detailed technical specification for instrument cables
TRANSCRIPT
DETAILED TECHNICAL SPECIFICATION
FOR
INSTRUMENT CABLES
TS-I02
CONTROLLED COPY UN-CONTROLLED COPY
00 16.06.2017 First issue GS PG SSR
REV. NO. DATE DESCRIPTION PREPARED CHECKED APPROVED
DOCUMENT NO.
NO. OF SHEETS (including cover
sheet)
TS-I02
6
AVANT-GARDE
DETAILED TECHNICAL SPECIFICATION FOR INSTRUMENT CABLES
DOC. NO. TS-I02 REV NO. 00 DATE: 04.07.2017 PAGE NO. 2 of 6
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TABLE OF CONTENTS
1.0 Scope of Work ................................................................................................................................ 3
2.0 Scope of Supply .............................................................................................................................. 3
3.0 Scope of Services ............................................................................................................................ 3
4.0 Technical Specification .................................................................................................................. 3
5.0 Inspection and Testing ................................................................................................................... 5
6.0 Drawings & Documents to be Submitted ..................................................................................... 6
6.1 Drawings & Documents to be submitted along with the offer ............................................... 6 6.2 Drawings & Documents to be submitted after award of contract ......................................... 6
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DETAILED TECHNICAL SPECIFICATION FOR INSTRUMENT CABLES
DOC. NO. TS-I02 REV NO. 00 DATE: 04.07.2017 PAGE NO. 3 of 6
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1.0 Scope of Work
1.1 The scope of work covered in this specification includes design,
engineering, procurement, manufacture, shop testing and inspection,
packing and forwarding, transportation, supply, unloading, handling at
site, erection, cleaning, testing, commissioning, trial operation, final
painting and performance testing of all instrumentation cables specified.
1.2 The scope shall include all necessary work and supply of all items
whether mentioned in these specifications or not, but which are necessary
for the satisfactory, reliable and safe operation and maintenance of the
plant and equipment required for achieving guaranteed performance of the
plant. Any items, device or material even if not included during the
tender stage but found necessary for the safe and satisfactory functioning
of the units shall be supplied, erected and commissioned by the BIDDER / SUPPLIER.
2.0 Scope of Supply
2.1 Supply of instrumentation cables, signal cables and control cables as
specified / as required.
3.0 Scope of Services
3.1 Laying of all Instrumentation cables from field instruments, Motorized
valves and all other panels supplied by BIDDER / SUPPLIER to
PURCHASER’s DCS marshalling rack.
4.0 Technical Specification 4.1 General
4.1.1 All cables shall have PVC insulated primary insulation of 85 °C PVC.
Inner and outer jacket shall be 90 °C PVC and shall be fire retardant low
smoke type with Antirodent properties. Oxygen index of PVC shall be
over 30% and temperature index shall be over 250 °C. Insulation grade
shall be 1100 V and shall meet insulation resistance, voltage and spark test
requirements as per BS EN 50288-7.
4.1.2 The cables shall be twisted and armoured. Armour over inner jacket shall
be galvanized steel wire only.
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DETAILED TECHNICAL SPECIFICATION FOR INSTRUMENT CABLES
DOC. NO. TS-I02 REV NO. 00 DATE: 04.07.2017 PAGE NO. 4 of 6
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4.1.3 Inner jacket and outer jacket colour of the cables shall be black. Outer
jacket colour of the signal cable, control cable shall be light blue and grey
respectively.
4.1.4 The completed cable maximum DC resistance of the conductor shall be
12.3ohm/Km at 20 °C for 1.0 Sq.mm conductor. The mutual capacitance
of the pair or adjacent core shall not exceed 250 pF/m at a frequency of
1 KHz. The capacitance between any core and screen shall not exceed
400 pF/m. L/R ratio of adjacent cores shall not exceed 40 microhenry/ohm
for cables with 1.0 Sq.mm. The drain wire resistance including shield
shall not exceed 30 ohm/Km. Running length of the cable shall be printed
atleast at every meter interval.
4.2 Signal Cables (Pair/Triad):
The single pair/triad and multi pair/triad cables shall be of 1.0 Sq. mm
conductor size, made of electrolytic annealed tinned copper conductor of 7
strands with each strand of 0.43-mm diameter. All signal cables shall be
shielded. Multi pair cables shall be both individually and overall shielded.
Shield shall be aluminium backed Mylar/Polyester tape bonded together
with the metallic side down, helically applied with either side having 25%
overlap and 100% coverage. The minimum shield thickness shall be 0.05
mm. The drain wire shall be provided for both individual pair and over all
shields and shall be 0.5 Sq.mm multi stranded bare tinned annealed copper
conductor. The drain wire shall be in continuous contact with aluminium
side of the shield. Pair identification shall be blue and white. Triad
identification shall be blue, white and brown.
4.3 Control Cables:
The control cable shall be 1.5 Sq.mm conductor size made of electrolytic
annealed tinned copper conductor of 7 strands with each strand of 0.53-
mm diameter. The control cable shall be over all shielded. Shield shall be
aluminium backed Mylar/Polyester type. Each core shall be identified by
colour or by number at regular intervals. 4.4 K type Compensating cables:
The conductor material for K type compensating cable is Chromel (+) and
Alumel (-). Diameter of wire shall be 0.81 mm (20 AWG). The insulation
material shall be extruded HR PVC type C of IS:5831. The colour
identification for cable shall be Yellow and red. The taping material shall
be Polyester tape with thickness 0.023 mm (Min) of 25% Overlap and
100% coverage. The inner sheath material shall be PVC type ST2 of
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DETAILED TECHNICAL SPECIFICATION FOR INSTRUMENT CABLES
DOC. NO. TS-I02 REV NO. 00 DATE: 04.07.2017 PAGE NO. 5 of 6
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IS:5831. The colour of the inner sheath shall be black. The outer sheath
material shall be extruded FR PVC type ST2 of IS:5831 and the colour of
the outer sheath shall be yellow. The conductor resistance (max) shall be
1995 Ohm /km at 20 Deg C. The insulation resistance (min) shall be 100
MOhm/km. Oxygen index of PVC shall be over 30% and temperature
index shall be over 250 Deg C as per ASTMD 2863.
4.5 Type of cables
4.5.1 Instrumentation signal cables shall be considered for all analog input and
output signals, Instrumentation control cables shall be considered for all
digital input and output signals.
4.5.2 Size of the instrument signal cable shall be as below
� Branch cable:
4-20mA - 1P x 1.0 sqmm
T/C - 1P x 20 AWS
RTD - 1T x 1.0 Sqmm
� Main cable:
4-20mA - 12P x 1.0 sqmm or 6P x 1.0 Sqmm.
T/C - 12P x 20 AWS or 6P x 12 AWS
RTD - 6T x 1.0 Sqmm or 10T x 1.0 Sqmm
4.5.3 Size of the instrument control cable shall be as below
� Branch cable:
DI/DO - 2C x 1.5 sqmm
� Main cable:
DI/DO - 12C x 1.5 sqmm or 24C x 1.5 Sqmm
5.0 Inspection and Testing
5.1 Inspection and testing cables shall be carried in two major test procedures
as indicated below
Physical test
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Electrical test
5.1.1 Physical test
Physical test involves measurements of size, thickness of the various parts
of the cables. Size of the conductor & armour wire, diameter of each core
and over all cable shall be checked. Similarly thickness of insulation, outer
sheath, and inner sheath shall be tested. Checking of numbering on core /
pair and marking on outer sheath shall be the part of physical test
5.1.2 Electrical test
The following shall be tested during to ensure the parameters as specified
in the approved documents
- Resistance of Conductor & insulation,
- capacitance & inductance values
- Tensile strength of core and sheath,
- Elongation of core and sheath.
In addition to the above high voltage test and heat shock test shall be
carried out.
6.0 Drawings & Documents to be Submitted
6.1 Drawings & Documents to be submitted along with the offer
6.1.1 NIL
6.2 Drawings & Documents to be submitted after award of contract
6.2.1 Quality Assurance plan for cables
6.2.2 Instrument Cable Schedule
DETAILED TECHNICAL SPECIFICATION
FOR
HT & LT CABLES
TS-E13
CONTROLLED COPY UN-CONTROLLED COPY
00 12.06.2017 First issue JP SSR SSR
REV. NO. DATE DESCRIPTION PREPARED CHECKED APPROVED
DOCUMENT NO.
NO. OF SHEETS
(including cover sheet)
TS-E13
7
AVANT-GARDE
DETAILED TECHNICAL SPECIFICATION FOR HT & LT CABLES
DOC. NO. TS-E13
REV NO. 00
DATE 12.06.2017
PAGE NO. 2 of 7
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TABLE OF CONTENTS
1.0 Standards 3 2.0 General Construction 3 3.0 PVC Cables 3 4.0 LT XLPE Cables 4 5.0 HT XLPE Cables 4 6.0 Testing 5 7.0 Packing and Marking 6 8.0 Drawings & Documents to be submitted 6
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DETAILED TECHNICAL SPECIFICATION FOR HT & LT CABLES
DOC. NO. TS-E13
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DATE: 12.06.2017
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1.0 Standards
1.1 The design, manufacture and testing of cables shall comply with the
latest issue of the standards mentioned in the Design Basis.
2.0 General Construction
2.1 The cables shall be brand new and in good condition. These shall be
suitable for laying in trays, trenches, ducts, conduits and underground
buried installation with uncontrolled backfill and possibility of
flooding by water. Extra PVC / Rubber end caps for each XLPE Cable
size shall be supplied.
2.2 All cables shall have sequence marking for length. Cables shall also have embossment at regular intervals for brand, voltage grade and size.
3.0 PVC Cables
3.1 All power / control cables for use on medium voltage systems shall be
heavy duty type, 1100 V grade with aluminium / copper conductor,
PVC insulated, inner sheathed, armoured and overall PVC sheathed.
3.2 The construction of the conductors shall be ‘stranded’ for all cables. Conductors of nominal area less than 16 Sq.mm shall be circular only.
Conductors of nominal area 16 Sq.mm and above may be circular or
shaped.
3.3 The core insulation shall be with PVC compound applied over the
conductor by extrusion and shall confirm to the requirement of Type
‘A’ compound of IS: 5831. Control cables having 5 core and above
shall be identified with prominent and indelible ‘Arabic Numerals’ on the outer surface of the insulation. Colour of the numbers shall be
white with a spacing of maximum 500 mm between two consecutive
numbers.
3.4 The inner sheath shall be applied over the laid-up cores by extrusion
and shall be of PVC confirming to the requirement of Type ST1 PVC
compound of IS:5831. The extruded inner sheath shall be of uniform
thickness of size not less than those specified in IS.
3.5 For multicore cables, the armouring shall be by single round
galvanized steel wires where the calculated diameter below armouring
does not exceed 13 mm and galvanized steel strips where this
dimension is greater than 13 mm.
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DETAILED TECHNICAL SPECIFICATION FOR HT & LT CABLES
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3.6 The outer sheath for the cables shall be applied by extrusion and shall
be PVC compound conforming to the requirement of type ST1
compound of IS: 5831. To protect the cables against rodent and
termite attack, suitable chemicals shall be added into the PVC
compound of the outer sheath.
4.0 LT XLPE Cables
4.1 All cables shall be of heavy duty type, 1100V grade with aluminium
conductor, XLPE insulated, inner sheathed, armoured and overall PVC
sheathed.
4.2 The construction of the conductors shall be ‘stranded’ for all cables. Conductors of nominal area less than 16 Sq.mm shall be circular only.
Conductors of nominal area 16 Sq.mm and above may be circular or
shaped.
4.3 The core insulation shall be with cross-linked polyethylene unfilled
insulating compound. It shall be free from void and shall withstand all
mechanical and thermal stresses under steady state and transient
operating conditions.
4.4 The inner sheath shall be applied over the laid up cores by extrusion
and shall conform to the requirement of Type ST2 compound of IS:
5831. The extruded inner sheath shall be of uniform thickness of size
not less than those specified in IS.
4.5 For multicore cables, the armouring shall be by single round
galvanized steel wires where the calculated diameter below armouring
does not exceed 13 mm and galvanized steel strips where this
dimension is greater than 13 mm.
4.6 The outer sheath for the cables shall be supplied by extrusion over the
armouring and shall be of PVC compound confirming to the
requirement of Type ST2 compound of IS: 5831. To protect cable
against rodent and termite attack, suitable chemicals shall be added
into the PVC compound of the outer sheath.
5.0 HT XLPE Cables
5.1 All cables shall be with Aluminium Conductor, XLPE insulated,
screened, sheathed, armoured and overall PVC sheathed. Insulation of
cables shall be of 11 kV, Unearthed (UE) grade & 33kV Earthed (E)
type.
5.2 The construction of the conductors shall be dry cured type, stranded
and compacted circular for all cables.
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DETAILED TECHNICAL SPECIFICATION FOR HT & LT CABLES
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5.3 The cables shall be provided with both conductor screening and
insulation screening. The conductors shall be provided with non-
metallic extruded semi-conducting shielding.
5.4 The core insulation shall be with cross-linked polyethylene unfilled
insulating compound. It shall be free from void and shall withstand all
mechanical and thermal stresses under steady state and transient
operating conditions and insulation shall be dry cured.
5.5 The insulation shielding shall consist of non-metallic extruded semi-
conducting compound in combination with a non-magnetic metallic
screening of copper. The insulation screen shall be strippable without
application of heat. The copper screen shall be capable of carrying the
single line to ground fault current of 1 kA for duration of one (1)
second, for three cores together.
5.6 The conductor screen XLPE insulation and insulation screen shall all
be extruded in one operation by ‘Triple Extrusion’ process to ensure perfect bonding between the layers. The core identification shall be
coloured strips or by printed numerals.
5.7 The inner sheath shall be applied over the laid up cores by extrusion
and shall conform to the requirement of Type ST2 compound of IS:
5831. The extruded inner sheath shall be of uniform thickness of size
not less than 0.7 mm for all sizes of cables.
5.8 For multicore cables, the armouring shall be by galvanized steel strips
and armouring for single core cables shall be with hard-drawn
aluminium round wire of 2.5 mm diameter.
5.9 The outer sheath for the cables shall be supplied by extrusion over the
armouring and shall be of PVC compound confirming to the
requirement of Type ST2 compound of IS: 5831. To protect cable
against rodent and termite attack, suitable chemicals shall be added
into the PVC compound of the outer sheath.
6.0 Testing
6.1 The cables shall be tested and examined at the manufacturer's works.
All the materials employed in the manufacture of the cable shall be
subjected, both before and after manufacture of the cable, to
examination, testing and approval by PURCHASER /
CONSULTANT. Manufacturer shall furnish all necessary information
concerning the supply to the PURCHASER.
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6.2 After completion of manufacture of cables and prior to despatch,
cables shall be subjected to type, routine, acceptance and special tests
as detailed below. The test reports for all cables shall be got approved
from the PURCHASER / CONSULTANT before despatch of the
cables.
6.3 All routine tests as listed in standards mentioned in the Design Basis,
shall be carried out respectively for PVC cables and XLPE cables.
6.4 The inner and outer sheath of XLPE cables shall be subjected to all the
tests applicable for PVC cables. The test requirement for insulation
and sheath of PVC cables shall be as per latest revision of standards
mentioned in the Design Basis.
6.5 The SUPPLIER shall produce type test certificates as and when
demanded by the PURCHASER / CONSULTANT. These tests shall
also be conducted on mutually agreed terms, if insisted by the
PURCHASER / CONSULTANT.
7.0 Packing and Marking
7.1 Cable shall be despatched in wooden drum of suitable barrel diameter,
securely battened, with the take-off end fully protected against
mechanical damage. The wood used for construction of the drum shall
be properly seasoned, sound and free from defects. Wood
preservatives shall be applied to the entire drum.
7.2 On the flange of the drum, necessary information such as
manufacturer's name, type size voltage grade of cable, length of cable
in meters, drum No. cable code, ISI Certification mark, gross weight
etc., shall be printed. An arrow shall be printed on the drum with
suitable instruction to show the direction of rotation of the drum.
8.0 Drawings & Documents to be submitted
8.1 Drawings & Documents to be submitted along with offer
8.1.1 Bidder credentials as per the schedule
8.1.2 Schedule of deviation
8.1.3 Filled-in data sheets
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DETAILED TECHNICAL SPECIFICATION FOR HT & LT CABLES
DOC. NO. TS-E13
REV NO. 00
DATE: 12.06.2017
PAGE NO. 7 of 7
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8.2 Drawings & Documents to be submitted after award of contract 8.2.1 Drawing & Document Submission Schedule
8.2.2 Bar Chart for the design, manufacture and delivery
8.2.3 Filled-in Technical Data Sheets
8.2.4 Quality Assurance Plan.
SR. NO. BaaN ID Cable Type Discription G. Total (Mtr)
1 CAB0001 1Px 1.0 Sq. mm Signal Cable 6000
2 CAB0002 1Tx 1.0 Sq. mm RTD Triad Cable 1000
3 CAB0003 1Px20AWG Thermocouple Cable 1300
4 CAB0004 2Cx1.5 Sq. mm Control Cable 3500
5 CAB0005 3Cx2.5 Sq. mm Power Cable 1300
6 CAB0006 2Px 1.0 Sq.mm Multipair Signal Cable 1000
7 CAB0007 6Px 1.0 Sq.mm Multipair Signal Cable 800
8 CAB0008 12Px 1.0 Sq.mm Multipair Signal Cable 5300
9 CAB0009 9Cx1.5 Sq.mm Multicore Control Cable 7000
10 CAB0010 15Cx1.5 Sq.mm Multicore Control Cable 5000
11 CAB0011 24Cx1.5 Sq.mm Multicore Control Cable 3500
12 CAB0012 12Tx 1.0 Sq. mm Multicore RTD Cable 2000
13 CAB0013 12Px20 AWS Multipair Thermocouple Cable 300
14 CAB0014 3Cx6 Sq.mm Power Cable 400
15CAB0015
2 Pair x 0.20
Sqmm
Modbus Cable (Armoured) by DCS
supplier300
16 CAB0016 1C X 16 SQ MM EARTHING CABLE COPPER 500
CABLE ANNEXURE SHEET