX 1 CABLE DATA SHEET (KOC-E-023) Data sheets for indent and purchase o f cable T o be completed in block capitals b y purchaserfvendor pHEET 1: TO BE COMPLETED BY THE PURCHASER Type Refketter):
ITEM REF No: Cable Type: Standard (Tick appropriate) D Flame Retardant
D L o w Smoke & Acid Emission
0 Special (see schedule)
D 4501750V
0.611 kV
D DC O 3 Phase a.c.
0 Single Phase a.c. Other
3. Number of cores and Construction (See attached schedule)
4. Nominal cross sectional area of cores (See attached schedule)
5. Lengths (See attached schedule)
6. Conductors:
0 As per attached schedule 0 As per attached schedule
10. Armour:
D SWBA
D Unfilled Trenches
Page 17 o f 18
SHEETS 2 & 3:
TO BE COMPLETED BY THE MANUFACTURERISUPPLIER
1. Current Ratings in:(Vendor standard ratings for standard conditions)
Air: Duct: Ground: Please supply details of standard conditions for temperatures, thermal resistivities, proximity other cables, etc.
2. Resistance (ohmlkm):
Max d.c. at 20C Max a x . at 20C
3. Volt drop (per amp per metre) for each cable type:
4. Fault current (KA) for each cable type:
Duration Conductor 1.0 sec
2 5 0 degC
5. Diameter (mm):
under arrnour over armour overall
For each cable type
6. Weight (kgikm) for each cable type:
7. Bending radius (mm) for each cable type:
8. Materials Used for each cable type:
Insulation: Bedding: Sheath: Armour
9. Oxygen index for each cable type (where specified):
(minimum 28)
10. Halogen Acid Evolution (where specified):
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