SAES-P-104

Engineering Standard SAES-P-104 Wiring Methods and Materials

29 December 2021

Document Responsibility: Electrical Systems Designs & Automation Stds Committee

Contents

1 Scope … 2

2 Conflicts, Deviations, and Commentary … 2

3 References … 2

4 General … 8

5 Wire and Cable … 8

6 Connections and Terminations … 12

7 Enclosures … 15

8 Conduit, Conduit Fittings, and Supports … 17

9 Cable Trays … 20

10 Underground Cable Systems … 22

11 Submarine Power Cable … 25

12 Cable Sizing … 27

13 Cable Testing after Installation … 29

14 Cable Separation … 32

15 Conduit and Cable Sealing … 33

Revision Summary … 34

Previous Issue: 20 February 2019

Contact: (MAHAYNRX)

Next Planned Update: 29 December 2023 Page 1 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

Scope

1.1

1.2

1.3

1.4

1.5

1.6

1.7

This Standard prescribes mandatory requirements for the design and installation of insulated power and control wiring and cable systems. It also prescribes minimum mandatory requirements for outdoor enclosures for electrical equipment and wiring that are not covered by another SAES or SAMSS.

For the purpose of this standard, control wiring is wiring used for the connection of electrical control and monitoring devices associated with power systems, such as pushbuttons, relays, meters and transducers, etc.

For the purpose of this standard, wiring connected on one or both sides to instruments, distributed control systems, computers, etc., is considered instrumentation wiring and is covered by SAES-J-902.

Fiber optic cables dedicated to the control of power systems, such as intertrip and switchgear control shall be installed as per SAES-T-919 and the applicable SAES-T series. This shall include composite power-fiber optic cables and composite submarine cables.

This standard does not apply to internal wiring of manufactured equipment covered by SAMSS, or manufactured equipment labeled, listed or certified by a testing agency recognized by Saudi Aramco.

This standard does not apply to overhead distributions systems. Refer to SAES- P-107.

Hazardous area classification shall be in accordance with the requirements of SAES-B-068.2

Conflicts and Deviations

Any conflicts between this document and other applicable Mandatory Saudi Aramco Engineering Requirements (MSAERs) shall be addressed to the EK&RD Coordinator.

Any deviation from the requirements herein shall follow internal company procedure SAEP-302.

References

All referenced specifications, standards, codes, drawings, and similar material are considered part of this engineering standard to the extent specified, applying the latest version, unless otherwise stated.

3.1

Saudi Aramco References

Saudi Aramco Engineering Procedure

Saudi Aramco: Company General Use

Page 2 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

SAEP-302

Waiver of a Mandatory Saudi Aramco Engineering

Requirement

Saudi Aramco Engineering Standards

SAES-A-112

SAES-B-006

SAES-B-008

SAES-B-009

SAES-B-064

SAES-B-068

SAES-H-001

Meteorological and Seismic Design Data

Fireproofing in Onshore Facilities

Restrictions to Use of Cellars, Pits, and Trenches

Fire Protection and Safety Requirements for

Offshore Production Facilities

Onshore and Nearshore Pipeline Safety

Electrical Area Classification

Coating Selection and Application Requirements for

Industrial Plants and Equipment

SAES-H-004

Protective Coating Selection and Application

Requirements for Offshore Structures and Facilities

SAES-J-902

SAES-O-204

SAES-P-100

SAES-P-107

SAES-P-111

SAES-P-116

SAES-Q-001

SAES-T-911

SAES-T-919

SAES-T-928

Electrical Systems for Instrumentation

Security Lighting System

Basic Power System Design Criteria

Overhead Distribution Systems

Grounding

Switchgear and Control Equipment

Criteria for Design and Construction of Concrete

Structures

Telecommunication Conduit System Design

Submarine Fiber Optic Cable (1.4)

Telecommunications - OSP Buried Plant

Saudi Aramco Materials System Specifications

09-SAMSS-097

Ready-mixed Portland Cement Concrete

15-SAMSS-502

Medium Voltage Power Cable 5 kV through 35 kV

15-SAMSS-503

Submarine Power Cable 5 kV through 35 kV

15-SAMSS-504

Submarine Power Cable 69 kV through 230 kV

Saudi Aramco Standard Drawings

Page 3 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

AA-036025

AB-036273

AB-036326

AD-036874

Four-Way Manhole (2 Sheets)

Surface Marker - Underground Electric Cable

Standard Sign - Underground Electric Cable

Installation - Direct Buried Electric Cable and

Conduit

Saudi Aramco General Instructions

GI-0002.705

Performance Certification of High Voltage Cable

GI-1021.000

Splicers (formerly GI-0401.082)

Street and Road Closure: Excavations, Reinstatement and Traffic Controls

Saudi Aramco Pre-commissioning Forms

Form P-041

Form P-042

HV Cables 5-15-36 kV

HV Cables 69 – 115 kV

3.2

Industry Codes and Standards

The following industry standards are mandatory when and to the extent referenced in this standard:

American National Standards Institute

ANSI C80.1

ANSI C80.3

Electrical Rigid Steel Conduit

Electrical Metallic Tubing - Zinc Coated

ANSI C119.4

Copper and Aluminum Conductor Connectors

American Society for Testing and Materials

ASTM B8

Concentric-lay-stranded Copper Conductors, Hard,

Medium-hard, or Soft

ASTM B496

Compact Round Concentric-lay-stranded Copper

Conductors

American Society of Mechanical Engineers

ASME B1.20.1

Pipe Threads, General Purpose (Inch)

Association of Edison Illuminating Companies

AEIC CS8

Specification for Extruded Dielectric, Shielded

Power Cables Rated 5 Through 46 kV - 4th Edition

Page 4 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

AEIC CS9

Specification for Extruded Insulation Power Cables

and Their Accessories Rated Above 46 kV through 345 kV AC - 2nd Edition

British Standards Institution

BS 6121-1

BS 62444

Mechanical Cable Glands

Cable glands for electrical installations

Institute of Electrical and Electronic Engineers

IEEE 400.2

IEEE Guide for Field Testing of Shielded Power

IEEE 400

IEEE 442

IEEE 575

Cable Systems Using Very Low Frequency (VLF) (less than 1 Hz)

Guide for Field Testing and Evaluation of the Insulation of Shielded Power Cable Systems Rated 5 kV and Above

IEEE Guide for Soil Thermal Resistivity Measurements

IEEE Guide for Bonding Shields and Sheaths of Single-Conductor Power Cables Rated 5 kV through 500 kV

IEEE 835

IEEE Standard Power Ampacity Tables

Insulated Cable Engineers Association

ICEA S-94-649

Concentric Neutral Cables Rated 5,000 – 46,000 Volts

ICEA S-97-682

Utility Shielded Power Cables Rated

5,000 – 46,000 Volts

ICEA-S-108-720

Extruded Insulation Power Cables Rated

Above 46 -345 kV

International Electrotechnical Commission

IEC 60227

Polyvinyl Chloride Insulated Cables of Rated Voltages up to and including 450/750 V

IEC 60228

Conductors of Insulated Cables

IEC 60332-1-2

Tests on Electric Cables under Fire Conditions – Part 1-2: Test for Vertical Flame Propagation for a Single Insulated Wire or Cable – Procedure for 1 kW Pre-mixed Flame

IEC 60332-3-23

Tests on Electric Cables under Fire Conditions – Part 3-23: Test for Vertical Flame Spread of

Page 5 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

IEC 60364

IEC 60502-1

IEC 60502-2

IEC 60840

IEC 62067

Vertically-mounted Bunched Wires or Cables – Category B

Low Voltage Cable Electrical Installation

Power Cables with Extruded Insulation and their Accessories for Rated Voltages from 1 kV up to 30 kV – Part 1: Cables for Rated Voltages of 1 kV and 3 kV

Power Cables with Extruded Insulation and their Accessories for Rated Voltages from 1 kV up to 30 kV – Part 2: Cables for Rated Voltages from 6 kV up to 30 kV

Power Cables with Extruded Insulation and their Accessories for Rated Voltages above 30 kV (Um = 36 kV) up to 150 kV (Um = 170 kV) – Test Methods and Requirements

Power Cables with Extruded Insulation and their Accessories for Rated Voltages above 150 kV (Um = 170 kV) up to 500 kV (Um = 550 kV) – Test Methods and Requirements

IEC 60229

Electric Cables – Tests on Extruded Oversheaths

with a Special Protective Function

IEC 60529

Classification of Degrees of Protection Provided by

Enclosures

IEC 60287

Electrical Cables Calculation of Current Rating

IEC 61238-1

Compression and Mechanical Connectors for Power

Cables up to 36 kV - Test Methods and Requirements

IEC 62444

Cable glands for electrical installations

National Electrical Manufacturers Association

NEMA 250

Enclosures for Electrical Equipment (1,000 Volts

Maximum)

NEMA FG 1-R1

Fiberglass Cable Tray Systems-(1993)

Page 6 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

NEMA ICS 6

NEMA RN 1

Enclosures for Industrial Control and Systems

Polyvinyl-Chloride (PVC) Externally Coated

Galvanized Rigid Steel Conduit and Intermediate Metal Conduit

NEMA TC 2

NEMA TC 3

Electrical Polyvinyl Chloride (PVC) Conduit

PVC Fittings for Use with Rigid PVC Conduit and

Tubing

NEMA TC 6 & 8

PVC Plastic Utilities Duct for Underground

Installations

NEMA TC 9

Fittings for PVC Plastic Utilities Duct for

NEMA VE 1

NEMA VE 2

Underground Installation

Metal Cable Tray Systems

Cable Tray Installation Guidelines

National Fire Protection Association

NFPA 70

National Electrical Code (NEC)

Underwriters Laboratories

UL 44

UL 83

UL 1277

UL 2556

UL 651A

UL 797

UL 568

Thermoset-Insulated Wires and Cables

Thermoplastic-Insulated Wires and Cables

Power and Control Tray Cables with Optional

Optical Fiber Members

Wire and Cable Test Methods

Schedule 40 and 80 High Density Polyethylene

(HDPE) Conduit

Electrical Metallic Tubing – Steel

Non-metallic Cable Tray Systems

3.3

Other References

Saudi Building Code National Committee and Saudi Electricity Company Standard

Saudi Building Code (SBC)

Volume 4

11-TMSS-01

Power Cable XLPE Insulation, Al or Cu Conductor,

11-TMSS-02

Single Core, Rated 69 kV

Power Cable XLPE Insulated, Copper Conductor, Single Core, Rated 110 kV, 115 kV, 132 kV, 230 kV, and 380 kV

Page 7 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

11-TMSS-04

Power Cable XLPE Insulated, MV 11 kV, 13.8 kV,

33 kV, or 34.5 kV

General

4.1

Design and installation of wiring and cable systems shall be in accordance with Saudi Building Code, ANSI/NFPA 70 (National Electrical Code, NEC), and IEC as supplemented by this standard.

4.2

Severe corrosive environments are locations and installations listed in SAES-P-100.

4.3

4.4

Locations where chemicals are being handled, enclosures, conduits, fittings, and wirings must be resistant to the chemicals present.

For the purpose of this standard only, outdoor locations correspond to wet or damp locations; and indoor locations correspond to dry locations unless defined by National Electrical Code as wet or damp locations. Wet and dry locations are defined by the National Electrical Code Article 100.

Note 4.4:

A structure enclosed by walls on three sides only, and has a roof, is considered an outdoor location. A non-air conditioned building is considered an indoor location. A shop that has its doors kept open to facilitate entry of vehicles is considered an indoor location.

Wire and Cable

5.1 Wires and cables shall have copper conductors. Aluminum conductors are

permitted to be used in non-industrial applications for sizes 25 mm² or larger up to 35 kV.

5.2

Equipment grounding conductor shall be provided with each power circuit in same run as mandated in SAES-P-111.

Exception:

Except common equipment grounding conductors as permitted in SAES-P-111.

5.3

Basic Wire and Cable Specifications

5.3.1 Low voltage jacketed cables shall comply with NEC or IEC 60502-1.

5.3.1.1 NEC low voltage cables shall be rated 600/1,000 V, shall have a minimum temperature rating of 90°C dry/75°C wet, and shall be tested in accordance with UL 2556 standards including vertical tray flame test. (e.g., UL 1277, for type TC tray cables)

Page 8 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

5.3.1.2

IEC 60502-1 type cables shall be rated 600/1,000 V, shall have a minimum rating of 85°C, and shall meet the flame test of IEC 60332-3-23.

5.3.2 Low voltage unjacketed insulated wires shall be copper and in

accordance with NEC or IEC 60227.

5.3.2.1 NEC low voltage wires shall be rated 600/1,000 V, shall have a

minimum temperature rating of 90°C dry/75°C wet, and shall be tested in accordance with UL 2556 standards and meet vertical tray flame test, if required. (e.g., UL 83 for THHN/THWN and UL 44 for XHHW).

5.3.2.2

IEC 60227 type low voltage wires shall be rated 450/750 V, shall have a minimum rating of 70°C, and shall meet the flame test of IEC 60332-1-2.

5.3.2.3 Low voltage unjacketed insulated wires shall not be used in

cable trays (except when used as grounding conductors or listed and marked for use in cable trays), duct banks involving manholes, or direct burial applications.

Notes: 5.3.2.1 and 5.3.2.2

Fire-resistant cables are required when crossing any fire- hazardous zone as per SAES-B-006, to satisfy fireproofing requirements.

Exception to Sections 5.3.1 and 5.3.2:

For wiring of equipment such as lighting fixtures, etc., that require higher temperature wires and cables, the above minimum temperature ratings shall be increased accordingly.

5.3.2.4 Low voltage control and protective wires shall be heat and

flame retardant, rating 90°C maximum operating temperature, type SIS as listed in NFPA 70 or approved equivalent, rated 600/1,000 V, with insulated, tinned, and stranded annealed copper conductor.

5.3.3 Medium voltage power cables, rated 5 kV through 35 kV, to be used on systems with nominal voltages between 2 kV and 34.5 kV, [excluding submersible pump (down hole), portable, and motor lead cables] shall comply with 15-SAMSS-502.

5.3.4 Aluminum power cables rated, 5 kV through 35 kV, shall comply with

11-TMSS-04 and IEC-60502-2.

Page 9 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

5.4

5.5

5.6

5.7

5.3.5 Power cables rated 69kV and above, with solid dielectric insulation, shall

comply with 11-TMSS-01 or 11-TMSS-02.

5.3.6 Submarine power cables, 5 kV through 35 kV, shall comply with

15-SAMSS-503 and 69 kV through 230 kV shall comply with 15-SAMSS-504.

Cables manufactured in accordance with IEC 60502-1 and rated 600/1,000 V, having similar constructions to those listed in NEC Article 505, are suitable for use in Class I, Zone 2 locations. Medium-voltage cables meeting the requirements of 15-SAMSS-502 are suitable for use in Class I, Zone 2 locations.

For land cable concentric neutral wire, metallic armor, and metallic sheaths shall be protected with a PVC or equivalent jacket.

Power and control conductors shall be stranded. Solid copper conductors (Class 1) 6 mm² (10 AWG) and smaller may be used in non-industrial locations. Mineral Insulated (MI) cables and specialty cables (e.g., downhole pump motor cables, high temperature cables, etc.) with solid conductors are also permitted. Stranded power, control and grounding conductors shall have stranding in accordance with ASTM B8 Class B or C, or ASTM B496, or IEC 60228 Class 2. Flexible cords, portable cables, battery leads and motor leads may have finer stranding in accordance with appropriate UL Standards or the manufacturers’ recommendations.

Splicing of conductors shall be kept to a minimum. The maximum number of field splices permitted in any one circuit for new installations of cables rated above 1,000 V (excluding submarine cables) is the number made necessary by the use of maximum standard reel size with full length cables. In case of accidental damage of cable core during installation, additional necessary splices are permitted with the concurrence of the cable Proponent. In the event of a minor damage to outer jacket during installation, shrinkable split sleeve shall be applied to repair the jacket. Splices and terminations on cables rated above 1,000 V shall be made by personnel certified in accordance with Saudi Aramco General Instruction GI-0002.705. Conductors used for grounding metallic shields at termination or maintaining shield continuity through splices, isolated from the armor, shall have a current rating not less than the metallic shield.

5.8

Cable of multi-conductor control cables shall be numbered or color-coded by colors other than green or green with yellow stripes.

5.9

Size of Conductors

5.9.1 Minimum size of conductors shall meet the requirements of Table 1.

Page 10 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

5.9.2 Maximum size of conductors rated up to 35 kV shall be 500 mm² or

1,000 kcmils for three-core power cable.

Table 1 – Minimum Copper Conductor Size

Voltage

Size

600 V and below (control)*

1.5 mm²(16 AWG)

600 V and below (power)*

2.5 mm²(14 AWG)

5 kV

15 kV

35 kV

69 kV

115 kV

230-380 kV

10 mm²(8 AWG)

35 mm²(2 AWG)

50 mm²(1/0 AWG)

120 mm² (4/0 AWG)

400 mm² (750 kcmil)

500 mm2 (1,000 kcmil)

Note: * Including associated grounding conductors.

5.10 Cables for security lighting (perimeter and area lighting) shall be armored or metal clad, installed underground and rising inside the lighting poles. See SAES-O-204.

5.11 For installation and application purposes, armored cable manufactured to

IEC 60502-1 or IEC 60502-2 shall be considered equivalent to type MC (Metal Clad) cable.

Exceptions:

In Class I, Division 1 and Zone 1 hazardous locations, only cables specifically permitted by NEC Article 505 are allowed without rigid steel conduit;

Cable terminators shall be approved for the specific type of cable used;

Note 5.11:

Armored cable Type AC per NEC, referred to also as Type BX, not to be confused with the above, is light duty cable, and is not permitted in hazardous locations. Metal clad cable type MC per NEC is permitted in Class I, Division 2 and Zone 2, and if listed in Class I, Division 1 and Zone 1 locations.

5.12 Type MC cable and armored cable shall be permitted to be installed and exposed where it is not subject to damage by vehicular traffic or similar hazards. Sections of exposed type MC or armored cable shall be supported at intervals not exceeding 1.8 meters. Other types of cable shall not be installed or exposed above ground, and shall be installed in cable trays, conduit, or where flexibility is required in flexible conduit as permitted in NEC.

Exceptions:

Page 11 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

Equipment grounding conductors shall be permitted to be installed exposed where they are protected from physical damage.

Exposed cable section due to cable gland installation not more than 600 mm (2 ft) in length.

5.13 For cables rated 5 kV through 35 kV, Metal-Clad (MC) or armored power cables shall be used for underground installations; un-armored type cables shall be used for cable tray (TC type) or conduit systems installations.

Exception:

If the cable run has transition from direct burial to cable tray, then the cable shall be armored for the entire length or to the nearest point where it become practical to change to unarmored cable.

5.14 The grounding of shields, sheaths, armor and other materials in cable systems

shall be in accordance with SAES-P-111.

5.15 Circulating currents and induced voltage effects within shields and/or sheaths of

single core cables rated above 1,000 V shall be considered and minimized to a safe level. Design of cable, lay out, arrangements, and penetration to equipment shall minimize induced voltage and circulating currents to safe limits.

Note 5.15:

More design aspects can be found in IEEE 575: Guide for the Application of Sheath-bonding Methods for Single-conductor Cables and the Calculation of Induced Voltages and Currents in cable Sheaths.

5.16 Fireproofing of cables shall be in accordance with SAES-B-006 (onshore facilities) or SAES-B-009 (offshore facilities). See also paragraph 12.6.3.

Connections and Terminations

6.1

Compression (crimped) and mechanical (non-reversible) type connectors shall be used for splicing and terminating stranded conductors, except as indicated in paragraphs 6.3 to 6.5 below, and except as specified in SAES-P-111 for grounding conductors. The use of solder lugs is prohibited. Compression terminal connectors for 120 mm² (4/0 AWG) and larger conductors shall be two hole design. All compression connectors for 10 mm² (8 AWG) and larger conductors shall have a manufacturer’s reference compression die number and conductor size printed or stamped on the connector.

Exceptions:

The use of dieless compression tools is acceptable, provided that the tool is suitable for the connector, and (for 10 mm² (8 AWG) and larger conductor connectors), the tool ram embosses the tool manufacturer’s logo on the crimp.

Page 12 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

Single hole compression terminal connectors for 120 mm² (4/0 AWG) and

larger conductors are permitted for terminations on manufactured equipment that has integral provisions for single hole lugs only.

All lugs and connectors shall be tested in accordance with the latest revision of IEC 61238-1 or ANSI C119.4.

6.2

For copper to copper conductors, splicing connectors or terminal lugs shall be copper rated only. Copper to aluminum conductors splicing connectors or terminal lugs, shall be copper-aluminum rated only. Aluminum to aluminum conductors, splicing connectors shall be aluminum rated only.

Exception:

Separable load-break or dead-break connectors (elbows) having non-copper current carrying components, are permitted, provided they are marked and approved as suitable for copper conductors.

Spring pressure type twist-on connectors, and pressure set screw connectors with insulating caps are permitted (a) for lighting and receptacle circuits in non-hazardous locations, and (b) in non-industrial applications.

Use of connectors or terminals other than compression type, except solder connectors, supplied as integral parts or components of manufactured equipment such as molded case circuit breakers, contactors, outlets, etc., is permitted.

6.3

6.4

6.5

Insulated ring tongue, locking fork tongue, flanged fork tongue and pin type compression (crimped) terminals shall be used for control wiring.

Exception:

Only ring tongue compression (crimped) terminals shall be used for current transformer circuits.

6.6

6.7

6.8

Cable glands, on each end of armored cable, shall be designed to bond the armor to the gland independently from shield/sheath grounding (i.e., listed as suitable for grounding).

All threaded cable fittings including terminators (glands) for metric size cables shall have tapered (NPT) threads in accordance with ASME B1.20.1.

Cable glands shall be designed to permit disconnection without the need to rotate the cable or the equipment on which the gland is terminating (e.g., sealing glands shall have a built-in union). In severe corrosive environments, cable glands shall be protected against corrosion, by either a heat/cold shrink sleeve, anti-corrosion tape or PVC shroud.

6.9

Cable and Wire Identification at Terminations

Page 13 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

6.9.1

6.9.2

Identification of cables shall include the cable number and destination (e.g., load equipment tag number).

Individual control wires shall be identified with one label at each end. The label shall identify the number of the terminal to which the wire is connected and identify the terminal of the opposite end of the wire.

Exception to 6.10.1 and 6.10.2:

Alternate identification schemes, which conform to established internal practice, may be used for extensions to existing facilities with prior approval of the Facility Proponent.

6.9.3

Individual phases of power circuits shall be identified by color coding to be synchronized as per SBC color-coding conductors, or by other means (e.g., marked A, B, and C). Insulated grounding conductors by colors green or green with yellow stripes.

6.9.4 Marking Methods

Wires at termination points shall be identified by the use of permanently imprinted or embossed wire markers of the heat-shrinkable or slip-on type. Slip-on wire markers shall be sufficiently tight so that they will not slip unintentionally. Wrap-around, rigid snap-on, or adhesive type markers are not permitted for wire or cable identification. Cables may be identified by special plastic or non-corrosive metal labels held with cable ties, or similar methods. Colored insulating tapes may be used for phase identification of power circuit conductors.

6.10 Voltage stress relief shall be provided at terminations of cables with insulation

shields.

6.11 Creepage Distance of Terminations

Paragraphs 6.13.1 to 6.13.3 apply only to terminations operating at 2.4 kV and above in air, except terminations with conductive or semi-conductive outer surfaces [e.g., they do not apply to potheads or separable connectors (elbows)].

Note 6.13:

Creepage distance is measured between line and ground, but is based on the line-to-line voltage; e.g., for 13.8 kV outdoor terminations, each phase shall have a creepage distance of 552 mm to ground minimum.

6.11.1 Medium and high voltage terminations (operating at 2.4 kV and above)

installed outdoors shall have a minimum creepage distance to ground of 40 mm per kV line-to-line nominal system voltage.

Page 14 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

6.11.2 Medium and high voltage terminations installed indoors shall have a minimum creepage distance to ground of 25 mm per kV line-to-line nominal system voltage.

6.11.3 Medium and high voltage terminations installed inside enclosures

located outdoor shall be considered indoor terminations if the enclosures are rated NEMA Type 3 or 4, or IEC 60529 Type IP54. And shall be considered outdoor terminations if the enclosure a lesser degree of protection (e.g., NEMA Type 3R).

6.12 AWG connectors may be used for metric size conductors, and vice versa, provided the connector range spans the actual cross-sectional area of the conductor. For compact stranded conductors, standard connectors suitable for non-compact conductors of the same size may be used. No down-sizing of standard connectors for compact stranded conductors is allowed.

Note 6.14:

Before compression on a compact stranded conductor, a standard connector usually appears too loose, but since the cross-sectional area of copper is the same, the end result after compression is the same.

6.13 Cable glands for hazardous and non-hazardous locations shall be in accordance with BS 6121-1, BS 62444 or IEC 62444, except threads shall be in accordance with paragraph 6.8 above. In addition, cable glands for hazardous locations must comply with all applicable requirements of the NEC, SAES-P-100, and paragraph 15.1 below.

Enclosures

Equipment and terminal enclosures, unless otherwise specified in other Electrical SAESs or SAMSSs, shall meet the requirements of this section. Outdoor enclosure conduit connection shall be installed with bottom or side entries.

7.1

In outdoor plant areas and within the perimeter of process units for non- hazardous area, equipment and terminal enclosures shall be:

(a) NEMA 250/NEMA ICS 6 Type 4 or better; or

(b) NEMA Type 3 or better manufactured copper free cast aluminum

(aluminum with a maximum of 0.4% copper ), or plastic (including fiberglass) (e.g., Enclosures for indoor or outdoor locations, Types 3, 3X, 4, and 4X); or

7.2

In other outdoor installations for non-hazardous area, equipment and terminal enclosures shall be:

Page 15 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

(a) NEMA Type 3 or 4 or better; or

(b) IEC 60529 Type IP54 or better.

7.3

In installations located in severe corrosive environments as defined in paragraph 4.2, equipment and terminal enclosures for non-hazardous area shall be:

(a) NEMA Type 3X or 4X (except galvanized and/or painted or coated carbon

steel sheet metal enclosures are not permitted); or

(b) NEMA Type 3 or 4, manufactured of copper free cast aluminum (aluminum with a maximum of 0.4% copper), or plastic (including fiberglass); or

(c) IEC 60529 Type IP 54 or better, manufactured of stainless steel (Type 304 or better), copper free cast aluminum, or plastic (including fiberglass).

In outdoor locations, enclosures for small dry-type transformers shall be totally enclosed NEMA Type 3R. In severe corrosion environments, enclosure material shall be suitable for the application (e.g., 3RX).

In hazardous (classified) locations, enclosures that are required to be approved for Class I locations by NEC Article 505, shall meet the hazardous area equipment application requirements of SAES-P-100 and NEC, in addition to all applicable requirements of paragraphs 7.1 to 7.4 above (e.g., Enclosures for indoor locations, NEMA Types 7 and for indoor or outdoor locations, NEMA Type 8). See also Section 15.

7.4

7.5

7.6

Enclosures that are rated (a) NEMA Type 3, 4 or 4X, or (b) IEC 60529 Type IP54, or better, shall have Type 300 Series stainless steel hardware.

Exception:

Aluminum enclosures may have aluminum or aluminum alloy hinges and operating handles. Fasteners and hinges used on an enclosure shall be resistant to corrosion and shall comply with the same requirements as the enclosure.

7.7

Enclosure Breathers and Drains

Enclosures and junction boxes having an internal volume exceeding 2,000 cm³ shall be provided with Type 300 Series stainless steel breather and drain fittings, or a combination of breather and drain fitting. Enclosures shall be provided with tamper-resistance factory assembled breather/drainer (or provision for future breather/drainer) system where required.

Exception:

Factory sealed multigang, push button, and similar control stations are exempted from this requirement.

Page 16 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

Conduit, Conduit Fittings, and Supports

8.1

Underground Conduit

8.1.1

Direct buried conduit shall be PVC conduit Type DB-120 (minimum modulus of elasticity 3450 MPa (500,000 psi)) per NEMA TC 6 & 8 or Type EPC-40-PVC per NEMA TC 2, High Density Polyethylene (HDPE) conduit as specified in NEC or UL 651A or PVC coated rigid steel conduits.

Exception:

Direct buried conduit in Class I Zone 1 shall be threaded, rigid steel, hot dip galvanized and PVC coated.

8.1.2

Concrete encased conduit shall be PVC conduit Type EB-35 or DB-120 (minimum modulus of elasticity 3450 MPa (500,000 psi)) per NEMA TC 6 & 8 or Type EPC-40-PVC per NEMA TC 2 or rigid steel conduits.

Notes 8.1:

Internal diameters of NEMA TC 6 & 8 conduit are larger than NEMA TC 2 conduit internal diameters; consequently, the maximum number of conductors permitted in NEMA TC 6 & 8 conduits may be slightly larger.

8.2

Conduits installed exposed (e.g., not embedded in walls) above ground in outdoor, industrial facilities shall be threaded, rigid steel per ANSI C80.1, and in addition, it shall be hot-dip galvanized. See also Paragraph 10.6.

Exception:

Where flexibility is required, liquid-tight flexible metal conduit (in non-hazardous and Class I, Division 2 and Zone 2 hazardous locations) or explosion-proof flexible couplings (in Class I, Division 1 and Zone 1 hazardous locations) shall be used.

8.3

Conduits above ground in severe corrosive environments shall be as specified in paragraph 8.2 and, in addition, shall be factory PVC coated (minimum thickness of PVC: 40 mils ( 1 mm ) per NEMA RN 1.

Exception:

Where flexibility is required, liquid-tight flexible metal conduit (non-hazardous and Class I, Division 2 and Zone 2 locations) or explosion-proof neoprene coated or PVC coated flexible couplings (in Class I and Zone 1 locations) shall be used.

8.4

Electrical metallic tubing (EMT) is acceptable only in non-hazardous indoor locations. EMT shall comply with the requirements of ANSI C80.3. (e.g., UL 797 Electrical Metallic Tubing - Steel)

Page 17 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

8.5

Intermediate metal conduit (IMC) is prohibited.

8.6

The minimum conduit size shall be 19.05 mm (¾ inch) or equivalent in metric size, except for, instrumentation wiring, prefabricated skids, and in non- industrial areas, in which case the minimum size conduit shall be 12.7 mm (½ inch).

8.7

Conduit and threaded conduit fittings shall have tapered (NPT) threads in accordance with ASME B1.20.1.

8.8

Field cut conduit threads shall be coated with a zinc rich protective coating.

8.9

Conduit Fittings

8.9.1

Conduit fittings for outdoor galvanized rigid steel conduit and liquid-tight flexible metal conduit shall be cast or forged steel, cast iron or malleable iron, either hot-dip galvanized (preferably), or zinc electroplated as supplied by the manufacturer. No aluminum fittings and fitting covers shall be used outdoors. Gray cast iron split type (EYSR) retrofit sealing fittings may be used if required for repair purposes.

Exception:

Galvanized rigid steel conduit hubs and liquid-tight flexible metal conduit hubs, manufactured from zinc, that are UL or CSA listed are also acceptable.

8.9.2

Conduit fittings for galvanized rigid steel conduit and liquid-tight flexible metal conduit used above ground in severe corrosive environments shall be as specified in paragraph 8.9.1 and in addition, shall be protected by one of the following methods:

Factory-coating with PVC (minimum thickness of PVC: 40 mils) shall be per NEMA RN 1. Internal surfaces of PVC sleeves (boots) and other mating PVC surfaces shall be coated with PVC patching compound. Uncoated plugs and other bare metal shall be coated with PVC patching compound, or as specify in SAES-H-001 (onshore) or SAES-H-004 (offshore).

Field repair only-coating prior to installation in accordance with SAES-H-001 (onshore) or SAES-H-004 (offshore) can be used. Remove any hydrocarbon contamination with proper solvent. In addition, the surface shall be roughened using sweep blasting prior to coating so that the zinc is not removed. Painting should begin as soon as possible after cleaning and profiling.

Page 18 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

c) By heat-shrinkable tubes or wrap-arounds, where the geometric

configuration permits it.

Exception:

8.9.3

8.9.4

8.9.5

8.9.6

Red leaded brass or silicon bronze conduit fittings may be used as an alternative to the above in severe corrosive environments.

Conduit fittings for direct buried PVC coated rigid steel conduit shall be protected as per 8.9.2.

Threads of plugs, junction boxes and other fittings shall be lightly lubricated with rust preventive grease before assembly.

Exception:

Installation of conduits in an indoor and air-conditioned buildings are not required.

The use of conduit unions with underground conduit shall be avoided whenever possible.

Fittings for NEMA TC 6 & 8 Type PVC conduit shall be in accordance with NEMA TC 9. Fittings for NEMA TC 2 Type PVC conduit shall be in accordance with NEMA TC 3. TC 9 and TC 3 fittings are generally not interchangeable.

8.10 Supports

8.10.1 Channel erector system components (Unistrut or similar) punched type

used to support conduits, cables, cable trays, enclosures, lighting fixtures, and other electrical equipment shall be made of steel or iron, either hot-dip galvanized (preferably) for both indoor/outdoor used, or zinc electroplated as supplied by the manufacturer for only indoor used. All field cuts portions shall be painted with zinc rich protective coatings. Outdoor support and accessories other than mentioned shall be hot dipped galvanized.

8.10.2 Channel erector system components (Unistrut or similar) punched type

used to support conduits, cables, cable trays, enclosures, lighting fixtures and other electrical equipment in severe corrosive environments shall be:

(A) As specified in paragraph 8.10.1, and, in addition, protected by

the methods outlined in paragraphs 8.9.2 (a) or (b), or

(B) Stainless steel; or

Page 19 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

Type 300 Series stainless steel or better.

8.10.3 Process piping shall not be used to support conduits, except with the Proponent’s approval. If process piping is used to support conduits, adequate corrosion protection at the interface between the piping and support fittings shall be provided.

Note 8.10:

Plant structural members used as supports for conduit and other electrical equipment are outside the scope of this section. Attachment hardware (clamps, bolts, nuts, etc.) must however, comply with the requirements of this section.

8.11 Conduit fill shall not exceed the maximum filling percentage specified in

NEC Ch.9.

Cable Trays

9.1

Cable tray material shall be copper-free aluminum (aluminum with a maximum of 0.4% copper), or fiberglass. For offshore applications, cable tray material shall be fiberglass. For indoor air conditioned areas galvanized carbon steel is allowed. Cable trays shall be of the ladder (two side-rail) type. For aluminum cable tray installed outdoor, ventilated flanged type covers shall be used. Covers shall be installed and secured with stainless steel banding and fasteners (grade 316 in sever corrosive areas and 304 in other areas), one band per ½ m of cover length, with a minimum of six bands per cover. Cable trays run vertically in outdoor areas shall have covers on both sides. Cable tray system shall be used to support cables or raceways only.

Exceptions:

Cable tray covers are not required if cable trays are installed inside buildings.

Stainless steel cable trays shall be used when required by SAES-B-006, to satisfy fireproofing requirements. Stainless steel cable trays shall meet all other requirements of this section.

Cable tray covers may be deleted during the design stage with a written direction of the facility Proponent.

Heavy duty clamps suitable for outdoor installation can be used in windy areas.

Note 9.1:

Cable tray covers provide additional protection for cables from deterioration caused by sunlight, and provide protection from mechanical damage. If cable tray covers are not installed, cable trays should be located to minimize the potential for mechanical damage and to minimize the effects of sunlight on the cables. The ampacity of cables installed in uncovered cable trays exposed to

Saudi Aramco: Company General Use

Page 20 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

9.2

9.3

9.4

9.5

9.6

9.7

9.8

sunlight is reduced; see paragraph 12.2.

Aluminum and galvanized carbon steel cable tray shall be designed, manufactured, rated, tested, and installed in accordance with NEMA VE 1 and NEMA VE 2. Method A (Loading to Destruction) shall be used for determining the rated load capacity. Minimum individual rung load capacity shall be 90 kg. Minimum thickness of covers shall be 1 mm.

Fiberglass cable tray shall be designed, manufactured, rated, and tested in accordance with NEMA FG 1-R1 or UL 568. Minimum individual rung load capacity shall be 90 kg. Fiberglass cable trays shall be fire retardant and sunlight (ultraviolet radiation) resistant.

Note 9.3:

Molded and compression molded parts (such as screws, joints etc.) are not recommended.

The working load for cable trays shall consist of the weight of the cables (or tubing, etc.) including future additions (if required), plus a concentrated static load of 90 kg at the center of the span. If the cables plus future additions do not fill the selected cable tray to its NEC capacity, the weight of additional cables of the largest size contained in the tray, filling the cable tray to its NEC capacity (or smaller and/or varying size cables if this would maximize utilization of the available space), shall be added for calculating the working load. The concentrated static load may be converted to an equivalent uniform load using the formula in NEMA VE 1 or NEMA FG 1-R1. The working load shall not exceed the rated load capacity of the cable tray defined in NEMA VE 1 or NEMA FG 1-R1 (destruction load divided by a safety factor of 1.5).

Cable Tray Installation Guidelines for cable tray systems shall be in accordance with NEMA VE 2.

The maximum spacing between expansion joints shall be based on a temperature differential of 55°C (100°F) and expansion gap settings shall be in accordance with NEMA VE 2, based on a minimum temperature of 0°C and a maximum temperature of 55°C.

Cable trays shall be installed as a complete system. Cable tray systems shall not have mechanically discontinuous segments of cable tray runs.

Cables may be extended from cable trays to equipment if (a) they are armored or metal clad and are properly supported in accordance with NEC requirements, or (b) they are installed in rigid or flexible conduits.

9.9

Process piping shall not be used to support cable trays.

Page 21 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

9.10 Deflection of the cable tray system (several sections spliced together as a

continuous beam), when loaded to the working load as defined in paragraph 9.4, excluding the concentrated static load, shall not exceed L/100 (L=span length). (e.g., maximum permissible deflection for a 6 m span is 60 mm).

Underground Cable Systems

10.1 The minimum depth of burial requirements for underground installations shall

be as specified in Table 2. See also Standard Drawing AD-036874.

Table 2 – Minimum Cover Requirements (Depth of Burial)

Millimeters from Grade Level to the Top Surface of Cable, Conduit or Duct Bank

System Voltage

Direct Buried Cables

Direct Buried PVC or HDPE

Duct Bank or Direct Buried PVC coated Rigid Steel

600 V and below

Over 600 V to 35 kV

Over 35 kV

610

920

1070

460

610

760

460 (1)

Note:

(1) 610 mm under roads and other areas subject to vehicular traffic.

Note 10.1:

GI-1021.000 lists additional requirements for cables installed under roads.

Exception:

Minimum burial depth for ground grid conductors shall be in accordance with SAES-P-111; however, minimum burial depth for ground grid conductors under roads, parking lots and other areas subject to vehicular traffic shall be not less than 610 mm.

10.2 Cables that cross under paved roads, concrete slabs, railroads, or other areas that

would require extensive or impractical excavations to replace, shall be run in duct banks per Paragraph 10.5 or in PVC coated rigid steel conduits per Table 2.

Note 10.2:

Asphalt-paved parking lots and plant areas paved with asphalt for soil stabilization are not within the scope of this Paragraph. No duct banks or sleeves are required in these cases.

10.3

In rocky areas where digging must be minimized, in areas where Table 2 depths would result in cables being below the water table, or to avoid underground

Page 22 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

obstructions such as other cables, conduits or piping, cables may be installed in one of the following configurations:

a) PVC coated rigid steel conduit with a total cover not less than 300 mm,

which shall include a 50 mm thick (minimum) reinforced concrete slab over the conduit; or

b) PVC coated rigid steel conduit with a total cover not less than 150 mm, which shall include a 100 mm thick (minimum) reinforced concrete slab over the conduit; or

c) A reinforced concrete encased duct bank with 150 mm of total cover,

measured from the top of the upper conduit, which shall include a minimum of 100 mm of concrete over the upper conduit.

Concrete tiles cannot be used in lieu of the concrete slab in (a) or (b) above. The top layer of the concrete slab or the duct bank shall be mixed with red dye. (Minimum thickness of red concrete layer: 5 mm).

10.4 Precast 50 mm thick red concrete tiles, red plastic tiles (12 mm minimum

thickness), or PVC coated steel fence fabric shall be placed 300 mm above direct buried cable or direct buried conduit, in accordance with Standard Drawing AD-036874. In addition, a yellow warning tape shall be installed over the tiles or fence fabric. This paragraph does not apply to a) ground grid conductors and connections to ground grids or grounding electrodes, b) where paragraph 10.3 configurations are used, or c) under elevated substations.

10.5 Duct Banks

10.5.1 Duct banks shall consist of conduit(s) encased in concrete.

10.5.2 Concrete shall be in accordance with SAES-Q-001 and 09-SAMSS-097.

10.5.2.1

In duct banks with rigid steel conduits, unreinforced non- structural concrete [with minimum 28 day design compressive strength of 14 MPa (2,000 psi)] shall be used.

10.5.2.2

10.5.2.3

In duct banks with PVC conduit, under areas with no traffic, or occasional traffic (including roads with occasional traffic), unreinforced non-structural concrete as in paragraph 10.5.2.1 shall be used.

In duct banks with PVC conduit, under areas with frequent traffic, such as roads and parking lots inside plants or communities, reinforced concrete [with minimum 28 day design compressive strength of 28 MPa (4,000 psi)] shall be used.

Page 23 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

10.5.3 There shall be a minimum of 75 mm of concrete from the outside

surface of the duct bank to any conduit or reinforcing steel.

10.5.4 Fabricated spacers shall be used at intervals not exceeding 2.4 meters. The spacers shall provide a minimum conduit separation of 50 mm for 50.8 mm (2 inch) conduits and larger, and 25 mm for 38.1 mm (1½ inch) conduits and smaller.

10.5.5 Conduit runs within the duct bank shall be made continuous, by the use of threaded steel couplings for rigid steel conduit, and PVC solvent cement with PVC couplings or belled ends for PVC conduit. The internal surface of the duct bank shall be free of sharp edges or burrs.

10.5.6 Bell end fittings or protective bushings shall be provided on each duct

where it terminates.

10.5.7 The top layer (5 mm minimum thickness) of the concrete shall be

mixed with red dye.

10.5.8 Duct banks shall have a minimum of two spare ducts, unless this

number is decreased by facility proponent.

10.6 The end(s) of ducts and conduit terminating below grade or in open air shall be

sealed with duct sealing putty or an equivalent compound.

10.7 PVC conduits shall not be extended above grade in industrial facilities.

Where above grade extensions of buried PVC conduits are required, a transition shall be made underground, using threaded PVC to rigid steel conduit adapters.

Exceptions:

PVC stub-ups extending up to a maximum of 150 mm above ground and not attached to equipment are permitted;

B) Where concealed (embedded) in walls, floors, and ceilings.

Equipment grounding conductors running separately from power conductors (e.g., connections to ground grids) may be installed above ground in PVC conduit; if installed in rigid steel conduit; both ends of the conduit shall be bonded to the conductor.

10.8 Metallic conduit entering (from below grade) switchgear, control cabinets and similar enclosures sitting on the ground shall be cut and threaded 50 mm above finished grade level, and a threaded insulated grounding bushing shall be installed. PVC conduit entering switchgear, control cabinets and similar enclosures shall be cut flush with finished grade level, and shall have its inner edge filed to a smooth radius.

Page 24 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

10.9 Cables and conduits entering buildings shall comply with paragraphs 5.2 and 5.4

of SAES-B-008. (See also Section 15.2).

10.10 The location of underground cable, conduit or duct bank shall be marked in

accordance with Standard Drawings AB-036273 or AB-036326.

Exception:

No underground cable markers are necessary inside switchyards and under elevated substations.

10.11 Manholes containing cables rated 5 kV and above shall be in accordance with

Standard Drawing AA-036025.

Exception:

Manholes containing cables rated 5 kV and above, having different shape and size but equivalent structural strength to Standard Drawing AA-036025 manholes (same wall thickness, etc.), are permitted.

10.12 Manholes and handholes shall not be located in hazardous (classified) locations,

or where prohibited by SAES-B-008. Where permitted inside hydrocarbon- handling plants, all ducts inside all manholes and handholes shall be sealed with duct sealing.

10.13 Cables crossing pipeline corridors shall be installed in accordance with

SAES-B-064.

10.14 The minimum crossing or parallel clearance between direct buried cables or conduits and underground piping, including hydrocarbon pipelines that fall outside the scope of SAES-B-064, shall be 500 mm. For conduits, the crossing clearance may be reduced to 100 mm, if underground obstructions make it difficult to meet the 500 mm requirement. For direct buried cables, the same reduction is permitted if both cables are installed in a PVC sleeve at the crossing. Direct buried cables, conduits, or duct banks shall not be installed directly above or below parallel underground piping.

10.15 Direct buried cables and conduits shall be installed in a single layer, except

where rearrangement is necessary at transitions to multi-layer concrete encased duct banks or for entering buildings.

10.16 Installation of cables in outdoor concrete-walled trenches with metal or concrete

slab covers is not permitted.

Submarine Power Cable

11.1 Cable Burial

Page 25 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

11.1.1 Route assessment of submarine cable shall be performed taking in

consideration issues like water depths and area topology, tidal currents or surf action, marine habitats, and other requirements associated with the environmental impact assessment (EIA).

11.1.2 For water depth less than 7.5 m measured at the Lowest Astronomical Tide (LAT), submarine cable shall be buried with a minimum of 1 m.

11.1.3

In areas within 100 m of a platform structure, submarine cable shall be;

a) buried a minimum of 1 m, b) protected with grout-filled bags, c) by a split tubing protection system, or d)

similar protection method recommended by the manufacturer.

11.1.4 The horizontal spacing between separate circuits of the land section

shall be minimum of 4.5 m. The horizontal spacing between cables in the submarine section, excluding that portion of the cable within 200 m of the platform, shall be equal or more than the mean water depth at that location unless a reduced spacing is approved by the Proponent of the submarine cables.

11.2 Platform Transition

Submarine cable shall be physically protected from the bottom of the jacket leg to the point of cable armor termination, by a trough, tube or direct mounting to the jacket leg. Cables shall not hang unprotected.

11.2.1 The submarine cable shall be anchored below the riser section by either

of the following methods:

• Preformed cable grip(s) attached to a jacket leg by means of

hot-dip galvanized chains.

• Galvanized Carbon Steel (CS) armor clamp designed to withstand the maximum tension exerted on the cable due to dragging. The galvanized CS armor below the J-Tube entrance to the flange shall be protected by applying PVC coating on each strand or protected with corrosion protection material at the area inside the J-Tube.

11.2.2 The cable armor shall be terminated in an armor clamp located in a

vertical riser section below the cable disconnecting device. The clamp shall provide positive anchoring and grounding of the armor wires, in addition to terminating and grounding the inner flat armor tapes.

Page 26 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

11.3 Cable Crossings

11.3.1 The minimum cable crossing separation distance between submarine

cable and pipeline or cable shall be 300 mm.

11.3.2 Material used to provide separation shall be concrete mattresses.

11.3.3 The cable shall be stabilized from rolling on both sides of the crossing using suitable material such as concrete mattresses or ballast modules.

11.3.4 The angle of crossing shall be as close to 90 degrees as technically

feasible, allowing for minimum bending radius and locations of other seabed assets and features.

Cable Sizing

The sizing of power cables in the Saudi Aramco System shall be based on the following:

12.1 Load Factor – 100%

12.2 Ambient Temperatures

Outdoor Exposed To Sun (cables in conduit system,

or cables in uncovered cable trays)

: 56°C

Outdoor Shaded (for exposed cables, cables in conduit, or cables in covered cable trays in the sun)

Indoor Non-air-conditioned

Indoor air-conditioned

Soil Temperature

Sea Water Temperature

Exception:

: 50°C

: 35°C

: 40°C

: 30°C

The summer design dry bulb temperature at 1% per SAES-A-112 for the specific location may be used as the outdoor shaded location ambient temperature (or increased by 10°C, if exposed-to-sun ambient temperature).

Note:

Monthly normal maximum soil temperature as per SAES-A-112 can be used (if available) to consider accurate temperature de-rating factor.

12.3 Earth Thermal Resistivity (RHO)*

Land

1.2 K-m/watt

Page 27 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

Concrete (For Duct Banks)

Sea Bottom

Note:

1.0 K-m/watt

0.8 K-m/watt

Before backfilling, the results from the actual measurements of RHO, shall be equal or less than the above value. Measurements must be performed during a dry period. For large projects, performing such measurements per IEEE 442 is recommended.

12.4 Additional Conditions - Shielded Cables

Shields Bonded and Multi-point Grounded (at both ends and possibly additional points).

12.5 Additional Conditions - Submarine Cables

Maximum Conductor Operating Temperature

90°C

Maximum Conductor Emergency Temperature

: 110°C

Maximum Conductor Short Circuit Temperature

: 250°C

Maximum Shield Short Circuit Temperature

: 150°C

12.6 Ampacity Sources and Calculations

12.6.1 ANSI manufactured cables, ampacity calculations and cable sizing

shall be based on the NEC, or from the tables in IEEE 835, IEC manufactured cables, ampacity calculations and cable sizing shall be based on the IEC 60364, and IEC 60502-2, series standards.

Note 12.6.1:

Duct bank de-ratings shall be considered where such duct runs exceed 3 meters and overall cable ampacity shall be based on the duct portion of the entire run.

12.6.2 The sizing of cables rated 69 kV and above shall be per IEC 60287

series standards, and the sizing of specialty cables, such as down-hole pump motor cables, high temperature motor leads, etc., shall be in accordance with manufacturers’ guidelines.

12.6.3 A derating factor of 0.85 shall be applied to cables that are fireproofed by coating or wrapping with a compound or other material, unless the fireproofing compound or material manufacturer recommends a different derating factor value.

12.6.4 Cable derating can be determined by utilizing approved software to

calculate ampacities, based on NEC, IEC, or IEEE 835 tables.

Page 28 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

12.6.5 Where connected to terminations, devices, etc., having a lower

temperature rating, conductors shall be sized based on this lower temperature rating. See NEC Article 110.

12.6.6 For cable sizing adjustment for fault conditions, the fault location shall be assumed to be at the load end of the cable. For low voltage cables, fault duration time shall be a minimum of 110% of the clearing time of the protective device providing primary protection to the cable (maximum total clearing time in the case of fuses). For medium voltage cables, fault duration time shall be a minimum of 110% of the clearing time of the protective device providing backup protection to the cable and this time shall not exceed 1.0 second.

12.6.7 For the basis of selecting a feeder ampacity which supplies distribution

equipment, shall be equal to the lower of:

The continuous current rating of the distribution equipment main

bus or

The site rating of the upstream transformer.

Exception:

Switchgear directly feeding another switchgear, shall be based upon using 110% of the sum of the operating load plus all known future loads.

Notes 12.6.7:

• Distribution equipment would generally be equipment that will

distribute power to multiple devices. Examples are MV switchgear, panel-boards, control-gear, switchboards, switchrack, etc.).

• Note that SAES-P-116 requires the equipment (including cables)

connected to the primary or secondary of the transformer to be rated based upon the site rating of the transformer.

• The maximum operating current used for voltage drop calculation shall be based on using 110% of the sum of the operating load(s) plus all known future loads (Amperes) as defined in SAES-P-100.

Cable Testing after Installation

13.1 Low voltage (600, 450/750, or 600/1,000 V rated) cables, including splices to existing cables, shall be 1,000 V DC insulation resistance  tested after installation and prior to placing in service (during commissioning).

13.2 Medium voltage cables (5 kV through 35 kV) shall be tested as follows:

a) New cable installation including splicing, shall be 5 kV DC insulation resistance

Page 29 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

test before and after backfilling prior to placing in service (during commissioning).

In addition, cable shall be tested after backfilling and prior to placing in service (during commissioning) by one of the following methods:

• DC High-Potential test as per Table 3 or • AC test as per IEC 60502-2.

b) New cable to be spliced with existing cable, shall be 5 kV DC

insulation resistance test before and after splicing with existing cable. In addition. The new cable shall be tested after cable laying and before splicing by one of the following methods:

• DC High-Potential test as per Table 3 or • AC test as per IEC 60502-2.

If the existing cable has been in service for less than five years, the new and existing cable combination shall be tested as specified in Table 3.

Note 13.2 (b):

Under special circumstances, upon agreement with cable proponent for testing the existing old cables in service for more than five years, Isothermal Return Current (IRC), Very Low Frequency (VLF tanδ) test as per IEEE 400.2 or Partial Discharge as per IEEE 400, may be applied to determine the condition of old cables.

13.3 High voltage cables (69 kV and above) shall be tested after installation (during commissioning) to the voltage level listed in Table 3. Soak test is an acceptable alternative for cables rated at 69 kV and above.

Note 13.3:

Lower voltage and/or shorter durations may be used for AC test to be performed on cables that have been in service for more than five years.

Table 3 – DC and AC High-Potential Field Test Voltages

Cable Voltage Rating (Insulation Thickness)

After Installation – before Cable is Placed in Regular Service

In Service – First 5 Years

5 kV (115 mils) or 6/10 kV (3.4 mm)

15 kV (220 mils) or 12/20 kV (5.5 mm)

35 kV (345 mils) or 18/30 (9 mm)

69 kV

115 kV

24 kV DC (a)

48 kV DC (a)

72 kV DC (a)

72 kV AC (b)(c)

128 kV AC (b)(c)

Saudi Aramco: Company General Use

9 kV DC

18 kV DC

27 kV DC

Page 30 of 34

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

Cable Voltage Rating (Insulation Thickness)

132-138 kV

220-230 kV

380-400 kV

Notes:

After Installation – before Cable is Placed in Regular Service 132 kV AC (b) (c)

180 kV AC (b)(c)

260 kV AC (b)(c)

In Service – First 5 Years

a) Source of test voltage values: IEC 60502-2, DC test voltage equal to 4 U0 applied for 15 min for Medium voltage cables rated 5 kV through 35 kV. The above values also applied on cables manufactured in accordance with AEIC CS8, ICEA S-97-682, and ICEA S-94-649. Cable in service for first 5 years, reduced value 1.5 U0 applied for 15 min for medium voltage cables rated 5 kV through 35 kV.

b) The waveform shall be substantially sinusoidal and the frequency shall be between 20 Hz and 300 Hz and shall be applied for 1 h. Source of test voltage values: ICEA-S-108-720, IEC 60840, and IEC 62067.

c) Values apply to both IEC and AEIC CS9 type cables.

13.4 The integrity of the oversheath (overall jacket) of direct buried cables rated 5 kV

and higher shall be tested by conducting a 5 kV DC Insulation resistance test.

Additionally, DC High-Potential test, as per IEC 60229 shall be conducted. The DC High-Potential value shall be 4 kV/1 mm for one minute and not to exceed 10 kV, and shall be applied between the cable insulation metallic shield (screen)/sheath (or armor, if any) and ground. Medium voltage (5–35 kV) direct buried cables shall be backfilled, and the backfill shall be soaked in water. For 69 kV and above cables, the outer jacket of the cable shall be coated with manufacturer-applied graphite. Oversheath (overall jacket) cable testing shall be performed after laying and installation of each cable section and before splicing.

Note 13.2 and 13.3:

For Medium voltage direct buried cable installation, 100 to 150 mm of backfill moist sand cover over the cable applied to make a good contact with all of the outer surface of the oversheath. It is recommended, wherever possible, to perform high potential tests on buried cables prior to backfilling, to avoid excavation costs if the cables do not pass the tests.

13.5 Submarine power cable testing shall be as per 15-SAMSS-503 and 15-SAMSS-504.

Notes 13.2 - 13.5:

• The results of all tests performed on cables rated 5 kV and above shall be

documented on Saudi Aramco Pre-commissioning Form P-041 or P-042, or on an equivalent form containing the same information.

Page 31 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

•

In the event of conflict between this standard and information listed on the forms, this standard takes precedence over the forms.

Cable Separation

14.1 Minimum separation requirements between power or control cable, and instrument

cable (see paragraphs 1.3 and 14) shall be in accordance with SAES-J-902.

14.2 Minimum separation requirements between a power or control cable, and any

communication cable shall be in accordance with SAES-T-911 or SAES-T-928.

14.3 There are no minimum separation requirements between power and/or control

conductors for DC or AC circuit voltages less than 1,000 V, provided the insulation is rated at least 600 V or 450/750 V.

Note 14.3:

While it is technically acceptable to install power cables operating at less than 1,000 V with no separation or with little separation, this may require a significant increase in conductor size, because separation between power cables affects their ampacity.

14.4 Minimum separation (above or below ground) between a power cable operating

at 1,000 V or above, up to 34.5 kV, and a parallel or crossing power or control cable operating at less than 1,000 V, shall be 300 mm.

Exceptions:

• When the medium voltage cable is armored or metal clad or installed in rigid steel

conduit, or installed in cable tray separated from the low voltage cable by solid fixed metallic barriers.

• Or when the low voltage cable is installed in rigid steel conduit.

14.5 Minimum separation (above or below ground) between any cable operating at

34.5 kV or above, and cables operating at 34.5 kV or below, shall be 1 m.

14.6 Redundant parallel feeders, direct buried or in direct buried conduits, supplying industrial loads or other loads that are critical in accordance with SAES-P-100, shall be separated by a minimum distance of 1.8 meters.

Note 14.6:

Two feeders are considered redundant if they are capable of supplying power to the same loads so that each feeder can be considered a backup supply circuit for the other. Examples include the feeders that provide power for double-ended switchgear (including feeders to the related transformers) and the feeders supplying each end of a loop fed distribution system.

Exception:

Page 32 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

Redundant feeders, direct buried or in direct buried conduits shall maintain 1.8 m separation, except where rearrangement is necessary at road crossing encased concrete duct banks or for entering buildings.

Conduit and Cable Sealing

15.1 The following requirements Supplement NEC Articles 505 (e.g., Class I Zone 1

AEx d IIA T3):

15.1.1 Conduit sealing fittings shall not be used.

15.1.2 Conduits that cross hazardous location boundaries shall terminate in

the open air at both ends of the conduit.

15.1.3 When cables entering enclosures are required to be sealed by the NEC,

they shall be sealed by means of barrier type cable glands, utilizing sealing compound, (EEx d) or be an MI cable. These are called explosion proof glands by some manufacturers, flameproof by others. See SAES-P-100 for third party approval requirements. Flameproof (EEx d) non-barrier type cable glands, without sealing compound, are not acceptable.

15.2 Cable entry into control buildings and similar buildings in hydrocarbon processing

plants below grade shall be in accordance with all of paragraphs 15.2.1 to 15.2.4 below.

15.2.1 Penetration of the wall of the building basement or underfloor space shall be via short horizontal sections of PVC conduits (sleeves) that will be encased or grouted into the wall.

15.2.2 The inside of the sleeves shall be sealed to provide fire retardancy on

the building interior side.

15.2.3 The cables outside the building shall be direct buried for a distance of

at least 2 meters (see also paragraph 10.14).

15.2.4 Multi-conductor cable penetrations shall be made with intact cable jackets. If individual conductors are required to be sealed by other Saudi Aramco standards, the sealing shall be done at the most convenient location inside the building.

Page 33 of 34

Saudi Aramco: Company General Use

Document Responsibility: Electrical Systems Designs and Automation Standards Committee Issue Date: 29 December 2021 Next Planned Update: 29 December 2023

Wiring Methods and Materials

SAES-P-104

Revision Summary

29 December 2021 Editorial revision to change the revision cycle from three years (20 February 2022) to five

years (20 February 2024) and to comply with SAEP-301.

20 February 2019

24 February 2014

Major revision. The new revision incorporates various major comments generated during the workshop attended by standard stakeholders such as CSD, Power Systems Engineering Department, FPD and SAPMT. Major revision.

Summary of Change Form

No.

Paragraph Number

Change Type (New, Modification,..)

Technical Change(s)

5.1

Modification

5.3.4

Modification

Allowing Aluminum conductors for non-industrial applications for sizes 25 mm² or larger up to 35 kV.

Power cables rated 69 kV and above shall comply with 11-TMSS-01 and 11-TMSS-02.

Table 1

Modification

Modifying minimum conductor sizes.

Modification

Modifying requirements for different type connectors.

New

Adding requirements for cable glands.

Modification

For offshore applications, cable tray material shall be fiberglass.

New

Modification

Adding a section for submarine cable crossing.

Duct back de-ratings shall be considered where such duct runs exceed 3 meters.

Adding Exception to 12.6.7 for the basis of sizing.

Modifying Cable Testing after Installation

6.2

6.7

9.1

11.3

12.6.1

12.6.7

Page 34 of 34

Saudi Aramco: Company General Use

Project: Q-31108 - Tecnicas - Riyas Folder: RFQ Files

Infinity

Explorer

Graph View

Backlinks