koc-i-011 rev.1

KUWAIT OIL COMPANY (K.S.C.)

DOC NO. KOC-I-011

KOC STANDARD FOR INSTRUMENT CABLES

(KOC-1-0 1 1 )

ISSUING AUTHORITY:

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STANDARDS DIVISION

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KOC STANDARD. FOR INSTRUMENT

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CABLES

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DOC NO. KOC-1-011 FORMERLY 0 1 5-JH-1912

1 1 1 SEP95 Approved as a KOC Jeff Healey Standard

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I I I I TEL: 61450 I

DATE DESCRIPTION Prepared by TEL: 61450

B P SECONDEE ENGINEER

SSD TEL:

61 541

CONTENTS

DOC NO. KOC-I-011

1 3.0 TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 I 4.0 REFERENCE DOCUMENTS & STANDARDS . . . . . . . . . . . . . . . . . . . . . . 4

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5 .0 ENVIRONMENTAL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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1 6 .0 MATERIAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6.1 GENERAL

Voltage Designation Conductors Insulation Filling and Bedding Armour (Metallic Covering) Screens & Drain wires Packing, Marking and Documentation

6.2 CABLE TYPES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 . 0 TESTING 13 I 8 .0 SPECIAL APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3

Flame Retardent Cables Fire Resistant Cables Low Halogen Acid and Smoke Emissions Oxygen Index Additional Tests for Fire Resistant Cables

9.0 DATASHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4

10.0 DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I 11.0 QUALITYASSURANCE 1 4

1 12.0 APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 1 5 1 Appendix 1 : Instrument Cable Data Sheet

SCOPE

DOC NO. KOC-1-011

This Standard .describes KOC1s minimum requirements for the Design, manufacture, testing and supply of lnstrument cables for use within the company facilities. It is developed for procurement of cables and includes a data sheet t o be completed for this purpose.

All instrument cables shall conform to the requirements of this standard, except as modified or be supplemented by the project specification data sheet.

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TERMINOLOGY

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Abbreviations

KOC: BS: IEC: IS Ex: XLPE: PVC: SWA: EPR: CSP: LCILY: GSWA: SWBA: TPE:

Kuwait Oil Company(K.S.C.) British Standard International Electrotechnical Commission Intrinsically Safe Equipment certified for use in hazardous areas Cross-linked Polyethylene Polyvinyl Chloride Single Wire Armouring Ethylene Propylene Rubber Chlorosulphonated Polyethylene Lead Covered Galvanised Steel Wire Armour Steel Wire Braided Armouring. Thermoplastic Elastomer

REFERENCE DOCUMENTS & STANDARDS

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 to the attention of KOC1s Controlling Department by Standards Division (if required).

lnstrument cables shall conform in design, materials and performance, except where otherwise specified, with the current issue and amendments of the following codes and standards prevailing on the effective date of the contract.

International Standards

IEC 227 PVC insulated cables of rated voltages up to and including 4501750V.

IEC 228 Conductors of insulated cables.

IEC 3 0 4

DOC NO. KOC-1-011

IEC 331

IEC 3 3 2

IEC 754 Part 1

ISAIANSI MC96.1

British Standards

BS 801

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BS 2782 Part 0

BS 5308 P t l

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BS 6207: Part 1

BS 6425 : Part 2

Standard colours for insulation of l ow frequency cables and wires.

Fire Resisting Characteristics o f Electric Cables.

Tests on Electric Cables under Fire Conditions.

Tests on gases evolved during combustion of electric cables.

American national Standards for temperature Measurement Thermocouples.

Specification for composition o f lead and lead alloy sheaths for electric cable.

Specification for galvanised mild steel wire for armouring cables.

Methods of testing plastics

lnstrumentation Cables: Specification for polyethylene insulated cables.

Specification for lnstrumentation Cables for Intrinsically Safe Circuits: PVC insulated cables.

Mineral insulated copper-sheathed cables w i th copper conductors.

PVC-insulated cables for electricity supply.

Specification for conductors in insulated cables and cords.

Performance requirement for cables required t o maintain circuit integrity under fire conditions.

Tests on gases evolved during the combustion of materials from cables.

Specification for elastomer insulated cables for fixed wiring in ships

UK Industry Standards.

EEMUA 133 Underground Armoured Cable Protected against Solvent Penetration and Corrosive Attack.

KOC standards.

DOC NO. KOC-1-011

KOC-G-004 KOC Standard for Packing, Marking & Documentation.

KOC-G-007 KOC Standard for Basic Design Data.

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5.0 ENVIRONMENTAL CONDITIONS

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The environment of Kuwait, is severe on all equipment and must be considered carefully before design and procurement of plant and equipment. It must be assumed that, unless otherwise specified, equipment may be subjected to sand and fine particle dust storms, sand laden winds, chemical contaminants, thunderstorms, heavy rain and extreme temperatures.

Humidity can pose a problem with relative humidity levels of 100% being part of the normal weather pattern.

Electrical equipment and materials shall be designed for continuous operation under ambient temperatures of -3OC to + 50°C.

KOC Standard for Basic Design Data, KOC-G-007, provides the detailed design information regarding the environmental, site, and utility supply conditions prevailing throughout the KOC facilities.

6.0 MATERIAL REQUIREMENTS

6.1 GENERAL

6.1.1 Voltage Designation

Instrument cables shall be designated for rated voltages or 600/1000 volts.

6.1.2 Conductors

The conductors shall comply with IEC 228 or BS 6360. Conductors shall be circular stranded or shaped stranded. 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 lnsulation

Insulation of the cores shall be suitable for the specified voltage designation and duty. The insulation shall be applied by an extrusion process to form a compact homogeneous body. Standard products should be purchased PVC, EPR, or XLPE all being acceptable as insulation on condition performance requirements are met. Where high temperature considerations are required and signal parameters can be met the use of MlCS cable is permissable.

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6.1.4 Filling and Bedding

The cable shall be circular and compact to meet the requirements for direct entry into Ex certified equipment.

Fillers shall be used in the interstices between each core or pair, and any central voids, where i t is not possible to achieve a compact and circular cross section wi th the extruded bedding.

6.1.5 Armour (Metallic Covering)

The armour specified in the Data Sheets shall be equal or an approved equivalent of that type which is detailed in BS 1442 or IEC 92-3, clauses 10.1 9, 10.20 & 10.21. KOC's preference is for Galvanised Steel Wire.

6.1.6 Screens & Drain Wires

The type of screening will be dependent on the signal and equipment concerned and will be specified on the Data Sheet. Overall screens to be Aluminium backed Mylar tape with copper drain wires under and in contact with the screen for the whole length of the cable.

6.1.7 Packing and Marking

The general requirements for packing and marking is covered by KOC Standard for Packing, Marking & Documentation, KOC-G-004.

a) MARKING OF SHEATHS & DRUMS (For core identification see approved cable list)

SHEATH

Where practicable the cables shall be marked every metre with the following:

Manufacturers Name National/lnternational Standard Identification

Cable Designation: No of cores & core sizes Voltage rating Sheath & Insulation type

The colour requirements for sheaths as well as cores is dependent on the plant design and will be specified in the data sheets.

DRUM

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.

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- Drum identification number. Voltage grade.

- Cable construction (eg XLPEILCIPVC, PVCISWAIPVC). - Number of cores and cross-sectional area. - Cable quantity. - Order number and item number. - Total weight of cable and drum.

Cables shall be drummed in maximum continuous lengths on 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 CABLE TYPES

6.2.1 General

The cable details noted on the next few pages are minimum requirements and test certification as indicated on the Data Sheet shall be provided to confirm compliance with the requirements.

Cable types 1 to 4 inclusive can also be used for below ground routing when a lead alloy wrapped sheath is included between the bedding and armour.

All Instrument Cables shall have outer sheaths formed from flame retardant PVC or similar meeting the test requirements of IEC 332, Category "A".

The cables listed are for use in general purpose instrument circuits. Details of specific cables such as signallsystem interface cables shall be specified on the data sheets.

All multi-pair cables operating below 50V shall incorporate a single telecommunication pair.

TYPE 1: Single pair or triple signal cables

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Grade Sheath Armour Tape

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Bedding Overall Screen Drain Wire

Core Insulation ldentification

Conductor

Twists

300t500 volt. PVC or CSP. Steel galvanised wire. A tape bearing the Approved Manufacturers name and year o f manufacture t o be laid under or over the core wrapping. TPE. Aluminium backed Mylar tape. Copper Wire under and in contact w i th the screen , running the full length o f the cable. PVC or EPR or XLPE. Cores colour t o be in accordance w i th BS 5308: Special colours can be specified in the Data Sheet but KOC's preference is bluelwhite for pairs, bluelwhite/brown for triples. 1.5 mm2 Stranded Annealed Tinned or bare Copper. 6-8 Twists per foot.

N.B. Lead sheathing required for below ground installations.

TYPE 2: Multi-pair or Multi-triple signal cables



Core lnsulation ldentification

Conductor

Twists

Telecommunication

3001500 volt. PVC or CSP. Steel galvanised wire. A tape bearing the Approved Manufacturers name and year of manufacture t o be laid under or over the core wrapping. TPE. Aluminium backed Mylar tape. Copper Wire under and in contact with the screen, running the full length o f the cable. PVC or EPR or XLPE. Cores colour t o be in accordance with BS 5308: Special colours can be specified in the Data Sheet but KOC's preference is bluetwhite for pairs, blue/white/brown for triples. Pairsltriples to be individually numbered. 1.0 mm2 Stranded Annealed Tinned or bare Copper. Pairs 6-8 Twists per foot , Bundle 2 Twists per foot. One additional pair , separately identified.


TYPE 3: Single pair solenoid valve and small power cables


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Bedding Core Insulation Identification Conductor

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Twists

60011 000 volt. PVC or CSP. Steel galvanised wire. A tape bearing the Approved Manufacturers name and year of manufacture to be laid under or over the core wrapping. TPE. PVC or EPR or XLPE. Coloured RedIBlack. 2.5 mm2 Stranded Annealed Tinned or bare Copper. Optional.


TYPE 4: Multi-core or Multi-pair solenoid valve and small power cables


Bedding Core Insulation ldentification

Conductor

Twists

6001 1 000 volt. PVC or CSP. Steel galvanised wire. A tape bearing the Approved Manufacturers name and year of manufacture to be laid over or under the core wrapping. TPE. PVC or EPR or XLPE. Cores coloured Redlblack and pairs numbered, or singles coloured white and numbered. 2.5 mm2 Stranded Annealed Tinned or Bare Copper. Optional.


TYPE 5: Single or Two pair thermocouple extension cable Refer to ISAIANSI MC96.1

DOC NO. KOC-1-011

Grade Sheath Sheath Colour

Armour Tape

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Bedding Overall & Pair Screens : Drain Wire

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Conductor

Twist

To suit Thermocouples. PVC or CSP. In accordance with coding colours of BS 4937, IEC 584-3 or ISAIANSI MC96.1 Steel Galvanised Wire. A tape bearing the Approved Manufacturers name and year of manufacture to be laid over or under the core wrapping. TPE. Aluminium backed Mylar tape Copper Wire under and in contact with the screen and running the full cable length. PVC or EPR or XLPE. In accordance with coding colours of BS 4937, IEC 584-3 or ISAIANSI MC96.1 Stranded or Solid core , Min. 1.0 mm2 Materials to suit Thermocouple Type. 6-8 Twists per foot.


TYPE 6: Multi-pair thermocouple extension cable Refer to ISAIANSI MC96.1


Bedding Overall & Pair Screens Drain Wire


Conductor

Twists

Telecommunication

To suit Thermocouples. PVC or CSP. Steel galvanised wire. A tape bearing the Approved Manufacturers name and year of manufacture to be laid under or over the core wrapping. TPE. Aluminium backed Mylar tape. Copper Wire under and in contact with the screen, running the full length of the cable. PVC or EPR or XLPE. In accordance with coding colours of BS 4937, IEC 584-3 or ISAIANSI MC96.1. Pairs to be individually numbered. Stranded or solid core, min. 1.0 mm2. Materials to suit Thermocouple Type. Pairs 6-8 Twists per foot , Bundle 2 Twists per foot. One additional pair, separately identified.


TYPE 7 : Multi-pair control room signal cables

Grade Sheath Tape


Core Insulation Identification

Conductor

Twists

300/500 volt. PVC or CSP. A tape bearing the Approved Manufacturers name and year of manufacture to be laid under or over the core wrapping. TPE. Aluminium backed Mylar tape. Copper Wire under and in contact with the screen , running the full length of the cable. PVC or EPR or XLPE. Cores colour to be in accordance with BS 5308: Special colours can be specified in the Data Sheet but KOC's preference is bluelwhite for pairs. Pairs to be individually numbered. 1.0 mm2 Stranded Annealed Tinned or bare Copper. Pairs 6-8 Twists per foot , Bundle 2 Twists per foot.

TYPE 8: Mineral Insulated Copper Sheathed Cable (MICS) to BS 6207 Part 1 Heavy Duty with Moisture Resistant Insulation. Above ground only.

Voltage grade 750 V

Insulation Compressed powdered mineral, chemically stable and non-corrosive to copper. A moisture resistant insulation version is now available (AEI).

Sheath Annealed copper.

Outer Sheath Extruded polyvinyl chloride. (When required)

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7.0 TESTING

All cables are to be subjected to routine tests at the manufacturers works in accordance with the relevant IEC or British Standard. Certification of the routine tests are to be provided in a Data book available at final inspection.

Type tests shall be carried out and certification provided t o demonstrate the additional requirements specified for Flame Retardant and Fire Resistant cables in section 8.0.

8.0 SPECIAL APPLICATIONS

8.1 Flame Retardant Cables

For use primarilly in offshore environments.

Cable totally constructed of materials which will not assist the spread of flame when the cable is exposed to combustion, meeting the test requirements set out in IEC 332.

8.2 Fire Resistant Cables

For use in essential circuits such as Fire & Gas and ESD and accommodation in offshore environments.

Cable constructed to allow continued normal operation for a period of 3 hours while exposed to a temperature of 750°C in accordance with IEC 331.

8.3 Low Halogen Acid and Smoke Emission

For use primarilly 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 data sheet and provide an analysis of the gas in compliance with BS 6425 Pt 2. Where low smoke emission and acid evolution are a requirement cables shall be specified to comply with the requirements of BS 6724, 721 1 & 6883 type D.

8.4 Oxygen lndex

For use primarilly in offshore environments where a value of 28 or greater is required.

All non metallic material components of the cable shall be tested for Oxygen lndex according to the requirements of a National Standard such as BS 2782 Pt 0, Method 141. The manufacturer shall state the value achieved and if applicable the equivalent standard used.

All correspondence, drawings, instructions, catalogues, data sheets, design calculations or any other written information shall be in the English Language. All dimensions, units of measurements, physical constants, etc. shall be in the SI units, unless otherwise specified. A Data book shall be provided containing the following:

a) Special installation instructions. b) All certification for routine and special tests. C) Test and inspection plans. d) Short circuit withstand capacities in graphical or formulae

format. e) Any appropriate literature and catalogues.

11.0 QUALITY ASSURANCE

The manufacturers shall operate a quality system to ensure that requirements of this Standard are achieved. The quality system shall preferably be based on the IS0 9000 series of standards and the manufacturer shall demonstrate compliance by providing a copy of the accredited certificate or the manufacturer's quality manual. Verification of the manufacturer's quality system is normally part of the prequalification procedure, and is therefore not detailed in the core text of this Standard.

8.5 Additional Tests for Fire Resistant Cables

Fire and Impact Resistance

Fire resistant cable shall be capable of operating when exposed to 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 bperating when exposed to a water spray during a fire as detailed in BS 6387. Cable ends are t o be sealed to prevent ingress of moisture during the test.

All tests are to be carried out on the same piece of cable.

9.0 DATA SHEETS

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 sheet 2 for completion by the manufacturer as part of their design verification.

In addition to the data sheets a schedule shall be provided specifying the exact cable lengths, the required cores and construction, sizing, and the specific cable markings and colour coding for each cable.

10.0 DOCUMENTATION

12.0 APPENDICES APPENDIX 1

INSTRUMENT CABLE DATA SHEET

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Data sheets for indent and purchase of cable To be completed in block capitals by purchaserlvendor

SHEET 1: TO BE COMPLETED BY THE PURCHASER

Cable Type No: Installation: AboveIBelow Ground? (Delete as applicable)

Type: 0 Flame Retardant Fire Resistant 0 Standard 0 Specific Interface

1. Nominal Voltage (Volts): 0 300/500 0 600/1000

2. Type: 0 DC Cl Single Phase a.c.

Cl Thermocouple Cl Other - Specify:

3. Frequency (Hz): 50 0 6 0 Not Applicable

4. Number of cores and Construction (See attached schedule).

5. Nominal cross sectional area of cores (See attached schedule)

6. Lengths (See attached schedule): Min Drum Length =

7. Conductors: Copper Cl Other - Specify: TI

8. Insulation:

9. Screen:

wisted pairs

To vendor's standard Cl Other - Specify:

No Cl Yes: 0 Overall Cl Individual pairltriple

10. Drain: Cl No Cl Yes Dia:

11. Bedding: To vendor's standard Cl Other - Specify

12. Tape: No 0 Yes: Min Thickness:

13. Lead Sheath: No Yes(Below Ground)

14. Armour: Cl SWA SWBA GSWA Other - Specify:

15. Outer Sheath: Cl Vendor's standard 0 Other - Specify: Colour:

16. Installation: Tray 0 Buried Unfilled Trenches

17. Certification: Routine Cl Type Copies:

Reqd: Wks after Inspection: With shipment:

18. Data (4wks from order): Cl Prints Transparencies Copies:

19. Inspection Required: Cl No Yes

20. Quality Plan Required: Cl No Cl Yes

21. Cable Marking & Colour Coding: (See attached schedule).

SHEET 2: TO BE COMPLETED BY THE MANUFACTURERISUPPLIER

DOC NO. KOC-1-011

1. Cable Dimensions:

Diameter under armour(rnm): Diameter over armour (mm): Overall Diameter (mm): Weight per km: Minimum Bending radii:

2. Resistance (ohmlkm): Max d.c. at 20°C Max a.c. at 20°C

3. Impedance (ohmlkm at 90°C and 60Hz):

4. Inductance (milliHlkm):

5. Capacitance (microF1km):

Core-Core: Core-Screen: El Core-Armour:

6. Cable armour resistance per km.:

7. Conductor loop resistance per km at 20°C (2x1 km of core):

8. Max loop resistance per km at up to 1 kHz (2x1 km of core):

9. Max LIR ratio:

10. Max mutual capacitance (microF1km):

11. Cable current carrying capacity:

12. Oxygen index for each cable type: (minimum 28)

13. Materials Used for each cable type:

Insulation:

Screen:

Bedding:

Sheath:

Armour:

Over Sheath:

14. Halogen Acid Evolution:

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Rating Factor:

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koc-i-011 rev.1

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