KOC STANDARD FOR INSTRUMENT CABLES

(KOC-1-01 1 )

ISSUING AUTHORITY:

STANDARDS DIVISION

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KUWAIT OIL COMPANY (K.S.C.)

J H l O l 1 R1 J?

DOC NO. KOC-1-01? Page 1 of 16

REV - 1 DOC NO. KOC-1-011 I CONTENTS

Page

1.0 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.0 GENERALIAPPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.0 TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.0 REFERENCE DOCUMENTS & STANDARDS . . . . . . . . . . . . . . . . . . . . . . 4

5.0 ENVIRONMENTAL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

6.0 MATERIAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

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

6.2 CABLE TYPES

7.0 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

8.0 SPECIAL APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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

9.0 DATASHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

10.0 DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

11.0 QUALITYASSURANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

12.0 APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Appendix 1 : Instrument Cable Data Sheet

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Page 3 of 16

1. SCOPE

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This Standard .describes KOCfs minimum re uirements for the Design, P manufacture, testing and supply of Instrument cables for use within the. company facilities. It is developed for procuremen$ of cables and includes a data sheet t o be completed for this purpose.

DOC NO. KOC-I-011

2.0 GENERALIAPPLICATION

All instrument cables shall conform to the require/nents of this standard, except I as modified or be supplemented by the project smpecification data sheet.

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1 3.0 TERMINOLOGY 1 I

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Abbreviations

KOC: BS: I EC: IS Ex: XLPE: PVC: SWA: EPR: CSP: LC1LY: GSWA: SWBA: TPE:

I Kuwait Oil Company(K.S.C.) British Standard International Electrote hnical Commission Intrinsically Safe

'! Equipment certified fo use in hazardous areas

Polyvinyl Chloride I Cross-linked Polyethylene

Single Wire Armouring Ethylene Propylene Ru ber

Lead Covered

b Chlorosulphonated ~o lbethy lene

Galvanised Steel Wire Armour I Steel Wire Braided Ar ouring. I Thermoplastic Elastomer I 4.0 REFERENCE DOCUMENTS & STANDARDS

In the event of conflict between this standard and the codes referenced herein, 1 the most stringent requirement shall apply, unless otherwise specified. I

Any exceptions or deviations from this standard, along wi th their merits and justifications, shall be brought to the attention of ~ O C ' S Controlling Department by Standards Division (if required).

lnstrument cables shall conform in design, matetials and performance, except where otherwise specified, wi th the cvrrent iskue and amendments of the following codes and standards prevailing on the kffective date of the contract.

International Standards

IEC 227 PVC insulated cables of rated voltages up to and including 450/750V.

REV - 1 DOC NO. KOC-1-011

IEC 304 Standard colours for insulation of low frequency cables and wires.

IEC 331 Fire Resisting Characteristics of Electric Cables.

IEC 332 Tests on Electric Cables under Fire Conditions.

IEC 754 Part 1 Tests on gases evolved during combustion of electric cables.

ISAIANSI MC96.1 American national Standards for temperature Measurement Thermocouples.

British Standards

BS 801 Specification for composition of lead and lead alloy sheaths for electric cable.

BS 1442 Specification for galvanised mild steel wire for armouring cables.

BS 2782 Part 0 Methods of testing plastics

BS 5308 P t l Instrumentation Cables: Specification for polyethylene insulated cables.

BS 5308 Pt2 Specification for Instrumentation Cables for Intrinsically Safe Circuits: PVC insulated cables.

BS 6207: Part 1 Mineral insulated copper-sheathed cables with copper conductors.

BS 6346 PVC-insulated cables for electricity supply.

BS 6360 Specrficat~on for conductors in insulated cables and cords.

BS 6387 Performance requirement for cables required to maintain circuit integrity under fire conditions.

BS 6425 : Part 2 Tests on gases evolved during the combustion of materials from cables.

BS 6883 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.

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DOC NO. KOC-1-0 1 1 Page 6 of 1 6 1 I REV - 1 KOC standards.

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

KO C-G-007

1. KOC Standard for Basic Design Data.

5.0 ENVIRONMENTAL CONDITIONS

The environment o f Kuwait, is severe on all equi ment and must be considered I carefully before design and procurement of plant and equipment. It must be I assumed that, unless otherwise specified, equipment may be subjected t o sand

and fine particle dust storms, sand laden winds, chemical contaminants, thunderstorms, heavy rain and extreme temperatures.

Humidity can pose a problem wi th relative humi ity levels of 100% being part of the normal weather pattern.

1 Electrical equipment and materials shall be desi,gned for continuous operation under ambient temperatures of -3 OC to + 50 O 0 .

KOC Standard for Basic Design Data, KOC-G-007, information regarding the environmental, site, prevailing throughout the KOC facilities.

6.0 MATERIAL REQUlREMENTS

6.1 GENERAL

6.1.1 Voltage Designation

Instrument cables shall be designated for rated or 60011 000 volts.

6.1.2 Conductors

provides the detailed design and utility supply conditions

voltages (Uo/U) of 3001500

The conductors shall comply wi th IEC 228 or ?S 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 insulati I n material wil l not corrode the conductors.

I 6.1.3 Insulation I Insulation of the cores shall be suitable for the sp cified voltage designation and

duty. The insulation shall be applied by an extru 6 ion process to form a compact homogeneous body. Standard products should bk purchased PVC, EPR, or XLPE all being acceptable as insulation on condition met.

performance requirements are

Where high temperature considerations are be met the use of MlCS cable is permissable.

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 it is not possible to achieve a compact and circular cross section with 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. KOCrs preference is for Galvanised Steel Wire.

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6.1 6 Screens & Drain Wires

6.1.4 Filling and Bedding

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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 wi th copper drain wires under and in contact wi th 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)

I SHEATH Where practicable the cables shall be marked every metre wi th 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.

I 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

. i robust and non-fading and give the following information.

11 DOC NO. KOC-1-011 I Page 8 of 16 REV - 1 Drum identification number. Voltage grade. Cable construction (eg XLPE+ClPVC, PVCISWAIPVC). Number of cores and cross-sectional area. Cable quantity. Order nurr~ber and item number. Total weight of cable and drum.

Cables shall be drummed in maximum continuous lengths on non I returnable cable drums with cable ends sealed and fixed to the drums. Cable drums shall be fitted with' battehs, fixed around the entire periphery of the drum.

1 6.2 CABLE TYPES

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

The cable detalls noted on the next few pages arle minimum requirements and test certification as indicated on the Data Sheet compliance with the requirements.

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

shall be provided to confirm

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

All multi-pair cables operating below 50V telecommunication pair.

shall incorporate a single

I DOC NO. KOC-I-011 Page 9 of 16 REV - 1 1

Grade Sheath Armour Tape

.a

Bedding Overall Screen Drain Wire

TYPE 1: Single pair or triple signal cables

Core Insulation ldentification

Conductor

Twists

3001500 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. 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 53.08: Special colours can be specified in the Data Sheet but KOC's preference is bluetwhite for pairs, bluetwhitetbrown 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

Grade Sheath Armour Tape

Bedding Overall Screen Drain Wire

Core Insulation ldentification

Conductor

Twists

Telecommunication

3001500 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. 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 bluetwhite for pairs, bluelwhitelbrown 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.

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

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TYPE 3: Single pair solenoid valve and small p d wer cables Grade 600/1000 volt. Sheath PVC or CSP. Armour Steel galvanised wire. Tape A tape bearing the Approved Manufacturers

name and year o 1 manufacture to be laid under or over the core

Bedding TPE. wrapping.

Core Insulation PVC or EPR or TLPE. Identification Coloured RedJBlack. Conductor 2.5 mrn2 stranbed Annealed Tinned or bare

Copper. Twists Opt~onal.

N.B. Lead sheathing required for below ground

TYPE 4: Multi-core or Multi-pair solenoid valve

Grade 600/1000 volt. Sheath PVC or CSP. Armour Steel galvanised Tape A tape bearing

name and year

installations.

and small power cables

wire. the Approved Manufacturers

of manufacture to be laid over or under the core wrapping.

Bedding TPE. Core Insulation i PVC or EPR or XLPE. Identification Cores coloured ded/black and pairs numbered, I or singles coloured white and numbered. Conductor I 2.5 mm2 Stranded Annealed Tinned or Bare

Copper. Twists Optional.

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

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

! Page 11 of 16

Bedding Overall & Pair Screens : Drain Wire

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Core Insulation ldentification

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.

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

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

Grade Sheath Armour Tape

Bedding Overall & Pair Screens : Drain Wire

Core Insulation ldentification

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.

N.B. Lead sheathing required for below ground installations. 3 %=

TYPE 7: Multi-pair control room signal cables

3001500 volt.

Overall Screen

Core Insulation Identification

Voltage grade

Outer Sheath (When required)

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

DOC NO. KOC-1-011 Page 1 3 of 1 6

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

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8.0 SPECIAL APPLICATIONS

8.1 Flame Retardant Cables

I For use primarilly in offshore environments. I 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.

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

I 8.3 Low Halogen Acid and Smoke Emission I For use primarilly in manned offshore environments. I A sample of each constituent component of the insulation, bedding and sheathing of the cable shall be tested in accordance wi th IEC 754 part 1. and the manufacturer shall state the total mass of acidic product released in the data sheet and provide an analysis o f the gas in compliance wi th 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 0.

8.4 Oxygen lndex

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

I

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.

8.5 Additional Tests for Fire Resistant Cables Fire and Impact Resistance

detailed in BS 6387.

Water Resistance During a Fire

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

9.0 DATA SHEETS

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 DOCUMENTA'TION

All correspondence, drawings, instructions, catlalogues, data sheets, design I 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 boo shall be provided containing the following:

I, a) Special installation instructions. b) All certification for routine aAd special tests. c l Test and inspection plans. d) Short circuit withstand capa ities in graphical or formulae

format. I

e) Any appropriate literature an catalogues.

11.0 QUALITY ASSURANCE

b The manufacturers shall operate a quality systeT 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 a~credited certificate or the manufacturer's quality manual. Verification of the manufacturer's quality system is normally part of the prequalification p/ocedure, and is therefore not detailed in the core text of this Standard.

12.0 APPENDICES APPENDIX 1

INS'TRLIMENT CABLE DATA SHEET

I

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

I SHEET 1: TO BE COMPLETED BY THE PURCHASER I I

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Cable Type No: .

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Installation: AbovelBelow Ground? (Delete as applicable)

Type: Flame Retardant Fire Resistant Standard Specific Interface

1. Nominal Voltage (Volts]: 3001500 60011 0 0 0

2. Type: DC Single Phase a x .

Thermocouple Other - Specify:

6 0 3. Frequency (Hz): 5 0 Not Applicable I ! I 4. Number o f cores and Construction (See attached schedule). I 1 I 5. Nominal cross sectional area of cores (See attached schedule) I I I 6. Lengths (See attached schedule): M in Drum Length = 7. Conductors: Copper Other - Specify: Twisted pairs

8. Insulation: To vendor's standard Other - Specify:

I 9. Screen: No Yes: Overall Individual pairltriple I I I 10. Drain: No Yes Dia: I I 11. Bedding: To vendor's standard Other - Specify

12. Tape: No Yes: Min Thickness: m m

13. Lead Sheath: No Yes(Below Ground)

14. Armour: SWA SWBA GSWA Other - Specify:

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

16. Installation: Tray 0 Buried Unfilled Trenches

17. Certification: Routine Type Copies:

Reqd: Wks after Inspection: With shipment:

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

19. Inspection Required: No Yes

' 1 20. Quality Plan Required: No 0 Yes I 21. Cable ,&larking & Colour Coding: (See attached schedule).

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I 1. Cable Dimensions: Diameter under armour(mm): Diameter over armour (mm): Overall Diameter (mm): Weight per km: Minimum Bending radii:

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

I 3. Impedance (ohmlkm at 90C and 60HzI: I I I 4. Inductance (rnilliHlkm): I I I 5. Capacitance (microFlkm): I I 6. Cable armour resistance per km.:

7. Conductor loop resistance per km at 20C (2x1 km of

Core-Core: Core-Screen:

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

Core-Armour:

9. Max LIR ratio: I 10. Max mutual capacitance (microFlkm):

11. Cable current carrying capacity: ~ a t i h ~ Factor: i 12. Oxygen index for each cable type:

(minimum 28)

I 13. Materials Used for each cable type: I I Insulation:

Screen:

Bedding:

Sheath:

Armour:

0ve; Sheath:

14. Halogen, Acid Evolution: