RUWAIS LNG PROJECT

SPECIFICATION FOR ELECTRICAL POWER, CONTROL AND EARTHING CABLES

COMPANY DOCUMENT REF. RLNG-000-EL-SP-0006 CONTRACTOR DOC. REF.

215122C-000-JSS-1620-0001

REVISION: 1

PAGE 1 OF 9

ADNOC GAS

Specification for Electrical Power, Control and Earthing Cables

COMPANY Contract No.

4700022871

JV TJN RUWAIS Contract No

215122C

Document Class

Class 2

Document Category (for Class 1)

OPERATING CENTER Contract No.

OPERATING CENTER Doc Ref.

SS-000-13826-0001

1

0

Issued For Construction

07-Aug-2024

K.M.M.Raja

ICR - Issue for Client Review

30-May-2024

J. Ghosh

E. Papeil S. Pandey A. Ghosh

E. Papeil R. Dewangan A. Ghosh

M. Sano / I.Sawaki

M. Sano

Rev.

Revision Purpose

Date

Prepared by Checked by Approved by

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RUWAIS LNG PROJECT

SPECIFICATION FOR ELECTRICAL POWER, CONTROL AND EARTHING CABLES

COMPANY DOCUMENT REF. RLNG-000-EL-SP-0006 CONTRACTOR DOC. REF.

215122C-000-JSS-1620-0001

REVISION: 1

PAGE 2 OF 9

Table of Contents

Contents

Page

1.0

INTRODUCTION… 4 1.1  Project Objective and Location … 4 1.2  Scope of the Document … 4 1.3  Holds List … 4 1.4  References … 5 1.5  Definitions and Abbreviations … 5 2.0  AMENDMENTS TO ADNOC GENERAL Engineering SPECIFICATION (AGES-SP-02-011) … 5 2.1  Section A -Contractual Requirements … 6 2.2  Section B -Technical Requirements … 7 3.0  APPENDIX … 9 3.1  Appendix 1 … 9

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RUWAIS LNG PROJECT

SPECIFICATION FOR ELECTRICAL POWER, CONTROL AND EARTHING CABLES

COMPANY DOCUMENT REF. RLNG-000-EL-SP-0006 CONTRACTOR DOC. REF.

215122C-000-JSS-1620-0001

REVISION: 1

PAGE 3 OF 9

Table of Changes compared to previous revision

Paragraph

Modification description

Remarks / Origin

This document has been updated from the FEED “359665-0000-070-SP-1600-013_Rev 0” document Introduction updated as per project template.

Definitions and Abbreviation information updated.

1.0

1.5

2.1.4

Reference Document number and list updated.

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RUWAIS LNG PROJECT

SPECIFICATION FOR ELECTRICAL POWER, CONTROL AND EARTHING CABLES

COMPANY DOCUMENT REF. RLNG-000-EL-SP-0006 CONTRACTOR DOC. REF.

215122C-000-JSS-1620-0001

REVISION: 1

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1.0

1.1

INTRODUCTION

Project Objective and Location

The ADNOC Ruwais LNG Project is a two train, near net-zero electrically driven LGN facility, targeting international markets. The feed gas for the project is supplied from the Habshan Gas Processing Plant via a new export gas pipeline. The plant will have two 4.8 MTPA (nominal capacity) electric driven LGN Trains with associated LNG storage/marine export facilities and utilities.

Figure 1 – Project Context

The ADNOC Ruwais LNG Project foresees the following main components at the facility:

 Onshore LNG Liquefaction facilities for 2 x 4.8 MTPA electrically driven LNG Trains (9.6MTPA total)

 Common facilities including inlet receiving facilities, LNG storage, BOG handling, flare, refrigerant

storage and support buildings.

 Utilities to support the facilities including import power from the national grid.

 Marine facilities for LNG export and bunkering.

1.2

Scope of the Document

This specification amends ADNOC General Engineering Specification for Electrical Power, Control and Earthing Cables AGES-SP-02-011 which is attached hereto in Appendix 1.

Section 2. of this document identifies the amendments to the ADNOC General Engineering Specification included in Appendix 1 for this ADNOC Ruwais LNG Project only.

1.3

Holds List

HOLD

DESCRIPTION

1

2

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SPECIFICATION FOR ELECTRICAL POWER, CONTROL AND EARTHING CABLES

COMPANY DOCUMENT REF. RLNG-000-EL-SP-0006 CONTRACTOR DOC. REF.

215122C-000-JSS-1620-0001

REVISION: 1

PAGE 5 OF 9

1.4

References

Document Number

Document Title

AGES-SP-02-011

Electrical Power, Control and Earthing Cables specification (Revision 1)

1.5

Definitions and Abbreviations

COMPANY

CONTRACTOR

EPC ADOC POC YOC

ABU DHABI NATIONAL OIL COMPANY (ADNOC) P.J.S.C. TJN Ruwais, Joint Venture of Technip Energies France-Abu Dhabi, JGC Corporation and National Marines Dredging Company (NMDC) Engineering Procurement Construction Abu Dhabi Operating center - National Marines Dredging Company Paris Operating Center - Technip Energies Yokohama Operating Center - JGC Corporation

Abbreviation

Definition

ECMS

ESD

IED

Electrical Control and Monitoring System

Emergency Shut Down

Intelligent Electronic Device

GOOSE

Generic Object-Oriented Substation Event

2.0

AMENDMENTS TO ADNOC GENERAL ENGINEERING SPECIFICATION (AGES-SP-02-011)

Instructions contained below such as “Add”, “Substitute”, “Revised”, or “New” shall be interpreted as follows:

1. Add: Requirements shall be a continuation of the paragraph in the referenced specification.

2. Substitute: The requirement of the referenced specification shall be replaced in its entirety by

the requirements below.

3. Revised: The requirement of the referenced specification shall be revised by the specific wording

below.

4. New: A new requirement as described below.

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SPECIFICATION FOR ELECTRICAL POWER, CONTROL AND EARTHING CABLES

COMPANY DOCUMENT REF. RLNG-000-EL-SP-0006 CONTRACTOR DOC. REF.

215122C-000-JSS-1620-0001

REVISION: 1

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2.1

Section A -Contractual Requirements

The following amendments and additions shall apply to the “AGES-SP-02-011”, Specification of Electrical Power, Control and Earthing Cables.

2.1.1 Clause 2.1 – International Codes and Standards

Delete the following Withdrawn Standards

DELETED

IEC TS 60859 Cable connections for gas insulated metal enclosed switchgear for rated voltages of 72.5kV and above

2.1.2 Clause 2.1 – International Codes and Standards

Substitute the following Standards with:-

IEC 60093

with

IEC 62631-3-1, IEC 62631-3-2 and IEC 62631-3-3

IEC 60331

with

IEC 60331-11 and IEC 60331-21

IEC 60885

with

IEC 60885-3

IEC 60446 with IEC 60445

2.1.3 Clause 2.1 – International Codes and Standards

Add the following Standards with:-

BS 1442

BS 6004

BS 6360

BS 6724

Specification for Galvanized Steel Wire

PVC Insulated cable (non-armoured) for power & lighting.

Conductors in insulated cables and cords

Armoured cables for electricity supply having thermosetting insulation with low emission of smoke and corrosive gases when affected by fire.

IEC 60287-1-1 Electric cables - Calculation of the current rating - Part 1-1:Current rating equations (100

% load factor) and calculation of losses – General

IEC 60287-2-1 Electric cables - Calculation of the current rating - Part 2-1: Thermal resistance -

Calculation of thermal resistance

IEC 60754-1

Test on gases evolved during combustion of materials from cables - Part 1: Determination of the halogen acid gas content

IEC 60754-2

Test on gases evolved during combustion of materials from cables - Part 2: Determination of acidity (by pH measurement) and conductivity

IEC 60811-100 Electric and optical fibre cables - Test methods for non-metallic materials - Part 100:

General

IEC 61034-1 Measurement of smoke density of cables burning under defined conditions - Part 1: Test

apparatus

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SPECIFICATION FOR ELECTRICAL POWER, CONTROL AND EARTHING CABLES

COMPANY DOCUMENT REF. RLNG-000-EL-SP-0006 CONTRACTOR DOC. REF.

215122C-000-JSS-1620-0001

REVISION: 1

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2.1.4 Clause 2.2: Normative References (Revised)

The following AGES references are substituted with Project documents as detailed below:

AGES Reference Project Document No.

Project Document Title

AGES-GL-02-001

RLNG-000-EL-BOD-0001

Electrical Design Basis

AGES-SP-02-001

RLNG-000-EL-SP-0002

Specification for Power Transformer

AGES-SP-02-002

RLNG-000-EL-SP-0004

Specification for Synchronous Motors

AGES-SP-02-004

RLNG-000-EL-SP-0005

Specification for Electrical Adjustable Speed Drives System

AGES-SP-02-006 RLNG-000-EL-SP-0009

Specification for Low Voltage Switchgear and Control gear

AGES-SP-02-007 RLNG-000-EL-SP-0003

Specification for Induction Motors

AGES-SP-02-008

RLNG-000-EL-SP-0014

AGES-SP-02-009 RLNG-000-EL-SP-0007

Deleted

N/A

RLNG-000-PM-PP-2003

AGES-SP-07-004 RLNG-000-PT-SP-0001

Electrical Control and Monitoring System Specification

Specification for Static Uninterruptible Power Supply

Equipment and Component Numbering Procedure

Specification for Protective Coating of Equipment, Piping & Structure

AGES-PH-02-001 RLNG-000-EL-SP-5101

Philosophy for Earthing, Bonding and Lightning Protection

N/A

RLNG-000-PM-SP-6006

JV Packing Marking and Shipping Instructions

2.2

Section B -Technical Requirements

Technical Amendments / Supplements to AGES-SP-02-011

The following amendments and additions shall apply to the “AGES-SP-02-011”, Specification of Electrical Power, Control and Earthing Cables.

2.2.1 Clause 6.1 – HV Power Cables (up to 33kV) - General Requirements

Add new Paragraph following:-

Nominal operational voltage for HV cables to be 3.3kV, 6.6kV, 11kV and 33kV with cable voltage grades as per following:-

J-DMS 14-Aug-2024 UNCONTROLLED WHEN PRINTED

Voltage Grade: Uo / U(Um) =

1.9/3.3kV (3.6kV)

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SPECIFICATION FOR ELECTRICAL POWER, CONTROL AND EARTHING CABLES

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REVISION: 1

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Voltage Grade: Uo / U(Um) =

3.6/6kV (7.2kV)

Voltage Grade: Uo / U(Um) =

6.35/11kV (12kV)

Voltage Grade: Uo / U(Um) =

19/33kV (36kV)

2.2.2 Clause 6.1 – HV Power Cables (up to 33kV) - General Requirements

Add new Paragraph:-

For cables laid underground with voltage grades of 6.35/11kV (12kV) and 19/33kV (36kV), a moisture blocking barrier shall be included such that the barrier shall stop longitudinal migration of water. A radial water blocking barrier shall also be included.

Non-conductive water blocking yarns and / or non-conductive water blocking tapes (less than 0.2mm thick) are acceptable for use inside conductors. The water blocking material shall not affect the performance of the conductor and conductor connections in terms of the ratings calculated in accordance with IEC 60287.

Any water blocking tapes used peripherally around conductors must be semi-conductive, readily removable and consist of one or two webs, a suitable super-absorbent powder mixture and carbon black.

All water blocking materials must have proven long term thermal stability at power cable operating conditions.

Water absorbent materials in a class of polymers described as “neutralised cross-linked polyacrylate acid” and also known by the generic term “polyacrylate absorbents” are also acceptable.

Water absorbent materials in a free powder form are not acceptable.

Mastic type water blocking materials are not acceptable.

The SUPPLIER shall provide details of the proportion of the cross-sectional area of the free space within the conductor envelope occupied by the water blocking material(s). Test results shall be submitted demonstrating the effectiveness of water-blocking method and materials proposed.

The above requirements are not applicable for any cables installed above ground.

2.2.3 DELETE Clause 6.1.7.1.

2.2.4 Clause 6.1.8

Add new Paragraph:-

Flexible conductors shall consist of plain or metal-coated annealed copper and supplied in accordance with Class 5 & 6 of IEC 60228. Resistance values to be in accordance with Table 5 & 6 of IEC 60228.

2.2.5 Clause 6.1.11.4

Substitute the Title: -

‘Laying Up’ with ‘Inner Coverings and Fillers’ as per IEC 60502 Clause 7.2.

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SPECIFICATION FOR ELECTRICAL POWER, CONTROL AND EARTHING CABLES

COMPANY DOCUMENT REF. RLNG-000-EL-SP-0006 CONTRACTOR DOC. REF.

215122C-000-JSS-1620-0001

REVISION: 1

PAGE 9 OF 9

2.2.6 Clause 22.1.2.1 – Conductors

Add new Paragraph: -

Moisture blocking barrier shall be included such that the barrier shall stop longitudinal migration of water. In addition, a radial water blocking barrier shall also be included.

2.2.7 DELETE requirements for “Lead” in the following Clauses: -

Clause 22.1.2.3, Clause 22.1.2.4, Clause 22.2.1, Clause 22.2.2.5, Clause 22.2.2.6.

2.2.8 Clause 22.2.2.1 – Conductors

Add new Paragraph: -

A radial water blocking barrier shall also be included.

3.0

APPENDIX

3.1

Appendix 1

AGES-SP-02-011: Electrical Power, Control and Earthing Cables (41 Sheets)

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ADNOC Classification: Internal

THE CONTENTS OF THIS DOCUMENT ARE PROPRIETARY AND CONFIDENTIAL.

ADNOC GROUP PROJECTS AND ENGINEERING

ELECTRICAL POWER, CONTROL AND EARTHING CABLES

Specification

APPROVED BY:

NAME: Abdulmunim Al Kindy TITLE: Executive Director PT&CS EFFECTIVE DATE:

AGES-SP-02-011

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ADNOC Classification: Internal

GROUP PROJECTS & ENGINEERING / PT&CS DIRECTORATE

CUSTODIAN ADNOC

Group Projects & Engineering / PT&CS Specification applicable to ADNOC & ADNOC Group Companies

REVISION HISTORY

DATE

REV.

NO

28-Feb-2022

1

PREPARED BY (Designation / Initial) Ali Naser Bagarwan/ HOD Electrical Eng. - GP&E

REVIEWED BY (Designation / Initial) Mahmoud Abdel Hakim/ HOD Pipelines Eng. - GP&E

ENDORSED BY (Designation / Initial) Najem Qambar/ VP Group Eng.- GP&E

ENDORSED BY (Designation / Initial) Ebraheem AlRomaithi / SVP- GP&E

Reuben Yagambaram/ Mgr. Offshore Portfolio - GP&E

Ali Al Breiki/ VP Upstream Projects - GP&E

Group Projects & Engineering is the owner of this Specification and responsible for its custody, maintenance and periodic update.

In addition, Group Projects & Engineering is responsible for communication and distribution of any changes to this Specification and its version control.

This specification will be reviewed and updated in case of any changes affecting the activities described in this document.

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ADNOC Classification: Internal

INTER-RELATIONSHIPS AND STAKEHOLDERS

a. The following are inter-relationships for implementation of this Specification:

i. ADNOC Upstream and ADNOC Downstream Industry, Marketing & Trading Directorate.

ii. ADNOC Onshore, ADNOC Offshore, ADNOC Sour Gas, ADNOC Gas Processing. ADNOC LNG,

ADNOC Refining, Fertil, Borouge, Al Dhafra Petroleum, Al Yasat

b. The following are stakeholders for the purpose of this Specification:

iii. ADNOC PT&CS Directorate

c. This Specification has been approved by the ADNOC PT&CS is to be implemented by each ADNOC Group company included above subject to and in accordance with their Delegation of Authority and other governance-related processes in order to ensure compliance.

d. Each ADNOC Group company must establish/nominate a Technical Authority responsible for compliance

with this Specification.

DEFINITIONS

“ADNOC” means Abu Dhabi National Oil Company.

“ADNOC Group” means ADNOC together with each company in which ADNOC, directly or indirectly, controls fifty percent (50%) or more of the share capital.

“Approving Authority” means the decision-making body or employee with the required authority to approve Policies & Procedures or any changes to it.

“Business Line Directorates” or “BLD” means a directorate of ADNOC which is responsible for one or more Group Companies reporting to, or operating within the same line of business as, such directorate.

“Business Support Directorates and Functions” or “Non- BLD” means all the ADNOC functions and the remaining directorates, which are not ADNOC Business Line Directorates.

“CEO” means chief executive officer.

“Group Company” means any company within the ADNOC Group other than ADNOC.

“Specification” means this Power, Control and Earthing Cables specification.

CONTROLLED INTRANET COPY The intranet copy of this document located in the section under Group Policies on One ADNOC is the only controlled document. Copies or extracts of this document, which have been downloaded from the intranet, are uncontrolled copies and cannot be guaranteed to be the latest vers

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ADNOC Classification: Internal

TABLE OF CONTENTS

GENERAL … 7

INTRODUCTION … 7

PURPOSE … 7

DEFINITIONS AND ABBREVIATIONS … 7

SECTION A – GENERAL … 10

REFERENCE DOCUMENTS … 10

INTERNATIONAL CODES AND STANDARDS … 10

ADNOC SPECIFICATIONS … 12

STANDARD DRAWINGS … 12

OTHER REFERENCES … 12

DOCUMENT PRECEDENCE … 13

SPECIFICATION DEVIATION / CONCESSION CONTROL … 13

DESIGN CONSIDERATIONS / MINIMUM DESIGN REQUIREMENTS … 13

SYSTEM PARTICULARS … 13

OBSOLESCENCE … 14

DESIGN PARAMETERS … 14

ENVIRONMENTAL / SITE DATA … 14

AREA CLASSIFICATION … 14

SECTION B – TECHNICAL REQUIREMENTS … 15

TECHNICAL REQUIREMENTS … 15

HV POWER CABLES (UP TO 33KV) - GENERAL REQUIREMENTS … 15

LV POWER, CONTROL AND EARTHING CABLES - GENERAL REQUIREMENTS … 19

LV SINGLE CORE CONDUIT CABLE (WIRE) … 23

ADDITIONAL SPECIFIC REQUIREMENTS … 24

CABLE TERMINATIONS AND JOINTS … 24

SECTION C – OTHER REQUIREMENTS … 25

DETAILS OF SCOPE SUPPLY … 25

GENERAL … 25

SUPPLIER’S RESPONSIBILITY … 25

QUALITY CONTROL AND ASSURANCE … 25

SUB-CONTRACTORS, SUB-SUPPLERS … 25

MATERIAL CERTIFICATION … 25

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ADNOC Classification: Internal

INSPECTION AND TESTING REQUIREMENTS … 26

GENERAL … 26

TEST REPORTS … 26

TYPE TESTS … 26

ROUTINE TESTS … 27

ADDITIONAL TESTS … 28

SPECIAL TESTS … 28

SITE TESTS … 28

SPARE PARTS … 29

PAINTING, PRESERVATION AND SHIPMENT … 29

PAINTING … 29

PRESERVATION AND SHIPMENT … 29

COMMISSIONING … 30

TRAINING… 31

DOCUMENTATION / MANUFACTURER DATA RECORDS … 31

GENERAL … 31

REQUIRED DOCUMENTATION … 32

DATA TO BE FURNISHED BY THE MANUFACTURER … 32

GUARANTEES AND WARRANTY … 33

SPECIAL ENGINEERING SERVICEREQUIRMENT FOR SINGLE POWER CABLE (>5KV) … 33

SECTION D – STANDARD DRAWINGS & DATASHEETS … 34

DATASHEET TEMPLATES … 34

STANDARD DRAWINGS … 34

SECTION E – APPENDICES … 35

ADDITIONAL REQUIREMENTS FOR CABLES ABOVE 33KV UP TO 220KV … 35

REQUIREMENTS FOR 66KV AND 132KV CABLES … 35

REQUIREMENTS FOR 220KV CABLES … 37

LIST OF TABLES

TABLE 1.1 LIST OF ABBREVIATIONS………………………………………………………………………….8

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ADNOC Classification: Internal

LIST OF FIGURES

NONE

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ADNOC Classification: Internal

GENERAL

Introduction

This specification describes minimum requirements for the design, manufacturer, testing at works and supply of power cables (up to 220kV), control and earthing cables.

The Specification Parts A to D provide general requirements for all cables up to 220kV and detailed type and construction details for cables up 33kV. Section E provides additional details on preferred cable types for voltages above 33kV. The design, manufacture and testing of these cables is to be agreed with COMPANY before final selection based on Project and Operating group requirements. Specific requirements for cable construction and testing, etc. shall be provided on data sheets.

Purpose

The purpose of this specification is to ensure consistency in selection, design and construction of power, control and earthing cables.

For project and site specific additional requirements, refer to supplementary requirements stated in respective project’s Purchase Requisition documentation.

Definitions and Abbreviations

1.3.1

Definitions

The following defined terms are used throughout this specification.

‘[PSR]’ indicates a mandatory Process Safety Requirement

“COMPANY” means ADNOC, ADNOC Group or an ADNOC Group Company, and includes any agent or consultant authorized to act for, and on behalf of the COMPANY.

“CONTRACTOR” means the parties that carry out all or part of the design, engineering, procurement, construction, commissioning or management for ADNOC projects. CONTRACTOR includes its approved MANUFACTURER(s), SUPPLIER(s), SUB-SUPPLIER(s) and SUB-CONTRACTOR(s).

“MANUFACTURER” means the Original Equipment Manufacturer (OEM) or MANUFACTURER of one or more of the component(s) which make up a sub-assembly or item of equipment assembled by the main SUPPLIER or his nominated SUB-SUPPLIER.

‘may’ means a permitted option

‘shall’ indicates mandatory requirements

‘should’ means a recommendation

“SUB-CONTRACTOR” means any party engaged by the CONTRACTOR to undertake any assigned work on their behalf. COMPANY maintains the right to review all proposed SUB-CONTRACTORs; this right does not relieve the CONTRACTOR of their obligations under the Contract, nor does it create any contractual relationship between COMPANY and the SUB-CONTRACTOR.

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ADNOC Classification: Internal

“SUPPLIER” means the party entering into a Contract with COMPANY to provide the materials, equipment, supporting technical documents and/or drawings, guarantees, warranties and/or agreed services in accordance with the requirements of the purchase order and relevant specification(s). The term SUPPLIER includes any legally appointed successors and/or nominated representatives of the SUPPLIER.

“SUB-SUPPLIER” means the sub-contracted SUPPLIER of equipment sub-components software and/or support services relating to the equipment / package, or part thereof, to be provided by the SUPPLIER. COMPANY maintains the right to review all proposed SUB-SUPPLIERS, but this right does not relieve the SUPPLIER of their obligations under the Contract, nor does it create any contractual relationship between COMPANY and any individual SUB-SUPPLIER.

1.3.2

Abbreviations

The abbreviations used throughout this specification are shown in Table 1.1

Table 1.1 List of Abbreviations

Abbreviations

AC

Al

BS

CCA

Cu

CSP

DC

EPC

Alternating Current

Aluminium

British Standards

Continuous Corrugated Aluminium sheath

Copper

Chlorosulfonated Polyethylene

Direct Current

Engineering, Procurement and Construction

EVAPA

is a blend of EVA and PA

EPR

EVA

FAT

GSWA

GSWB

HCL

HDPE

HOFR

HV

Hz

Ethylene Propylene Rubber

Ethyl Vinyl Acetate

Factory Acceptance Test

Galvanised Steel Wire Armour

Galvanised Steel Wire Braid

Hydrogen Chloride

High Density Polyethylene

Heat Oil and Flame Resistant

High Voltage (>1000V)

Hertz

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ADNOC Classification: Internal

Abbreviations

IEC

IEEE

ISO

ITP

kV

LC

LSHF

LV

MDPE

PA

PB

PP

PVC

SVL

UV

VSD

International Electrotechnical Commission

Institute of Electrical and Electronics Engineers

International Organization for Standardisation

Inspection and Test Plan

Kilovolt

Lead cover

Low Smoke Halogen Free

Low Voltage (≤1000V)

Medium Density polyethylene

Polyamide

Lead

Polypropylene

Polyvinyl Chloride

Surge Voltage Limiter

Ultraviolet

Variable Speed Drive

XLPE

Cross-linked Polyethylene

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ADNOC Classification: Internal

SECTION A – GENERAL

REFERENCE DOCUMENTS

International Codes and Standards

The following Codes and Standards shall form a part of this specification. When an edition date is not indicated for a Code or Standard, the latest edition in force at the time of the contract award shall apply.

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 60028

IEC 60060

IEC 60071

IEC 60079-14

IEC 60093

IEC 60112

IEC 60183

IEC 60227

IEC 60228

IEC 60229

IEC 60230

IEC 60270

IEC 60287

IEC 60331

IEC 60332

International standard of resistance for copper

High Voltage Test Techniques

Insulation coordination

Explosive atmospheres - Part 14: Electrical installations design, selection and erection

Methods of test for volume resistivity and surface resistivity of solid electrical insulating materials

Method for the determination of the proof and the comparative tracking indices of solid insulating materials

Guide to selection of high voltage cables

Polyvinyl chloride insulated cables of rated voltages up to including 450/750V

Conductors of Insulated Cables

Tests on cable oversheaths

Impulse tests on cables and their accessories

Partial discharge measurements

Calculation of the continuous current rating of cables (100% load factor)

Tests for electric cables under fire conditions – Circuit integrity

Tests for Electric Cables under fire conditions

IEC 60332-3-22

Test for Vertical Flame Spread of Vertically-Mounted Bunched Wires or Cables – Category A

IEC 60446

IEC 60502-1

IEC 60502-2

Basis and safety principles for man-machine interface, marking and identification

Cables for rated voltages of 1kV (Um = 1.2kV) and 3kV (Um = 3.6kV)

Cables for rated voltages from 6kV (Um = 7.2kV) up to 30kV (Um = 36kV)

IEC 60529

Degrees of protection provided by enclosures

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IEC 60364

IEC 60724

IEC 60754

IEC 60811

IEC 60840

IEC 60853

IEC TS 60859

IEC 60885

IEC 60949

IEC 60986

IEC 61620

IEC 62067

IEC 62155

Electrical installations in buildings

Short-circuit temperature limits of electric cables with rated voltages of 1 kV (Um = 1,2 kV) and 3 kV (Um = 3,6 kV)

Test on gases evolved during combustion of electric cables

Common Test Methods for Insulating and Sheathing Materials of Electric Cables and Optical Cables

Power Cables with extruded insulation and their accessories for rated voltages above 30kV (Um=36kV) up to 150kV (Um=170kV) – Test methods and requirements

Calculation of cyclic and emergency current rating of cables

Cable connections for gas insulated metal enclosed switchgear for rated voltages of 72.5kV and above

Electrical Test Methods for Electrical Cables

Calculation of thermally permissible short-circuit currents, taking into account non-adiabatic-heating

Guide to short circuit temperature limits of electric cables with rated voltages from 6kV (Vm=7.2kV) upto 30kV (Vm=36kV)

Insulating liquids – Determination of the dielectric dissipation factor by measurement of the conductance and capacitance – Test method

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

Hollow pressurized and unpressurized ceramic and glass insulators for use in electrical equipment with rated voltages greater than 1000V

IEC 62402

Obsolescence management

BRISTISH STANDARDS

BSI BS 7671

Requirements for Electrical Installations - IET Wiring Regulations

BS 5467

BS 6231

BS 6346

BS 6622

BS 7655-2.6

Electric cables. Thermosetting insulated, armoured cables for voltages of 600/1000V and 1900/3300 V

Electric cables-Single core & PVC insulated flexible cables of rated voltage 600/1000V for switchgear & controlgear wiring

Electric cables. PVC insulated, armoured cables for voltages of 600/1000 V and 1900/3300 V (Note: Standard withdrawn and not replaced 2005 but still referenced by some manufacturers)

Electric cables – Armoured cables with thermosetting insulation for rated voltages from 3.8/6.6 kV to 19/33 kV – Requirements and test methods. Specification for Insulating and Sheathing Materials for Cables. Cross-Linked Elastomeric Sheathing Compounds. Sheathing Compounds for Ships’ Wiring and Offshore Applications.

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BS EN 10257

BS EN 12548

BS EN 50307

IEEE STANDARDS

IEEE 575

Zinc or zinc alloy coated non alloy steel wire for armouring either power cables or telecommunication cables

Lead and Lead Alloys - Lead Alloy Ingots for Electric Cable Sheathing and for Sleeves

Lead and lead alloys - Lead and lead alloy sheaths and sleeves of electric cables

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

INTERNATIONAL STANDARDS ORGANISATION

ISO 9001

ISO 9004

Quality Management Systems - Requirements

Quality Management – Quality of an Organisation – Guidance to achieve sustained success

ISO 19011

Guidelines for Auditing Management Systems

ADNOC Specifications

Where a document listed below is not available or considered to be not applicable to the Project, each ADNOC COMPANY shall use their own relevant document. Additional reference documents may also be added by each ADNOC Company.

AGES-GL-02-001

Electrical Design Guidelines

AGES-SP-02-015

Field Commissioning of Electrical Installation and Equipment

AGES-SP-02-019

Bulk Electrical Materials

AGES-PH-02-001

Earthing, Bonding and Lightning Protection Philosophy

AGES-SP-04-006

Instrument and Control Cable Specification

A0-ENG-E-STD-241

Standard for Subsea Composite Cables (up to 132kV)

A0-ENG-L-SP-002

Specification for Mechanical Design and Installation of Subsea Cables

Standard Drawings

As per Material Requisition

Other References

UAE 2020

UAE Electricity wiring regulations

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DOCUMENT PRECEDENCE

The specifications and codes referred to in this specification shall, unless stated otherwise, be the latest approved issue at the time of contract award.

It shall be the CONTRACTOR’s responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.

The CONTRACTOR shall notify the COMPANY of any apparent conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein.

Resolution and/or interpretation precedence shall be obtained from the COMPANY in writing before proceeding with the design/manufacture.

In case of conflict, the order of document precedence shall be:

a. UAE Statutory requirements

b. ADNOC HSE Standards

c. Equipment datasheets and drawings

d. Project Specifications and standard drawings

e. Company Specifications

f. National / International Standards

SPECIFICATION DEVIATION / CONCESSION CONTROL

Deviations from this specification are only acceptable where the SUPPLIER / MANUFACTURER has listed in his quotation the requirements he cannot, or does not wish to comply with, and the COMPANY / CONTRACTOR has accepted in writing the deviations before the order is placed.

In the absence of a list of deviations, it will be assumed that the SUPPLIER / MANUFACTURER complies fully with this specification.

Any technical deviations to the Purchase Order and its attachments including, but not limited to, the Data Sheets and Narrative Specifications shall be sought by the SUPPLIER / MANUFACTURER only through Concession Request Format. Concession requests require CONTRACTOR’S and COMPANY’S review / approval, prior to the proposed technical changes being implemented. Technical changes implemented prior to COMPANY approval are subject to rejection.

DESIGN CONSIDERATIONS / MINIMUM DESIGN REQUIREMENTS

System Particulars

Power Cables covered in this specification will be used on the following systems:

a. 220kV - 3 - phase, 3 wire, 50Hz, neutral solidly earthed.

b. 132kV - 3 - phase, 3 wire, 50Hz, neutral solidly earthed

c. 66kV - 3 - phase, 3 wire, 50Hz, neutral solidly or resistance earthed

d. 33kV - 3 - phase, 3 wire, 50Hz, neutral solidly or resistance earthed

e. 11kV - 3 - phase, 3 wire, 50Hz, neutral resistance earthed

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f. 6.6kV - 3 - phase, 3 wire, 50Hz, neutral resistance earthed

g. 3.3kV - 3 - phase, 3 wire, 50Hz, neutral resistance earthed

h. 690V - 3 - phase, 3 or 4 or 5 wire, 50Hz, neutral solidly or resistance earthed

i. 415V - 3 - phase, 3 or 4 or 5 wire, 50Hz, neutral solidly earthed

j. 110V DC, 48V DC & 24V DC, 2 Wire, Un-earthed systems

k. 240V – 1-Phase, 3wire, 50Hz, neutral solidly earthed

Refer to AGES-GL-02-001 for additional details on system voltages and variations.

Obsolescence

Not Applicable.

Design Parameters

Refer to Data Sheet

Environmental / Site Data

Cables shall be installed as stated below:

a) Directly buried in the ground or in formed concrete trenches with backfill.

b) Within building.

c) Fastened to cable ladder rack or tray in the open air. Cable ladder rack or tray is likely to be exposed to direct sun light & will be provided with covers that will be arranged so as not to confine the heat generated by radiation from cables and the cover.

d)

In underground ducts.

Service conditions shall be as per AGES-GL-02-001 Sections 5.6 (Environmental /Site Data) and 6.13 (cable sizing) and used as basis for cable sizing.

Any more stringent site-specific conditions shall be indicated on data sheets. Soil thermal resistivity values obtained by test and interpreted as per Geotechnical survey may be used in place of specified worst-case values, provided they represent a true value of the material to be used for final installation (tested materials to be used for backfill with understood compaction and water content).

Area Classification

Hazardous Area Classification and Equipment Selection shall be in accordance with AGES-GL-02-001 for equipment selection.

Cables shall be suitable for installation in, or passing through, Potentially Explosive Hazardous Areas and shall be in compliance with the relevant requirements of IEC 60079-14 Clause 9.

Cable entries and glanding/termination arrangements shall be in compliance with the relevant requirements of IEC 60079-14 Clause 10.

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SECTION B – TECHNICAL REQUIREMENTS

TECHNICAL REQUIREMENTS

The below sections provide specifications for differing cable voltages and installations. In cases where cables are laid from process to non-process areas, underground to above ground areas etc., the more stringent specifications shall be applicable. Cable runs shall not be provided with joints in order to match any applicable less stringent area/installation requirements with reduced specification cables without specific approval from COMPANY.

HV Power Cables (up to 33kV) - General Requirements

6.1.1

The design and construction of the HV electrical power cables up to 33kV shall be in accordance with the codes and standards as specified in Section 2.

For cabling in existing plants, design philosophies and installations of existing facilities shall be followed.

6.1.2

All HV electrical power cables shall have the conductor cores identified as follows:

a. Single core - black.

b. Three cores - red, yellow, blue

6.1.3

The colour of the outer sheathing for onshore HV cables shall be:

a. 33kV cables - Orange RAL 2004

b. 11kV cables - Red RAL 2002

c. 3.3kV & 6.6kV cables - Yellow RAL 1016

unless approved otherwise or as indicated on data sheets.

For fire resistant cable, orange straps shall be applied over the outer sheath for identification every 1 meter. This shall be not affected by the environment of installation.

6.1.4

The colour of the outer sheathing for Offshore HV cables shall be:

33kV, 11kV, 3.3kV & 6.6kV cables - Red RAL 2002 with marking to indicate voltage grade.

For fire resistant HV cable, the outer sheathing shall be Orange with embossing to indicate voltage grade.

6.1.5

The cables shall be capable of continuous operation at highest system voltage as specified with maximum conductor operating temperature of 90°C and maximum temperature under fault conditions of not more than 250°C.

6.1.6

Hydrocarbons resistant sheathed cables shall be used in plant areas and where spillage of oil or hydrocarbons are expected.

6.1.7

Type of cables for High voltage up to 33kV shall be as follows:

Underground Onshore Installations (in areas subjected to hydrocarbons contamination):

Cu / XLPE / PVC / PB* / PVC / GSWA** / PVC

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Or

Cu / XLPE / AL/HDPE/PA /GSWA** / PVC

Underground Onshore Installations (in areas with no hydrocarbons contamination):

Cu / XLPE / PVC / GSWA** / PVC

Onshore Installations aboveground:

a.

In confined and manned areas:

Cu / XLPE / PVC / GSWA** / LSHF****

b.

In other areas:

Cu / XLPE / PVC / GSWA** / PVC

Offshore Installations:

Cu / EPR*** / SW4 / GSWB / LSHF****

Where:

PB*

: Lead sheath cables or equivalent eco-friendly sheathing shall be used subject to COMPANY approval for underground cables in hydrocarbon contaminated soil

GSWA**

: For single core cables Tinned copper or AWA shall be used instead of GSWA

(see below section on Metallic Armour)

EPR*** or XLPE

: Design philosophies and installations of existing facilities shall be followed, as

applicable.

LSHF****

: Manufacturer standard material that meets LSHF Requirement (equivalent to SW4 as per BS 7655, section 2.6) can be offered as per project datasheets.

Any specific requirements regarding cable construction shall be further detailed in the Project data sheets.

6.1.8

For installations requiring higher flexibility and smaller bending radius, braided armouring and higher number of stranding of the conductors shall be used. In case of such requirements, suitable cable class in accordance with IEC 60228 shall be indicated in the data sheets.

6.1.9

LSHF cables shall be installed in manned areas, confined spaces, etc. and where escape to an area with clean air is not possible.

6.1.10 All offshore and onshore cables shall be either intrinsically flame retardant to IEC 60332 or fire resistant

to IEC 60331 as indicated in the data sheets.

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6.1.11 Materials

Conductor

a. The cable conductors shall be class 2 (unless otherwise specified for flexible cables) round circular stranded, annealed high conductivity copper (99.99% purity), laid up and rendered smooth and free from defects likely to damage the insulation and shall in accordance with IEC 60228.

b. EVAPA insulated Cables shall be made of tinned annealed stranded copper conductor and XLPE

insulated cables shall be made of plain annealed stranded copper conductor.

c. Conductors shall be unbroken for full length. Spliced conductors are not acceptable.

Screening

The conductor screening and insulation screening shall be in accordance with subsection 7.2 & 7.3 of IEC 60502-2 respectively.

Insulation

a. Offshore Installations:

High voltage power cables shall be insulated with ethylene propylene rubber (EPR).

b. Onshore Installations:

High voltage power cables shall be insulated with cross-linked polyethylene (XLPE) for onshore installations.

Laying Up

The laying of cores of cables shall be as per IEC 60502.

Filler and binder materials shall be polyethylene or polypropylene or of equivalent non-hygroscopic & nonfibrous. The bedding is required to ensure that the overall cable is robust and round in shape, without internal gaps and of uniform cross section subject to allowable tolerances throughout the length of the cable.

Inner Sheathing

For XLPE insulated cables, an inner sheath of extruded PVC compound shall be provided over the bedding. It shall be resistant to ozone, dielectric discharge and surface tracking. The thickness of inner sheath shall comply with Table 8 of IEC 60502-2 (Edition 3.0).

For EPR insulated cables, an inner sheath of CSP or EVA compound shall be provided over the above bedding. If EVA is offered, then the material shall be equivalent or better than CSP, UV resistant, heavy- duty heat and oil resistant.

For EPR cable inner sheath shall be HOFR type RS3 and the improved characteristics of SW4 in accordance with BS 7655.

Alternate materials such as EVA (Ethylene Vinyl Acetate), type SHF2 in accordance with IEC 60092-539 360 and UV resistant, or equivalent can be acceptable.

For XLPE cables, an inner sheath of PVC compound (type ST2) shall be provided over the insulation screen.

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For all cables, inner sheath shall be flame retardant to IEC 60332-3-21/22.

Mica glass and polyester tapes shall be used where manufacturer considers necessary to meet the technical requirements specified.

Hydrocarbon Resistant Sheath

Hydrocarbon resistant sheath shall be provided over the inner sheath. This shall comprise of extruded Hydrocarbon resistant material(s) applied as a seamless tight-fitting tube(s) over the above sheathing.

Separation Sheath

Suitable separation sheath shall be applied over the hydrocarbon resistant material.

Metallic Armour

a. The power cables shall be provided with armouring unless otherwise specified.

b. For XLPE cables, Armouring shall be single layer galvanized steel wires with synthetic tape for multi core cables whereas aluminium wire or tinned copper armour shall be used for single core cables. The same shall be finalized in the datasheets.

c. For EPR cables, armouring shall be corrosion resistant non-magnetic braided (tinned phosphor bronze wire or equivalent) material for single core cables and Galvanized Steel Wire Braid (GSWB) for multi-core cables.

d. The armour shall provide the mechanical protection for the cable. Also, the electrical conductivity of

the armour shall be such that it is capable of carrying the earth fault current.

e. Armour for cables rated 3.3kV to 33kV shall be provided in accordance with section 13 of IEC 60502-

2 (Edition 3.0 dated 2014-02).

Outer Sheath

a. The outer sheath shall be extruded over the armour.

b. The tolerance of overall cable diameter shall not be more than ±1mm.

c. For EPR insulated cables, if EVA is offered, then the material shall be UV resistant (ISO4892 or

equivalent), heavy duty, heat and oil resistant.

d. For XLPE insulated cables, an outer sheath of PVC (Type ST2) insulation, UV resistant (ISO4892 or

equivalent), heavy duty, heat and oil resistant and termite resistant.

e. The outer sheath shall be intrinsically flame retardant as per IEC 60332-3-21/22.

f. For LSHF cables, manufacturer shall offer his Standard material that, meets LSHF requirements keeping on the retardancy property supporting documents to be submitted for review. HCL emissions evolved during combustion shall be less than 0.5% by weight of material. The oxygen index of both bedding and sheath shall not be less than 30. LSHF cables shall not be directly exposed to sun. Shade shall be provided to prevent direct sunlight.

6.1.12 Cable Assembly

a. Cores of a three-core cables rated 3.3kV shall be assembled in accordance with section 7 of IEC

60502-1.

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b. Cores of a three-core cables rated above 3.3kV and up to 33kV shall be assembled in accordance

with section 8 of IEC 60502-2.

6.1.13 Special requirements of converter/inverter application cables

HV Power cables supplying variable frequency drives and associated motors, power cable requirements including cable screening, whilst earthing requirements shall be provided in line with VSD manufacturers recommendations.

6.1.14

Identification

a. Core/Phase Identification

For cable core colour Identification, refer section 6.1.2.

b.

Cable Identification

The following information shall be marked on cable outer sheath every 5 meter along the entire length:

i. Manufacturer name,

ii. Number of cores,

iii. Conductor size,

iv. Insulation type,

v. Voltage grade,

vi. Year manufactured,

vii. Running length.

LV Power, Control and Earthing Cables - General Requirements

6.2.1

The design and construction of the electrical LV power, control and Insulated Earthing cables shall be in accordance with the codes and standards as specified.

6.2.2

The colour of the outer sheathing for LV power cables shall be black.

6.2.3

All electrical LV power cables shall have the conductor cores identified as follows (any variations or acceptable alternatives will be identified on data sheets:

a. Single core

• red or black.

b. Two cores

• red and black.

c. Three cores

• red, yellow, blue for 3 phase services.

• red, black, yellow/green for single phase services.

d. Four cores

• red, yellow, blue & black for 3 phase + Neutral.

• red, yellow, blue & yellow/green for 3 phase & earth.

e. Five cores

• red, yellow, blue and black and yellow with green stripes for 3 Phase +

  Neutral + Earth

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f. Earthing cable/wire - green/yellow for Electrical earthing cable (Instrument Clean Earthing cables shall be provided with green outer-sheath, and Instrument IS Earthing cables shall be provided with green outer-sheath with blue coloured markings at its terminations).

g. Control cable (multicore) – white colour with black core numbers on the insulation every linear

metre.

The colour of the outer sheathing shall be black for flame retardant and orange for fire resistant cables.

6.2.4

The cables shall be capable of continuous operation at highest system voltage as specified with maximum conductor operating temperature of 90°C and maximum temperature under fault conditions of not more than 250°C.

6.2.5

Hydrocarbons resistant sheathed cables shall be used where spillage of oil or hydrocarbons are expected.

6.2.6

Type of cables shall be as follows:

Underground Onshore Installations (in areas subjected to hydrocarbons contamination):

Cu / XLPE / PVC / PB* / PVC / GSWA** / PVC

Or

Cu / XLPE / AL/HDPE/PA / GSWA** / PVC

Underground Onshore Installations (in areas with no hydrocarbons contamination):

Cu / XLPE / PVC / GSWA** / PVC

Onshore Installations aboveground:

a.

In confined and manned areas:

Cu / XLPE / PVC / GSWA** / LSHF***

b.

In other areas:

Cu / XLPE / PVC / GSWA** / PVC

Offshore Installations:

Cu / EPR / LSHF*** / GSWA** / LSHF***

Where:

PB*

: Lead sheath cables or equivalent eco-friendly sheathing shall be used subject to COMPANY approval for underground cables in hydrocarbon contaminated soil

GSWA**

: For single core cables AWA shall be used instead of GSWA

LSHF***

: Manufacturer standard material that meets LSHF Requirement (equivalent to

SW4 as per BS 7655-2.6:2000) can be offered as per project datasheets.

Any specific requirements shall be further detailed in the Project data sheets.

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6.2.7

For installations requiring higher flexibility and smaller bending radius, braided armouring and higher number of stranding of the conductors shall be used. In case of such requirements suitable cable class in accordance with IEC 60228 shall be indicated in the data sheets. Cable specification for cables for special applications requiring high flexibility, such as lifts or crane catenaries, shall be Approved by COMPANY.

6.2.8

LSHF cables shall be installed in manned areas, confined spaces, etc. where escape to an area with clean air is not possible.

6.2.9

Insulation voltage grade shall be as per IEC 60502.

6.2.10 All offshore and onshore cables shall be either intrinsically flame retardant to IEC 60332 or fire resistant

to IEC 60331 as indicated in the data sheets.

6.2.11 Materials

Conductor

a. The cable conductors shall be class 2 (unless otherwise specified for flexible cables) round circular stranded, annealed high conductivity copper (99.99% purity), laid up and rendered smooth and free from defects likely to damage the insulation and shall in accordance with IEC 60228.

b. EPR insulated Cables shall be made of tinned annealed stranded copper conductor and XLPE

insulated cables shall be made of plain annealed stranded copper conductor.

c. Smaller sizes shall be circular in formation. Larger conductors shall be shaped to produce a compact design (i.e., sector formation). Multi-core cables having two cores or more shall have all cores of uniform cross section.

d. Conductors shall be unbroken for full length. Spliced conductors are not acceptable.

e. Minimum size shall be as per AGES-GL-02-001 Section 6.13.5.

Screening

Not applicable for LV cables (For VSD to motors or heater thyristor control panels to process heaters, screened cables shall be utilized).

Insulation

a. Offshore Installations:

Low voltage power cables shall be insulated with ethylene propylene rubber (EPR).

b. Onshore Installations:

Low voltage power cables shall be insulated with cross-linked polyethylene (XLPE) for onshore installations.

Insulation shall be rated for 90°C maximum conductor temperatures.

c. Earthing cables

Earthing cables shall be single core, PVC sheathed, 0.45/0.75kV (IEC) or 600/1000V (BS) Grade.

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Laying Up

The laying of cores of cables shall be as per IEC 60502-1. Non-hygroscopic fillers, binders etc. shall be used. This is required to ensure that the overall cable is robust and round in shape, without internal gaps and of uniform cross section subject to allowable tolerances throughout the length of the cable. The materials for fillers & binders shall be compatible with the insulation materials.

Inner Sheathing

For XLPE insulated cables, an inner sheath of extruded PVC compound shall be provided over the laid- up cores. The thickness of inner sheath shall comply with table 8 of IEC 60502-1.

For EPR cable inner sheath shall be HOFR type RS3 and the improved characteristics of SW4 in accordance with BS 7655.Alternate materials such as EVA (Ethylene Vinyl Acetate), type SHF2 in accordance with IEC 60092-539 and UV resistant, or equivalent can be acceptable.

For all cables, inner sheath shall be flame retardant to IEC 60332-3-21/22.

Mica glass and polyester tapes shall be used where manufacturer considers necessary to meet the technical requirements specified.

Hydrocarbon Resistant Sheath

Hydrocarbon resistant sheath shall be provided over the inner sheath. This shall comprise of extruded Hydrocarbon resistant material(s) applied as a seamless tight-fitting tube(s) over the above sheathing.

Separation Sheath

Suitable separation sheath shall be applied over the hydrocarbon resistant material.

Metallic Armour

a. The power cables shall be provided with armouring unless otherwise specified.

b. Armouring for multi-core cables shall be single layer galvanized steel wires with synthetic tape

whereas aluminium wire armour shall be used for single core cables.

c. The armour shall provide the mechanical protection for the cable. Also, the electrical conductivity of the armour shall be such that it is capable of carrying the earth fault current specified in data sheets.

d. Armour shall be provided in accordance with section 12 of IEC 60502-1 (Edition 3.0 dated 2021-02).

e. For EPR cables, armouring shall be corrosion resistant non-magnetic braided material for single core

cables and Galvanized Steel Wire Braid (GSWB) for multi-core cables.

Outer Sheath

a. The outer sheath shall be extruded over the armour.

b. The tolerance of overall cable diameter shall not be more than ±1mm.

c. The outer sheath shall be intrinsically flame retardant as per IEC 60332-3-21/22 and termite resistant.

d. For LSHF cables, manufacturer shall offer his Standard material that, meets LSHF requirements keeping on the retardancy property supporting documents to be submitted for review. HCL emissions evolved during combustion shall be less than 0.5% by weight of material. The oxygen index of both bedding and sheath shall not be less than 30.

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Special requirement of converter/inverter application cables

LV Power cables supplying variable speed drives and associated motors, power cable requirements including cable screening, whilst earthing requirements shall be provided in line with VSD manufacturers recommendations.

Identification

a. Core/Phase Identification

Conductor identification shall be by coloured insulation material (for Power) and core numbering (for Control).

b. Cable Identification

The following information shall be marked on cable outer sheath every 5 meter along the entire length:

i. Manufacturer name,

ii. Number of cores,

iii. Conductor size,

iv. Insulation type,

v. Voltage grade,

vi. Year manufactured.

vii. Running length.

LV Single Core Conduit Cable (wire)

6.3.1

Specific requirements for PVC insulated single core cable (wire) for use in conduit (for lighting and receptacle circuits in buildings) are:

Voltage grades - 450/750V (IEC) or 600/1000V (BS)

Conductor

- Stranded annealed copper

Insulation

- Extruded polyvinyl chloride (coloured Red, Yellow, Blue, Black, etc., as required).

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ADDITIONAL SPECIFIC REQUIREMENTS

Cable Terminations and Joints

Cables shall be supplied in single continuous length. Cable jointing is not acceptable unless otherwise approved in writing by COMPANY.

Where applicable, cable terminations and jointing for HV cables 22kV and above shall be carried out using suitable kits as per the rated voltage levels, cable design and connected equipment requirements. The kits shall be of proven design as approved by the cable and electrical equipment (switchgear, transformer, motor etc.) manufacturers and subject to approval by COMPANY.

SUPPLIER shall provide complete description and instructions for the supplied kits including information on jointing of the core, insulation, core and insulation semi-conducting layers, metallic screen or sheath, sheath covering, bedding and armour etc. Installation shall be by qualified and approved Contractors in accordance with cable manufacturer’s instructions.

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SECTION C – OTHER REQUIREMENTS

DETAILS OF SCOPE SUPPLY

General

The SUPPLIER Scope of Work shall include, but shall not be limited to, design, manufacture, inspection, testing, preparation for shipment, special tools and supply of documentation and manuals, and other services.

SUPPLIER’S Responsibility

The SUPPLIER shall be responsible for the supplied equipment in every respect including design, selection of materials and components, manufacturing and testing.

The SUPPLIER’s responsibility shall extend to his sub-contractors and sub-suppliers, if any.

The SUPPLIER shall be responsible for the production of all drawings and all documents related to the electrical materials.

It shall be the SUPPLIER’s responsibility to furnish all items essential for the safe and satisfactory installation and operation of the equipment.

The make and Country of Origin of all electrical materials shall be per approved Supplier list.

QUALITY CONTROL AND ASSURANCE

Equipment shall only be purchased from SUPPLIERS approved by ADNOC Category Management. This approval indicates that the SUPPLIER has an approved Quality management system and a proven track record in supply of this type of material.

SUB-CONTRACTORS, SUB-SUPPLERS

The SUPPLIER shall assume unit responsibility and overall guarantee for the cables and associated equipment.

The SUPPLIER shall transmit all relevant purchase order documents including specifications to his SUB- SUPPLIERS and Sub-Contractors.

It is the SUPPLIER’S responsibility to enforce all purchase order and specification requirements on his SUB- SUPPLIERS and Sub-Contractors.

The SUPPLIER shall submit all relevant SUB-SUPPLIER and Sub-Contractor drawings and engineering data to the CONTRACTOR.

The SUPPLIER shall obtain and transmit all SUB-SUPPLIER’S and Sub-Contractor warranties to the CONTRACTOR/COMPANY, in addition to the system warranty.

MATERIAL CERTIFICATION

Not Applicable

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INSPECTION AND TESTING REQUIREMENTS

General

Before leaving the SUPPLIER’S works, the cables shall be inspected and tested in accordance with the relevant IEC or BS Standards as listed in Section A of this specification.

The SUPPLIER shall provide an Inspection and Testing Plan (ITP) at least 8 weeks’ notice prior to the testing date.

The ITP shall be submitted for review and acceptance by the COMPANY and include Witness and Hold points in the programme for SUPPLIER, CONTRACTOR, and the COMPANY.

The COMPANY/CONTRACTOR or his nominee shall inspect the equipment and witness the required tests indicated in the Requisition at the time the equipment is offered for final inspection.

A detailed test procedure of factory tests shall be submitted at least 3 months in advance of any testing, detailing the proposed inspection, testing and witness testing programme throughout the design and build of the equipment.

Test certificates for each item of equipment shall be submitted prior to delivery for COMPANY acceptance.

With reference to the above, the term “item of equipment” refers to all materials supplied e.g., a drummed length of cable, termination or joint kit, special tools etc.

Test Reports

Test reports in accordance with the relevant IEC/BS standards including the following shall be submitted to COMPANY.

a. The design values

b. The tolerance values

c. The real values as measured, including, if any, the intermediate values causing provisional refusal.

SUPPLIER shall compile the records of all inspections and tests including routine tests and special tests in one document and shall submit as part of technical documentation.

Type Tests

12.3.1 SUPPLIER shall submit the type test certificates for each cable type for tests as required in the applicable

IEC and BS standards

12.3.2 Test certificates shall be from an internationally recognised, independent testing authority, and shall be

subject to COMPANY acceptance.

12.3.3 Unless any specific tests have been specified or indicated in the data sheets, type tests shall not be witnessed. However, the following type test certificates for tests carried out against the applicable IEC 60502-1 or IEC 60502-2 test regime shall be made available to COMPANY and submitted with the Bid for all cable types:

a. Oil immersion test

b. Ageing test

c. Water absorption

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d. Material tests on insulation and sheath

e. Ozone resistance (IEC 60811-403)

f. Resistance to Abrasion,

g. Stripping test,

h. Bend test

i. Fire withstand test (IEC 60331)

j. Reduced propagation (IEC 60332-3-10)

k. Smoke propagation (IEC 60332-2-2)

l. Halogen acid gas Content (IEC 60754-1)

m. HCL emission (IEC 60332-2).

12.3.4

In addition, for HV cables the following type test certificates for tests carried out against the applicable IEC 60840 or IEC 62067 test regime shall be made available to COMPANY:

a. Tensile Bending test,

b. Coiling Test,

c. Tan δ measurement (IEC 61620),

d. Heat Cycle test,

e. Shrinkage test for XLPE insulation,

f. Lightning Impulse test,

g. AC Voltage test for 4 hours,

h. Partial Discharge Test (IEC 60885-3),

i. Resistivity of semi-conducting screens and sheaths (IEC 62067),

j. Non Electrical type tests in accordance with IEC 60502 (for cables up to 36kV)

k. Water Penetration test on power core in accordance with CIGRE Electra 189.

Routine Tests

12.4.1 The required routine tests, test conditions and acceptance criteria for the cables shall be in accordance with the latest edition of IEC-60502-1 for cables up to 3kV, IEC 60502-2 for cables from 6kV to 33kV and IEC 60502-4 for cable accessories up to 33kV. Routine and Sample tests (Note sample tests are to be separately requested on data sheets) shall be carried out on each type and size of cables as per the agreed ITP.:

a. High Voltage Test,

b. Continuity and Resistance Test for Conductor/Screen,

c. Armour Resistance Test,

d. Partial Discharge Test (for HV cables),

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e. Thickness of Insulation,

f. Thickness of Non-metallic sheaths,

g.

Insulation Resistance (Voltage) Test,

h. Hot set test for XLPE insulations and elastomeric sheaths,

i. Check for correct colour and markings on insulation and sheath,

j. Measurement of external diameter,

k. Visual check on general appearance and finish,

l. Check for correct markings on drums,

m. Dimensional check (including over and under armour diameters).

n. Flame-retarding tests for sheath (sample test as per datasheet)

o. Oil Immersion test for sheath (sample test as per datasheet)

p. Ageing test for sheath (sample test as per datasheet)

q. Fire tests for all fire resistant cables (sample test as per datasheet)

12.4.2 The following routine tests shall be completed on all cable accessories:

a. Visual inspection of overall finish, painting, welds, metal works, lifting lugs, terminal fastening,

insulation, terminations, fixings, etc.

b. Dimensional checks – mounting, terminals, centre lines, overall dimensions and weight.

c. Check of the rating plate, nameplate and any additional markings and labels required by this

document.

d.

Insulation tests.

Additional Tests

If Required, to be stated in Material Requisition and/or datasheet

Special Tests

If Required, to be stated in Material Requisition and/or datasheet

Site Tests

Refer to AGES-SP-02-015, Field Commissioning of Electrical Installation and Equipment, for requirements for site testing of cables and accessories. All site tests are to be in accordance with IEC standards and in agreement with cable or accessory MANUFACTURER with regards test Voltage magnitude, durations and Frequency of test voltage.

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SPARE PARTS

a. The SUPPLIER shall propose:

i. A list of commissioning spare parts (if applicable for cable accessories)

ii. A list of 2 years operation spare parts (if applicable for cable accessories)

iii. A list of special tools required for erection, commissioning and maintenance

b. Special tools required for drum handling, cable pulling, testing, commissioning and maintenance

shall be shipped together with the cables and accessories.

c. Each spare part shall be separately packed and clearly identified for storage management.

PAINTING, PRESERVATION AND SHIPMENT

Painting

14.1.1 Surface preparation and painting for cable accessories shall be in accordance with the COMPANY

standard.

14.1.2 Alternatively, SUPPLIER may propose the standard for enhanced protection against corrosion in outdoor climates. The paint system applied shall provide adequate protection against the adverse effects of the climatic conditions specified. Full details of SUPPLIER’S painting specification shall be provided with the proposal for COMPANY approval.

14.1.3 The equipment shall be fully tropicalized.

14.1.4 Corrosion classification shall be:

a. C5-I corrosion classification (ISO 12944) for onshore facilities.

b. C5-M corrosion classification (ISO 12944) for offshore facilities.

Preservation and Shipment

14.2.1 Preparation for shipment shall be in accordance with the SUPPLIER’S standards and as noted herein. SUPPLIER shall be solely responsible for the adequacy of the preparation for shipment provisions with respect to materials and application, and to provide equipment at the destination in ex-works condition when handled by commercial carriers.

14.2.2 Adequate protection shall be provided to prevent mechanical damage and atmospheric corrosion in transit and at the jobsite. Equipment and materials shall be protected to withstand ocean transit and extended period of storage at the job site for a minimum period of 18 months. Equipment shall be protected to safeguard against all adverse environments, such as: humidity, moisture, rain, dust, dirt, sand, mud, salt air, salt spray, and seawater.

14.2.3 Preparation

for shipment and packing will be subject

rejection by COMPANY’S/CONTRACTOR’S inspectors. All costs occasioned by such rejection shall be to the account of the SUPPLIER.

inspection and

to

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14.2.4 After inspection and test, equipment shall be completely free of water and dry before start of preparation

for shipment.

14.2.5 Cables shall be drummed in maximum continuous lengths on non-returnable cable drums. Cable end

caps shall be provided 10 each per drum.

14.2.6 Cables ends shall be sealed and fixed to the drum. Cable drums shall be fitted with battens, fixed around

the entire periphery of the drum.

14.2.7 All cable drums shall have their identification reference clearly stencilled on the outside of both flanges.

14.2.8 Drum identification labels shall be permanently attached on the outside and inside of the drum flange.

Labels shall be stainless steel and give the following information:

a. Drum identification number

b. Voltage grade

c. Cable construction (i.e. XLPE, LC, PVC SWA, PVC)

d. Number of cores and cross-sectional area

e. Cable Length

f. Total Drum Weight (gross weight in kg)

g. Purchase Order number and item number

h. Project Name

i. MANUFACTURERS name, job number and factory reference

j. Temperature Rating

14.2.9

In addition to the information required by the specified standards, the following information shall be marked every one metre along the entire cable length on the external surface of the outer sheath.

a. Number of Cores

b. Size of Conductor

c. Voltage rating

d. MANUFACTURER’S name and cable type

e. Stock code number (COMPANY shall advise stock code philosophy)

f. The drum progressive length of cable at every meter (zero point being the cable end at its inner coil

on the cable drum)

g. Year of manufacture

Example: 4 Core 25 mm2, 1kV grade, XYZ Company, Type ABCD, xxx code, yyy meter, 2017

COMMISSIONING

The requirements for Commissioning shall be included in the Material Requisition document.

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TRAINING

The requirements for Training shall be included in the Material Requisition document.

DOCUMENTATION / MANUFACTURER DATA RECORDS

General

SUPPLIER shall submit the type and number of drawings and documentation for CONTRACTOR’S authorization or information as listed in the Material Requisitions and Purchase Orders.

Schedule of documents and data submittal shall be as agreed in the purchase order.

Comments made by CONTRACTOR on drawing submittal shall not relieve the SUPPLIER of any responsibility in meeting the requirements of the specifications. Such comments shall not be construed as permission to deviate from requirements of the Purchase Order unless specific and mutual agreement is confirmed in writing.

Each drawing shall be provided with a block in the bottom right-hand corner incorporating the following information:

a. Official trade name of the SUPPLIER.

b. SUPPLIER’S drawing number.

c. Drawing title giving the description of contents whereby the drawing can be identified.

d. A symbol or letter indicating the latest issue or revision.

e. Purchase order number and item tag numbers.

Revisions:

a. Document and drawing revisions shall be identified with symbols adjacent to the alterations.

b. A brief description of each revision shall be given in tabular form.

c.

If applicable, the authority and date of the revision shall be listed. The term “Latest Revision” shall not be used.

All documents shall show the relevant order number, item tag numbers and SUPPLIER’S references and shall be distributed as specified in the purchase order documents.

Graphic symbols for electrical diagrams shall be according to IEC 60617-DB. Device code numbers shall be as per ANSI C-37.2 -1996.

All documents and drawings shall be in English.

Installation, operating and maintenance manuals shall be arranged as follows:

a. The front cover, spine and inside page shall state the purchase order number and SUPPLIER’S reference

number.

b. The inside front page shall carry an index listing the contents of each section of the manual.

c.

Individual sections shall be completed and shall refer to the equipment actually supplied.

d. Published data shall also be included, including published data for bought-in items.

e. Full detail for installation, testing and commissioning shall be included.

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f. Recommended test data shall be stated, covering initial and also regular testing shall be given. For

example, high voltage AC or DC test values.

g.

Items requiring regular inspection, checking, testing and maintenance shall be listed and the time scale clearly indicated.

Required Documentation

The SUPPLIER shall provide, as a minimum, the following documentation relevant to Cables and accessories in English language:

Table 17.1 Documentation Required

Document

With Bid

Project Documentation

Filled-in Cable Data Sheets

Catalogue data for Cables and Accessories

Drum and Cable Marking Details

Electrical equipment list and Bill of Materials

List of sub-suppliers

Interconnection wiring diagram (ross-Bonding Link Boxes)

Inspection and Test Plan (ITP)

Compliance to specification, data sheet and requirements

Surface preparation and painting procedure (cable accessories)

Shipping, handling, packing and storage procedure

Test report and certificates

Type test certificates

List of Special Tools

X

X

X

X

X

X

X

X

X

Installation, commissioning, operating and maintenance manuals

The document numbering shall be in accordance with ADNOC numbering procedure

Data To Be Furnished By The Manufacturer

X

X

X

X

X

X

X

X

X

X

X

X

X

X

17.3.1 The following data shall be furnished (by completion of data sheets or provision of catalogue data) by

the SUPPLIER/MANUFACTURER together with respective tolerances where applicable:

h.

Insulation thickness

i. Diameter under armour

j. Diameter over armour

k. Overall Diameter

l. Current rating in air and ground for the ambient conditions specified.

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m. One second short circuit rating.

n. Resistances per km (conductor and armour at operating temperature), reactance per km and

capacitance per km at rated frequency (for HV cables only)

o. Maximum continuous drum length for each size of cable and drum weight in kg

p. Maximum pulling tension

q. Minimum bending radius (as a factor of overall diameter)

r. Cable weight in kg/km

s. Cable derating factors

t. Cable 1 second short circuit rating or Current vs. Time charts

u. Cross section Drawing showing make-up of cable

v. Details on moisture and chemical resistancy

GUARANTEES AND WARRANTY

The SUPPLIER shall guarantee, in accordance with the general conditions that the equipment shall meet the performance conditions specified in this specification, associated documents and data sheets.

SPECIAL ENGINEERING SERVICEREQUIRMENT FOR SINGLE POWER CABLE (>5KV)

Special engineering services shall be provided by the Cable Manufacturer to the CONTRACTOR in selecting the bonding scheme based on cable route length based on CONTRACTOR’s requirements. Additional material such as earthing cable, SVL (surge voltage limiter), junction box etc. shall be suggested to CONTRACTOR for further approval and procurement according to bonding scheme.

Nominal rating of the cable shall be declared by manufacturer based on bonding schemes.

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SECTION D – STANDARD DRAWINGS & DATASHEETS

DATASHEET TEMPLATES

Data sheets for Cables and Accessories shall be inserted and decided by COMPANY

Data sheet (Document number) TBA.

STANDARD DRAWINGS

TBA

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SECTION E – APPENDICES

ADDITIONAL REQUIREMENTS FOR CABLES ABOVE 33KV UP TO 220KV

Requirements for 66kV and 132kV Cables

22.1.1 Underground Onshore Installations (in process areas subjected to hydrocarbons contamination):

Cables shall be to IEC 60840, Single Core, with the following construction

Cu / XLPE / PB* / MDPE / AWA / PE

Or

Cu / XLPE / PVC / CCA / PVC / AWA / PE

Or

Cu / XLPE / AL/HDPE/PA / AWA / PE

Where:

PB*

: Lead sheath cables or equivalent eco-friendly sheathing shall be used subject to COMPANY approval for underground cables in hydrocarbon contaminated soil

AWA

: Aluminium Wire Armour (supplemented by aluminium tapes or tinned copper

wires if required)

CCA

: Continuous Corrugated Aluminium sheath

AL/HDPE/PA

: Poly-Al Laminate Sheath

22.1.2 Cable construction details are:

Conductors

The 66kV and 132kV cables shall have cross sectional area for meeting the prospective fault current for 1 second unless otherwise specified in the data sheet.

For all cables, conductors shall be class 2. Cable conductors shall be of high conductivity, Compacted stranded plain annealed copper with circular or shaped cross-section as per IEC 60228. The conductor shall be free from metallic and foreign particles, which may contaminate the insulation or cause high stress points.

The strands before shaping shall be smooth, uniform in quality, free from scale, inequalities, slits, splits, and other defects. The plain annealed copper shall be filled with water-blocking semiconducting compound. The water swelling tapes around each layer of conductor wires to form a water barrier to prevent water penetration along the conductor in case the cable is broken. A radial water barrier over the conductor alone is not acceptable. Typical minimum thickness of the water swelling tapes is 0.2mm.

Conductor Screen, Insulation and Insulation Screen

a. Conductor Screen

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The conductor screen shall consist of a binder tape applied over the conductor and a layer of black extruded super-smooth, semi-conducting compound which shall be firmly bonded to the inner surface of the insulation.

The minimum thickness of the extruded conductor screen shall be as specified in the Datasheet.

The outer surface of the conductor screen shall be cylindrical, smooth, and free of protrusions and irregularities. The outer surface of the conductor screen shall be firmly and continuously bonded to the inner surface of the insulation and shall have no tendency to separate from the insulation due to the effect of bending during installation, load cycling and short circuit under service conditions.

The resistivity of the extruded conductor screen shall not exceed 1000 Ω-m at 90°C.

b.

Insulation

The insulation shall be homogenous extruded ultra-clean cross-linked polyethylene (XLPE) complying with the requirements as specified in the relevant latest IEC standard.

The insulation shall be free from micro voids, contaminants, protrusions and moisture as specified in the above standard.

The lowest measured insulation thickness shall not fall below 90% of nominal insulation thickness.

The thickness of the insulation shall be as specified in the data sheets.

c.

Insulation Screen

The insulation screen shall be Extruded Semiconducting compound and water blocking semi-conductive tape over the insulation screen.

The resistivity of the extruded insulation screen shall not exceed 500Ωm at 90°C. The minimum thickness of the insulation screen shall be as specified in the Datasheet.

The inner surface of the insulation screen shall be smooth and free of protrusions and irregularities.

The inner surface of the insulation screen shall be firmly and continuously bonded to the outer surface of the insulation and shall have no tendency to separate from the insulation due to the effect of bending during installation, load cycling and short-circuit under service conditions.

Metallic Wire Screen

Metallic screen of plain annealed copper wire shall be applied over the semiconducting insulation screen. Annealed Copper wire screen shall be designed to carry the earth fault current specified for a period of one second without exceeding the permissible temperature rise.

The metallic sheath shall be impervious to moisture, tightly fitting and free from defects and impurities such as oxides that could give rise to failure under working conditions.

The lead sheath (according to BS EN 12548 & BS EN 50307), continuous corrugated aluminium sheath or AL/HDPE/PA sheath shall be in electrical contact with the wire screen to ensure equal potential between all wires.

Separation sheath

Inner sheath or core sheath shall be of semiconducting Polyethylene and lead alloy sheath according to BS EN 12548.

The minimum thickness of the lead sheath shall not fall below 5% +0.1mm of the nominal thickness.

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The sheath and screen shall be capable of carrying, without damage, the fault current for one second under the most severe fault condition. Lead alloy sheaths shall also have good creep ductility to provide the necessary mechanical strength for the cable due to the effect of bending during installation, load cycling and short circuit under service conditions.

Lead or aluminium sheathing shall be of uniform thickness and homogeneous construction, close fitting, seamless and free from porosity or defects and remain stable in service. Composition of sheathing and its thickness shall be suitable for resisting fatigue due to vibration and the construction shall be capable of withstanding the external and internal mechanical stresses likely to be encountered during manufacture, testing, transport, installations and service without puncture, fracture or stress cracking.

The lead alloy, corrugated aluminium or AL/HDPE/PA sheath shall have excellent corrosion resistance and provide radial protection from moisture, hydrocarbon and acid/alkali chemical ingress.

Bedding

Bedding for Armouring shall be semiconducting nylon tapes. Thickness of bedding & diameter over bedding shall be specified in data sheet.

Armouring

66kV and 132kV cables shall be provided with Aluminium Wire Armour. The armour shall provide the mechanical protection for the cable. The electrical conductivity of the armour shall be such that, it is capable of carrying the earth fault current specified in data sheets.

Outer Sheath

Outer sheath of cable shall be extruded layer of Low smoke halogen free (LSHF) intrinsically flame retardant with a thin semi-conductive layer outside. Outer sheath shall be black colour. The outer sheath material shall be semiconducting PE (MDPE) with all required properties for tensile strength, robustness, installation-bending radius etc. Cables shall meet the requirements of IEC 60332. The outer sheath shall be of UV resistant and Termite resistance properties. The oxygen index shall be of 30 or a numerically higher value. The outer sheath shall have a graphite smear layer applied to enable sheath testing.

Requirements for 220kV Cables

22.2.1 Underground Onshore Installations (in process areas subjected to hydrocarbons contamination):

Cables shall be to IEC 62067, Single Core, with the following construction

Cu / XLPE / PVC / PB* / PVC / AWA / HDPE

Or

Cu / XLPE / PVC / CCA / PVC / AWA / HDPE

Or

Cu / XLPE / AL/HDPE/PA / AWA / HDPE

Where:

PB*

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AWA

: Aluminium Wire Armour (supplemented by aluminium tapes or tinned copper

wires if required)

CCA

: Continuous Corrugated Aluminium sheath

AL/HDPE/PA

: Poly-Al Laminate Sheath

22.2.2 Cable construction details are:

Conductors

The conductor shall consist of plain segmental annealed high conductivity copper wires of 99.99% purity, complying with the class 2 requirements of IEC 60228. The conductor shall be clean and free from metallic and foreign particles, which may contaminate the insulation or cause high stress points.

The copper wire before shaping shall be smooth, uniform in quality, and free from scale, inequalities, spills, splits and other defects.

The term “annealed” signifies that the wire can stand elongation of at least 15 percent without fracturing before stranding, the test piece being not shorter than 150mm and not longer than 300mm.

When made up from shaped wires the conductor shall be clean and uniform in size and shape and its surface shall be free from sharp edges and unless otherwise approved shall be taped with a layer of conductive or semi-conductive material.

Not more than two joints shall be allowed in any of the single wires forming each length of conductor, and no joint shall be allowed within 300mm of any other joint in the same layer. The jointing of wires shall be made by brazing, silver soldering or electrical welding. No joint shall be made in the wire after it has been formed up into the required length.

The cable and conductor shall be watertight both in axial and radial direction because of water table.

Provision shall be made to prevent the longitudinal passage of water. This shall be achieved by the application of water swelling tapes around each layer of conductor wires to form a water barrier to prevent water penetration along the conductor in case the cable is damaged. A radial water barrier over the finished conductor alone is not acceptable.

Conductor Screen, Insulation and Insulation Screen

a. Conductor Screen

The conductor screen shall consist of a semi-conducting binder tape applied over the conductor and a layer of black extruded thermosetting super-smooth semi-conducting XLPE compound which shall be firmly bonded to the inner surface of the insulation. This layer shall be compatible with the insulation and the semi-conducting tape.

The thickness of the extruded conductor screen shall be as specified in the Technical Data sheets.

The outer surface of the conductor screen shall be smooth and free of protrusions and irregularities. The outer surface of the conductor screen shall be firmly and continuously bonded to the inner surface of the insulation and shall have no tendency to separate from the insulation due to the effect of bending during installation, load cycling and short circuit under service conditions.

The volume resistivity of the extruded conductor screen shall not exceed 1000 Ω-m at 90ºC.

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b.

Insulation

The insulation shall consist of homogeneous extruded super-clean cross-linked polyethylene (XLPE) complying with the requirements as specified in the relevant latest IEC Standard.

The insulation shall be free from micro voids, contaminants, protrusions and moisture as specified in the above standard.

The insulation raw material should be of super clean class.

The insulation shall also be explicitly resistant to the formation of water trees.

The thickness of the insulation shall be as specified in the Technical Data Sheets.

The average thickness of the insulation, when determined by the method described in Section 11 “Inspection and Tests” shall not be less than the minimum value stated in the data sheet. The thickness at any place may however be less than the specified nominal value provided that the difference does not exceed 10 percent of the specified nominal value.

The thickness of the semi-conductive screen or any separator on the conductor or over the insulation shall not be included in the thickness of the insulation.

Particular attention shall be given to insulation, voltage stress with particular reference to installation conditions and ingress and migration of moisture so as to ensure a long service life.

c.

Insulation Screen (non-metallic)

The insulation screen shall consist of an extruded layer of black thermosetting super-smooth semi- conducting compound applied directly over the insulation.

The thickness of the insulation screen shall be as specified on the Technical Data Sheets.

The inner surface of the insulation screen shall be smooth and free of protrusions and irregularities.

The inner surface of the insulation screen shall be firmly and continuously bonded to the outer surface of the insulation and shall have no tendency to separate from the insulation due to the effect of bending during installation, load cycling and short-circuit under service conditions.

The volume resistivity of the extruded insulation screen shall not exceed 500 Ω-m at 90ºC.

d. Manufacturing Process of Conductor Screen, Insulation and Insulation Screen

The conductor screen, the insulation and the insulation screen shall be mutually compatible and shall be continuous triple extrusion and completely dry cured by a common head in a common manufacturing process. For cooling after vulcanization, dry cooling is preferred. Details of the characteristics of the material and the curing process shall be set out in the data sheet.

To reduce the methane content of XLPE a heat treatment shall be carried out after curing for minimum 7days at 75ºC. The Cable Manufacturer shall provide evidence to have degassed the cable.

The extruded conductor screen, insulation and insulation screen shall be manufactured to the highest standard of concentricity, diameter roundness and longitudinal diameter, stability.

The Cable manufacturer shall provide a detailed description on the extrusion, curing, cooling and heat treatment processes.

AGES-SP-02-011

J-DMS 14-Aug-2024 UNCONTROLLED WHEN PRINTED

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ADNOC Classification: Internal

Bedding Tape

The core shall be taped overall with semi-conducting tape(s) to prevent mechanical damage to the cable core during manufacture and in service.

Cable fillers of polypropylene (PP) or equivalent shall be used to fill the voids in the cable and ensure a well-rounded finished product.

Insulation Screen (Metallic)

Copper wire screen of suitable cross section with a counter helix tape shall be applied over the semi- conducting bedding tape for the purpose of increasing the total short circuit current rating of the cable.

Longitudinal Water Blocking

Means shall be provided to prevent the longitudinal passage of water between the insulation screen/insulation screen copper wires and the lead sheath. Any material used shall be sufficiently conducting to prevent the development of harmful voltages between the lead sheath and insulation screen/insulation screen copper wires under all operating conditions.

The longitudinal water barrier shall consist of semi-conducting water swelling tapes applied over the extruded insulation screen/insulation screen copper wires.

The water barrier shall be applied such that the complete cable will meet the

requirements of water penetration test as specified in IEC 60840.

Metallic Sheath

The water impervious metallic sheath shall preferably consist of a seamless and continuously extruded tube of lead alloy, which shall meet the requirements of BS EN 12548 and BS 3909 standards. A thin layer of bitumen shall be applied over the sheath. Other alternatives such as Continuous Corrugated Aluminium or Poly-Al Laminate Sheath may be proposed for acceptance by COMPANY provided the alternative is supported by good technical and commercial considerations.

The metallic sheath shall be of best quality and shall be tightly extruded over the water-blocking layer.

The metallic sheath shall be impervious to moisture and free from defects and impurities such as oxides that could give rise to failure under working conditions.

Lead alloy sheaths shall also have good creep ductility to provide the necessary mechanical strength for the cable due to the effects of bending during installation, load cycling, and short circuit under service conditions.

The minimum thickness of the sheath when determined by the appropriate method described in the IEC test standards shall not be less than the appropriate value stated in the data sheet.

When carrying the specified short-circuit current the integrity and performance of any part of the cable shall not be deteriorated due to the rising temperature. The sheath temperature shall neither exceed the allowable temperature of the insulation nor of the outer sheath covering, whichever is the lower.

The metallic sheath thickness and its composition shall be sufficient to ensure adequate mechanical strength and to resist fatigue caused by vibration.

The minimum thickness of the lead or Aluminium sheath shall not fall below 5%+0.1mm of the nominal thickness.

AGES-SP-02-011

J-DMS 14-Aug-2024 UNCONTROLLED WHEN PRINTED

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All parties consent to this document being signed electronically -PT&CS/GP/INT/2022/5777

ADNOC Classification: Internal

The sheath and screen shall be capable of carrying, without damage, the fault current for one second under the most severe fault condition. The current density for the type of sheath used shall also be stated in the data sheet.

The Cable manufacturer shall prove by calculation that the metallic sheath and the insulation screen copper wires can withstand the short circuit current rating specified in the data sheet.

Metallic Sheath Bedding

The compounds applied over metallic sheaths shall be of such a nature that in the finished cables they do not crack or run at any temperature likely to be attained in transit to the Site, during installation or when the cables are in operation.

Sheath bedding provided on Continuous Corrugated Aluminium sheaths shall be easily strippable at terminations using provided special stripping tools.

The compounds shall have no detrimental effect on the sheath or outer covering.

Anti-corrosion Outer Protective Covering

The outer covering over the metallic screen and impervious metallic/laminated sheath shall be extruded black HDPE suitable for the operating temperature of the cable.

The minimum average thickness and minimum thickness at a point when measured in accordance with IEC tests methods shall not be less than the value stated in the data sheet.

Means shall be provided to prevent adhesion between turns and layers of the cable on the drum and between the cable and the drum or container at such temperatures as may be met with during transit to the site , at site, before laying or while stored.

The design and efficiency of the coverings shall not be affected by cleating or clamping arrangements supporting the cable. Particular care shall be taken to ensure that the outer covering is not damaged in any way.

The HDPE outer cover shall give protection against ants and termites.

The outer covering shall be of intrinsically fire retardant (IEC 60332-3-22) and UV resistant, Category A

An outer conductive graphite coating shall be applied to the covering to serve as an electrode for the voltage test on the outer covering.

AGES-SP-02-011

J-DMS 14-Aug-2024 UNCONTROLLED WHEN PRINTED

Rev. No: 1 Page 41 of 41 50 / 50

All parties consent to this document being signed electronically -PT&CS/GP/INT/2022/5777

Project: Q-32859 - NMDC - Ruwais Folder: RFQ Files