jeres-p-104 wiring methods and materials

JERES-P-104

Wiring Methods and Materials

Revision 2

Responsibility JER Engineering Division

04 November 2008

Jubail Export Refinery Engineering Standard

Jubail Export Refinery Engineering Standards

JERES-P-104 Rev. 2 Wiring Methods and Materials 04 November

2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by any means without prior approval by the Company.

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Revision Tracking

Revision Revision Date Scope of Revision

2 04 November 2008 Revised to update paragraph: 6.1; 9.3.2; 11.1.

1 11 July 2008 Revised to Update power supply of the refinery from 230 kV to 380 kV

0 29 April 2008 Issued for bid package.

04 17 April 2008 Integration of audit result

03 31 March 2008 Issued for bid package for review.

02 28 February 2008 Update

01 29 October 2007 The first official JERES-P-104 is issued.

00 06 February 2007 First draft issued is based on Saudi Aramco SAES-P-104 “Wiring Methods and Materials” issue date February 28, 2005. Document was modified to incorporate amendments and modifications.



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Table of Contents

Section Contents Page

1 Scope 4

2 Conflicts, Deviations and Clarifications 4

3 References 5

4 Definitions 7

5 General 7

6 Cables Routing 7

7 Cables Connections 16

8 Cable and Wire Identification 17

9 Material 19

10 Enclosures 28

11 Cable Trays and Ladders 29

Appendix

A Figures 31



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1 Scope

1.1 This Standard prescribes mandatory requirements for the design and installation of insulated power and control cables systems. Its also prescribes minimum mandatory requirements for outdoor enclosures for electrical equipment and wiring that are not covered by another JERES or JERMS.

1.2 For the purpose of this standard, control cable is cable used for the interconnection of electrical control devices, such as pushbuttons, electromechanical relays, meters, transducers, etc., associated with power systems, and also microprocessor based protection relays for power distribution and motors.

1.3 For the purpose of this standard, cables connected on one or both sides to instruments, distributed control systems, computer, etc., (except for AC power connections) is considered instrumentation wiring and is covered by others standards applied to instrumentation.

1.4 This standard also applies to the installation of fiber optic cables dedicated to the control of power systems that are not part of a communication system, and to the installation of composite power-fiber optic cables, including composite sub marine cables.

1.5 This document may not be attached to nor made a part of purchase orders.

2 Conflicts, Deviations and Clarifications 2.1 Any conflicts between this standard and other applicable Company Engineering

Standards (JERES), Material Specifications (JERMS), Standard Drawings (JERSD), Engineering Procedures (JEREP), Company Forms or Industry standards, specifications, Codes and forms shall be brought to the attention of Company Representative by the Contractor for resolution.

Until the resolution is officially made by the Company Representative, the most stringent requirement shall govern.

2.2 Where a licensor specification is more stringent than those of this standard, the Licensor’s specific requirement shall apply.



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2.3 Where applicable Codes or Standards are not called by this standard or its requirements are not clear, it shall be brought to attention of Company Representative by Contractor for resolution.

2.4 Direct all requests for deviations or clarifications in writing to the Company or its Representative who shall follow internal Company procedure and provide final resolution.

3 References

The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by this standard shall comply with the latest edition of the references listed below as of the CUT-OFF DATE as specified in the Contract unless otherwise noted.

3.1 The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by this standard shall comply with the latest edition of the references listed below, unless otherwise noted.

3.2 Company References

3.2.1 Company Engineering Standards

JERES-A-112 Meteorological and Seismic Design Data

JERES-B-006 Fireproofing for Plants

JERES-B-008 Restrictions to Use of Cellars, Pits, and Trenches

JERES-B-064 Onshore & Nearshore Pipeline Safety

JERES-B-068 Determination of Explosion Hazard Zones 0, 1 and 2

JERES-H-101 Approved Protective Coating System for Industrial Plants & Equipment

JERES-J-902 Electrical Systems for Instrumentation

JERES-O-113 Security Lighting System

JERES-P-100 Basic Power System Design Criteria

JERES-P-111 Grounding

JERES-Q-001 Criteria for Design and Construction of Concrete structures



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JERES-T-624 Telecommunications outside Plant – Fiber Optics

JERES-T-911 Telecommunication Conduit System Design

JERES-T-928 Telecommunications – OSP Buried Plant

Company Materials Specifications

JERMS-P-5502 Electrical cables

3.2.1 Company Standard Drawings

JERSD-P-001 Surface Marker – Underground Electric Cable

JERSD-P-002 Standard Sign – Underground Electric Cable

JERSD-P-0092 Typical installation – Power systems

3.3 Industry Codes and Standards

3.3.1 International Electrotechnical Commission

IEC 60 079 Electrical Apparatus for Explosive Gas Atmospheres

IEC 60 364 Electrical Installation of Buildings

IEC 60 529 Degree of Protection provided by Enclosures

IEC 60 227 Polyvinyl Chloride Insulated Cables of Rated Voltages up to and including 450/750V

IEC 60 228 Conductors of Insulated Cables

IEC 60 332-1 Tests on Electric Cables under Fire Conditions – Part 1: Test on a single Vertical Insulated Wire or Cable

IEC 60 332-3 Tests on Electric Cables under Fire Conditions – Part 3 – Test on Bunched Wires or Cables

IEC 60 502-1 Power cables with Extruded Insulation and their Accessories for Rated Voltage from 1kV up to 30kV – Part 1 – Cables for Rated Voltages from 1kV and 3kV



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IEC 60 502-2 Power cables with Extruded Insulation and their Accessories for Rated Voltage from 1kV up to 30kV – Part 2 – Cables for Rated Voltages from 6kV up to 30kV

4 Definitions 4.1 Definitions presented in this Standard and other JER documents have precedence

over other definitions. Conflicts between various definitions shall be brought to the attention of Company Representative by the Contractor for resolution.

Company: Jubail Export Refinery.

Company Representative: A designated person from the Company or an assigned third party representative.

Company Inspector: A designated person or an agency responsible for conducting inspection activities on behalf of the Company.

4.2 List of Definitions

Purposely left blank.

5 General

5.1 Lead sheath shall imperatively be provided for:

− Electrical network cables 34.5 kV and 380 kV,

− All the control and command cables between SEC substation and SS1, SS1 and SS11, SS1 and SS12 and also SS1 and SS16,

− All 4.16 kV cables coming from the emergency diesel generator shall be protected by a lead sealing sheath.

6 Cables Routing

6.1 Outdoor electrical cables routing

6.1.1 Outside substations and building, the electrical cables routing shall be as follow:

− In paved area : directly buried inside trenches or concrete trenches,



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− In unpaved area : directly buried inside trenches,

− In galvanized steel duct from the trenches up to the consumers for the underground cable routings,

− In galvanized cable trays/ladders, and/or galvanized steel ducts for aboveground cable routings.

− In duct banks under roads and pipe ways,

− In concrete gutter for 380 kV cables.

6.1.2 Outside of buildings, it is mandatory that electrical cables run in underground routing and go out of the ground only close to the consumers.

6.1.3 Design and installation of cables systems shall be in accordance with the last edition of relevant IEC (International Electrotechnical Commission).

6.1.4 For the purpose of this standard only, severe corrosive environments include:

− Outdoor offshore locations, and

− Outdoor onshore locations within one kilometer from shoreline.

6.1.5 Locations where chlorine or other corrosive chemicals are being handled are also corrosive environment. In these locations, enclosures, conduits, fittings and cables must be resistant to the chemicals present.

6.1.6 For the purpose of this standard only, outdoor locations correspond to wet or damp locations and indoor locations correspond to dry locations as defined as follow:

− Location Damp: A location protected from weather and not subject to saturation with water or other liquids but subject to moderate degrees of moisture. Examples of such locations include partially protected locations under canopies, marquees, roofed open porches and like locations, and interior locations subject to moderate degrees of moisture, such as some basements, some barns, and some cold storage warehouses.

− Location Dry: A location not normally subject to dampness or wetness. A location classified as dry may be temporarily subject to dampness and wetness, as in the case of a building under construction.



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− Location Wet: Installation under ground or in concrete slab or masonry in direct contact with the earth; in location subject to saturation with water or other liquids, such as vehicle washing areas; and in unprotected locations exposed to weather.

6.1.7 A structure enclosed by walls on three sides only, and having a roof, is considered as an outdoor location.

6.1.8 A non air-conditioned building is considered as an indoor location.

6.1.9 A shop that has its doors kept open to facilitate entry of vehicle is considered as an indoor location.

6.2 General requirements for underground cables routing

6.2.1 Trenches and concrete trenches routings

The underground cables shall be divided in two groups:

− The main distribution cables : Interconnection power cables between main electrical substations such as but not limited to:

1) HV 380kV - 34,5kV - 13,8kV cables,

2) Control cables for protections, interlocking, intertripping,

3) Telephone, etc.

− The other electrical cables including instrumentation cables.

6.2.2 The main distribution cables shall route in dedicated trenches and shall be arranged in a single layer. This arrangement will be only retained for the high voltage cables.

6.2.3 The other cables as for production units, pumping stations, etc., shall be routed in independent trenches and/or concrete trenches.

6.4 General routing

6.4.1 The cable trenches routing shall be designed with as purpose to avoid as maximum buried obstacles, buried piping, roads crossing, and cable crossing.

6.4.2 The cable trenches routing changes shall have a radius at least equal to 1.5m



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6.4.3 The cable layer crossing shall conform to the following rules:

− a layer of main distribution cables shall never be covered by an other cables layer,

− the top layer of cables shall be at 0.8m below grade level,

− Layers of cables shall crossing with a distance of 0.2m in such way as the top layer is at 0.8m below the grade level.

− The distance between a buried cable and a buried water pipe, gas pipe or hydrocarbon pipe shall be at least 0.2m.

6.4.5 Buried pipe crossing with buried electrical cables

The pipe shall receive protection constituted with a steel pipe protected against the corrosion. The protection pipe shall have a superior length of 2 m in the width of the trench with 1 m on each side of this one.

6.4.6 Cable trenches routing along a buried pipe

The buried cables shall have a distance of 2 m from a buried hydrocarbon pipes.

6.4.7 Pipe way crossing

Buried cables crossing a pipe way shall run in duct bank under this pipe way. The duct bank shall have a superior length of 2 m in the width of the pipe way with 1 m on each side of this one.

6.4.8 Road crossing

Buried cables crossing a road shall run in duct bank under this road. The duct bank shall have a superior length of 2 m of the width of road with 1 m on each side of this one.

6.4.9 Depth of burial

The minimum depth of burial requirements for underground installations shall be as specified as follow:



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Millimeters from Grade level to the axis of cables or duct bank

System Voltage Direct buried cables

Cables in concrete trenches (*)

Cables in duct bank

1000V and below 800mm 150mm 1060mm

Over 1000V to 36kV 800mm 250mm 1060mm

Over 36kV 1200mm 800mm 1200mm

* : from below of concrete cover

6.4.9.1 In rocky areas where digging must be minimized, in areas where depth specified here above would result in cables being below the water table, or to avoid underground obstructions such as other cables, conduits or piping, cables may be installed in 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.

6.4.9.2 Precast 50 mm thick red concrete tiles, red plastic tiles (12mm minimum thickness), or PVC coated steel fence fabric shall be placed 300 mm above direct buried conduit. In addition, a yellow warning tape shall be installed over the tiles or fence fabric.

6.4.10 Duct banks

6.4.10.1 Duct banks shall consist of PVC conduit, encased in concrete.

6.4.10.2 Concrete shall be in accordance with the following:

− In duct bank with PVC conduit under areas with no traffic, or occasional traffic (including roads with occasional traffic), unreinforced non structural concrete (with minimum day design compressive strength of 14 Mpa) shall be used.

− In duct bank with PVC conduit, under areas with frequent traffic, such as roads and parking lots inside Refinery or communities, reinforced concrete (with minimum 28 day design compressive strength of 28 Mpa) shall be used.



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6.4.10.3 There shall be a minimum of 160 mm of concrete from the outside surface of the duct to any conduit, and 50 mm to any reinforcing steel.

6.4.10.4 Fabricated spacer shall be used at intervals not exceeding 2.4 meters. The spacers shall provide a minimum conduit separation of 50 mm.

6.4.10.5 Conduit runs within the duct bank shall be made continuous by the use of PVC solvent cement with PVC couplings or belled ends for PVC conduit.

6.4.10.6 Bell end fittings or protective bushings shall be provided on each duct where it terminates.

6.4.10.7 The top layer (minimum 5mm thickness) of the concrete shall be mixed with red dye.

6.4.10.8 Duct bank shall have 20% spare ducts (minimum one).

6.5 380 kV cables routing

6.5.1 380 kV cables shall have a dedicated routing and trenches.

6.5.2 These dedicated trenches shall include only the following:

− The 380 kV cables,

− the control cables dedicated for the inter tripping, interlocking functions,

− The earthing cable.

Not any other cables shall be installed in these dedicated trenches.

6.5.3 380 kV cables shall be laid in a precast concrete gutter which shall be buried at least at 1.2m from the grade.

6.5.4 The precast concrete gutters elements shall be installed in the trench on a light concrete bed with a thickness of 10cm as a minimum and without any reinforcing steel.

6.5.5 380 kV cables which shall be single core type shall be laid in the concrete gutter in trefoil disposition. After cables pulling, the gutter shall be filled with sand and closed with a precast concrete cover. This cover shall be sealed on the gutter by means of cement.



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6.5.6 The two 380 kV feeder which supplies one Main Distribution substation shall have a different routing. If their routings are parallel, the distance between these two feeders shall be as minimum 4 meters.

6.5.7 The distance between 380 kV cables trenches and all other cable trenches shall be at least 1 meter.

6.5.8 Precast 50 mm thick red concrete tiles shall be placed 300mm above precast concrete gutters. In addition, a yellow warning mesh shall be installed over the tiles.

6.6 34.5 kV Cables routing

6.6.1 34.5 kV cables shall be armored type and be direct buried in trenches, concrete trenches in paved areas and in duct banks under roads and obstacles as pipe ways.

6.6.2 They shall be installed in the bottom of the trenches in only one layer and be separated from all other cables.

6.6.3 Redundant feeders, direct buried or direct buried in duct bank shall be separated by a minimum distance of 2 meters. Two feeders are considered redundant if they are capable of supplying power to the same loads so that each feeder can be considered a back up supply circuit for the other, including the feeder that provide power for double ended switchgear and the feeders supplying each end of a loop fed distribution system.

6.6.4 Precast 50 mm thick red concrete tiles shall be placed 300 mm above 34.5kV cables. In addition, a yellow warning mesh shall be installed over the tiles.



6.7.2 They shall be installed in the bottom of the trenches in only one layer if they are part of the distribution network and not be covered by other cables.

6.7.3 If they are dedicated to the motor supply, the 13.8 kV cables can be installed in trenches where others HV and LV cables are pulled.



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6.7.4 13.8 kV Motor supply cables if any shall preferably be installed in the bottom of the trench and separated from all other cables by means of tiles which shall be installed at least at 300 mm above these cables.

6.7.5 Minimum separation between two 13.8 kV redundant feeders shall be 2 meters.



6.8.2 They shall be installed in the bottom of the trenches. They can be pulled in the same layer as 13.8 kV cables but shall be separated from these 13.8 kV cables by means of concrete tiles disposed vertically between these two types of cables.

6.8.3 These HV cables shall be covered by means of concrete tiles placed 300 mm above these cables. LV cables can be placed above these HV cables.

6.8.4 Two feeders supplying a “normal motor and an “emergency” motor shall be separated by a minimum distance of 300 mm.

6.8.5 The LV control cables of HV motors shall be pulled with LV power cables.

6.9 LV Power and control cables routing

6.9.1 LV Power and control cables shall be armored type and be direct buried in trenches, concrete trenches in paved areas and in duct banks under roads and obstacles as pipe ways.

6.9.2 They shall be installed in trenches above HV cables if any.

6.9.3 The top layer of LV cables shall be covered by means of yellow warning mesh which shall be installed 300mm above this layer of cables. This warning mesh shall cover the total width of the trench.

6.10 Earthing cable routing

6.10.1 A earthing conductor shall be pulled in each cable trench or cable concrete trench realized in the Refinery. Refer to JERES-P-11 for detail.



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6.10.2 This earthing conductor shall be installed in the bottom of the trench at one corner of this one.

6.11 Underground cable routing identification

The location of underground cables, conduits or duct bank shall be marked in accordance with standard drawings JERSD-P-001 or JERSD-P-002.

6.12 Indoor electrical cables routing

6.12.1 In technical buildings and electrical substations, the electrical cables shall penetrate in cable vaults through cable entries which are located underground and are equipped with a smooth concrete ramp to joint the floor level of the cable vault. Refer to appendix 1.

6.12.2 These cable entries shall be designed to maintain the same cables disposition as in the trenches (distances between cables in the same layer, distances between layers).

6.12.3 These cable entries shall also be designed to maintain the segregation between the different types of cables.

6.12.4 All the armored cables coming from outside the building shall be laid directly on the floor of the cable vault, up to the equipment where they are connected

6.12.5 All the internal wiring of the building shall be laid on cable trays and ladder.

6.12.6 The cable routing inside the cable vault shall be designed taking into account the following:

− The cable routing shall be segregated for each voltage level.

− The cable tray/ladder supporting 380 kV cables shall be covered on his overall routing inside the cable vault. These cable trays/ladders shall be clearly identified and receive specific markings identifying the cables enclosed.

− The minimum distance between two layers of cable trays/ladders shall be 300 mm,

− The following internal cables shall be laid in a specific cable tray/ladder which shall not receive any other cables:

1) HV feeders from transformers to switchgears



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2) HV feeders between switchgears sections

3) LV feeders fro transformers to switchgears

4) LV feeders between switchgears sections.

7 Cables Connections

7.1 Compression (crimped) type connectors shall be used for splicing and terminating stranded conductors. The use of solder lugs is prohibited.

7.2 Compression terminals for cables with 150 mm² cross section and larger shall be solid type.

7.3 Compression terminals for cables cross section lower than 150 mm² can be tubular type.

7.4 Compression terminals for HV cables connections shall be solid type.

7.5 The crimping method of terminals shall be hexagonal crimping. The stamping crimping method is prohibited.

7.6 All compression connectors shall be tinned copper.

7.7 Pressure set screw connectors with insulating caps are permitted for lighting and receptacle circuits in non hazardous locations and in non industrial applications.

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

7.9 Uses of mechanical connectors or terminals supplied as parts of splice and termination kits (including connectors or terminals with breakout bolt heads) for 69kV cables and above are only permitted with the approval of Company.

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

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



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7.12 Medium and high voltage termination (operating at 4.16 kV and above) installed outdoor shall have a minimum creepage distance to ground of 40 mm per kV line to line nominal system voltage.

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

7.14 Medium and high termination installed inside enclosure located outdoors shall be considered indoor termination if the enclosed provide a degree of protection IP 65 according to IEC 60529. They shall be considered outdoor termination if the enclosures provide a lesser degree of protection.

7.15 High voltage terminations (69 kV and above) with shorter creepage distance than the above shall be subject of Company approval.

7.16 For all HV 13.8 kV, 34.5 kV and 380 kV cables, terminations shall be supplied and carried out by the HV cable manufacturer.

8 Cable and Wire Identification

8.1 Each cable and wire shall receive an identification label.

8.2 Identification of cables shall be defined as follow:

8.3 The identification tag of cables shall be divided in three main parts:

− one part defining the origin where the cable is connected,

− one part defining the type of cable and the cable number,

− One part defining the load where the cable is connected.

8.4 The origin shall be defined as follow:

− Substation number

− Switchgear number

− Cubicle or cell number

8.5 The type of cable shall be defined by a letter as follow:

− P :Power cable



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− C : Control cable

− L : Lighting cable

− H : Heat tracing cable

− M : Measurement cable

8.6 The number of cable is defined by a figure from 1 to n

8.7 The load where the cable will be connected shall be defined as follow:

− Substation number for a switchboard, Unit number for a consumer as a motor,

− Switchgear number or equipment number, Consumer number,

− Cubicle or cell number if any.

8.8 Markers shall be provided for each cable at 50m intervals, at each changes of direction, at each side of a duct bank, at each junction, at each entrance in a building, at each whole crossing cable, and at each end of the cable.

8.9 Individual control wire of a control cable shall be identified by two labels at each end. The first label (closest to the end of the wire) shall identify the number of the terminal to which the wire is connected. The other label shall identify the terminal of the opposite end of the wire.

8.10 Individual phases of power circuits shall be identified by color coding or other means (e.g., marked A, B and C or R, S and T). Neutral conductor shall be identified by color Blue, and insulated grounding conductor by color Green or Green with Yellow stripes.

8.11 Marking methods

8.11.1 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.

8.11.2 Cables shall be identified by stainless steel or special plastic label held with cable ties, or similar methods.



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9 Material

9.1 Cables

9.1.1 380 kV cable

Type of cable : Individual screen

Rated voltage (Uo/U(Um): 220 / 380 (420) kV

Conductor : Annealed copper, stranded class 2, round,

Conductor insulation : Triple extrusion inner screen/insulation/outer screen, rated temperature 90°C; Dielectric losses : tan δ < 8.10-4 ; Maximum rated dielectric stress : 16 kV/mm

Bedding or swelling tapes

Screen Layer of copper wires

Bedding or swelling tapes

Metallic shield Lead alloy sheath bonded to the protective outer sheath

Outer sheath Extruded, hydrocarbon resistant PVC sheath (PVC RH)

Color Black

9.1.2 4.16 kV, 13.8 kV, and 34.5 kV cable

These cables, installed underground and used for power distribution, shall have the following characteristics:



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Type of cable : Individual screen

6/10(12 kV) for 4.16kV

12/20(24 kV) for 13.8kV

Rated voltage (Uo/U(Um):

26/45(52 kV) for 34.5kV

Conductor : Annealed copper, stranded class 2, round, minimum cross section 35mm²

Conductor screen : Extruded compound layer for each conductor

Conductor insulation : Cross linked polyethylene – operating temperature 90°C, Final short circuit temperature 250°C

Core identification Red, black and white color for three-core cables and black for single-core cables.

Individual screen (per core) Extruded compound covered with bare copper tape. The bare copper tape is connected to the earth circuit, its cross sectional area is calculated to handle the single-phase fault current for one second, without exceeding its temperature limit.

Common sheath Elastoplastic sheath

Sealing sheath PVC sheath. If a lead sheath is specified, it shall be located under the PVC sheath

Armor Two galvanized steel tape or



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wires for three-core cables, or, Two aluminum tape or wires for single-core cables

Outer sheath Extruded, hydrocarbon resistant PVC sheath (PVC RH)

Color : 6/10(12kV) cable – Red / 12/20(24kV) cable – Green / 26/45 (52kV) cable - Black

9.1.3 HV 4.16kV Motor supply cable

These cables, installed underground and used to supply 4.16kV motors, shall have the following characteristics:

Type of cable : Collective screen

Rated voltage (Uo/U(Um): 6/6kV for 4,16kV


Conductor screen : Extruded compound layer for each conductor

Conductor insulation : Cross linked polyethylene – operating temperature 90°C - Final short circuit temperature 250°C

Core identification Red, black and white color for three-core cables and black for single-core cables.

Common screen Insulating tape covered with bare copper tape. The bare copper tape is connected to the earth circuit, its cross sectional area is calculated to handle the single-phase fault



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current for one second, without exceeding its temperature limit.

Sealing sheath PVC sheath. If a lead sheath is specified, it shall be located under the PVC sheath

Armor Two galvanized steel tape or wires for three-core cables, or, Two aluminum tape or wires for single-core cables

Outer sheath Extruded, hydrocarbon resistant PVC sheath (PVC RH) - Color : Red

9.1.4 4.16 kV - 13.8 kV - 34.5 kV cables for indoor links

These cables are used for power distribution inside electrical substations in order to connect HV/HV transformers and HV switchgear or in order to connect bus bar section (A and B) of HV switchgear and controlgear. They are generally single-core type, individually screened and installed on cable trays or in ducts. They shall have the following characteristics:

Type of cable : Individual screen,

6/10 (12kV) for 4.16kV

12/20 (24kV) for 13.8kV

Rated voltage (Uo/U(Um):

26/45 (52kV) for 34.5kV


Conductor screen : Extruded compound layer

Conductor insulation : Cross linked polyethylene – operating temperature 90°C - Final short circuit



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temperature 250°C

Individual screen (per core) Extruded compound layer covered with bare copper tape. The bare copper tape is connected to the earth circuit, its cross sectional area is calculated to handle the single-phase fault current for one second, without exceeding its temperature limit.

Sealing sheath (if the cable is specified as armored)

PVC sheath.

Armor (if specified) Two galvanized steel tape or wires for three-core cables, or, Two aluminum tape or wires for single-core cables

Outer sheath Extruded, PVC sheath

Color : 6/10(12 kV) cable – Red

12/20(24 kV) cable – Green

26/45 (52 kV) cable - Black

9.1.5 LV power and control cables for outdoor links

These cables, installed either underground or aboveground, are used to supply power to electrical consumers, and shall have the following characteristics:

The maximum cross section of low voltage power cables shall be

- 240 mm² for armored or non-armored multi-core cables

- 630 mm² for single-core cables

Rated voltage Uo/U: 600/1000V for up to 480V



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Conductor : Solid annealed copper, class 1 for cross sectional areas ≤ 4mm² Annealed copper, stranded class 2, round, for cross sectional area ≥ 6mm²


Core identification Power cables up to four cores shall be identified according to IEC 60227

Control cables conductors shall be identified by numerals. Markings shall be indelible

Common sheath Extruded PVC sheath

Sealing sheath (if the cable is specified as armored)

PVC sheath.

Armor Two galvanized steel tape or wires for three-core cables, or, Two aluminum tape or wires for single-core cables

Outer sheath Extruded, PVC sheath aliphatic hydrocarbon resistant (PVC RH)

Color : Black

9.1.6 LV power and control cables for indoor links

These cables are used in buildings (electrical substations, electrical technical rooms and control rooms, ...) in order to connect HV/LV transformers and LV switchgear or in order to connect bus bar section (A and B) of LV switchgear and controlgear. They shall be installed on cable trays and shall be halogen free with improved fire behavior. They shall have the following characteristics:

Rated voltage Uo,/U: 600/1000V for up to 480V



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Conductor : Solid annealed copper, class 1 for cross sectional areas ≤ 4mm² Annealed copper, stranded class 2, round, for cross sectional area ≥ 6mm²


Core identification Power cables up to four cores shall be identified according to IEC 60227

Control cables conductors shall be identified by numerals. Markings shall be indelible

Outer sheath Black colored, flame retardant and halogen free elastomer sheath.

9.1.7 Data transfer cables

These cables are used to exchange information between electrical substations or between an electrical substation and a technical room. They shall have the following characteristics:

Rated voltage : 750V

Conductor : Solid annealed copper, 0.9mm diameter

Conductor insulation : Solid polyethylene

Common sheath In star quads. One of the quads shall have aluminum tape shielding with a tinned copper drain wire of 0.5mm diameter.

Number of cores 14 or 28 quads

Core identification The quads shall be numbered and the quad wires shall be color coded.

General shielding By aluminum tape with a tinned copper drain wire 0,5 mm diameter and one



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shielded quad

Sealing sheath PVC sheath or lead sheath if required

Armor Two galvanized steel tape or wires for three-core cables

Outer sheath Black colored extruded PVC sheath, resistant to aliphatic hydrocarbons

9.2 Size of conductors

Size limits of conductors shall meet the requirements as follow:

Voltage Size

Minimum Maximum

Single core Multi cores

1000V and below (Control) 2.5 mm² Not applicable Not applicable

1000V and below (Power) 4 mm² 630 mm² 240 mm²

4.16kV (6/6kV) 35 mm² 630 mm² 240 mm²

4.16kV [6/10(12)kV] 35 mm² 630 mm² 240 mm²

13.8kV [12/20(24)kV] 35 mm² 630 mm² 240 mm²

34.5kV [26/45(52)kV] 35 mm² 630 mm² 240 mm²

380kV [220/380(420)kV] Not applicable 630 mm² Not applicable

9.3 Cable sizing



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9.3.1 The sizing of power cables shall be based on the standard JERES-P-100 chapter 9-13-2.

9.3.2 Moreover, the following data shall be taken into account:

− Load factor: 100 %. The current to be taken into account is the rated current of the electrical consumer (motor, transformer, …)

− Ambient temperatures:

1) Outdoor exposed to sun (for exposed cables, cables in conduit, and cables in uncovered cable trays) : as per JERES-A-112

2) Outdoor shaded (for exposed cables, cables in conduit, cables in covered trays in the sun, and cables in cable trays in the shade) : as per JERES-A-112

3) Indoor: 25 °C 61°C (HVAC) – 35°C inside cable room – 40°C max in case of HVAC failure.

4) Soil temperature : as per JERES-A-112

− Earth thermal resistivity:

1) Land : 120°C-cm/W

2) Concrete (for duct bank) : 85°C-cm/W

9.3.3 The sizing of cables rated 69 kV and above shall be in accordance with manufacturer guidelines.

9.4 Cable testing after installation

9.4.1 Low voltage cables, including splices shall be 1000V DC Megger tested after installation and prior any energization step.

9.4.2 Medium voltage cables (4.16 kV through 34.5 kV) shall be tested as follow:

− New installation of cables and splices shall be 5 kV Megger tested and DC high-potential tested after installation and prior to placing in service at voltage level specified in following table:

Cable voltage rating DC high-potential field test voltage



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6/6 kV 24 kV according IEC 60502-2

6/10 (12) kV 24 kV according IEC 60502-2

12/20 (24) kV 48 kV according IEC 60502-2

26/30 (36) kV 52 kV according IEC 60840

9.4.3 The integrity of the overall jacket of direct buried cables rated 5kV up to 36kV shall be tested by conducting a 5kV megger or high-potential test between the cable insulation metallic shield (and sheath or armor, if any) and the ground.

9.4.4 The integrity of the overall jacket of direct buried low voltage armored cables shall be tested by conducting a 500 V Megger test.

9.4.5 For the 380kV cables, site test shall be done to demonstrate the integrity of the cable oversheath after installation. The tests require the oversheath to have an outer “electrode” which may be moist backfill or a graphite layer.

9.4.6 A Direct voltage of 4 kV per millimeter of specified thickness of extruded oversheath shall be applied with a maximum of 10 kV between the metallic sheath or concentric wires or tapes and the outer electrode for a period of 1 min.

10 Enclosures 10.1 Equipment and terminal enclosures, unless otherwise specified in other electrical

standards shall meet the requirements of this section.

10.2 In indoor refinery areas, within the perimeter of process units, equipment and terminal enclosures shall be:

− copper free cast aluminum manufactured

− or plastic including fiberglass

− degree of protection IP 66 or better according IEC 60529 and IK 08 according to IEC 62262

− In outdoors refinery areas, outside the perimeter of process units, and other industrial areas, equipment and terminal enclosures shall have a



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degree of protection equal to IP 66 or better according to IEC 60529 and IK 08 according to IEC 62262

− In outdoor refinery and other industrial areas located in severe corrosive environments, equipment and terminal enclosures shall be:

− copper free cast aluminum manufactured

− Stainless steel (type 304 or better) manufactured

− or plastic including fiberglass

− Degree of protection IP 66 or better according to IEC 60529. and IK 08 according to IEC 62262

− In outdoor non industrial areas, equipment and terminals shall have a degree of protection equal to IP 66 or better according to IEC 60529 and IK 08 according to IEC 62262

− In hazardous (classified) locations, enclosures shall meet the hazardous area equipment application requirement of JERES-P-100 chapter 8.5 and relevant IEC standards requirements.

− Enclosures and junction boxes having an internal volume exceeding 2.000 cm3 shall be provided with stainless steel breather and drain fittings.

11 Cable Trays and Ladders 11.1 Cable trays and ladders material shall be:

− galvanized carbon steel in outdoor or indoor installations,

− Stainless steel for special applications (e.g. corrosive environment).

11.2 Cable trays installed outdoors shall have ventilated covers. Flanged type covers shall be secured with stainless steel banding, one band per ½ m of cover length, with a minimum of 6 bands per cover.

11.3 Cable ladders shall preferably be used for indoor cable routings.

11.4 If used outdoors, cable ladders shall be equipped with ventilated covers. Cable ladders running vertically in outdoor area shall have covers on both sides.



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11.5 The working load for cable trays and ladders shall consist of the weight of the cables including the future additions, plus a concentrated static load of 90 kg at the center of the span. The working load shall not exceed the rated load capacity of the cable trays and ladders defined by the manufacturer.

11.6 Location of supports for cable trays and ladders systems shall be in accordance with the recommendation of the manufacturer. Splices (joints) shall not be located over supports, and shall be located between supports and quarter points. No more than one splice shall be located between two adjacent supports.

11.7 The maximum spacing between expansion joints shall be based on a temperature differential of 55°C and expansion gap setting shall be in accordance with the recommendations of the manufacturer, based on a minimum temperature of 0°C and a maximum temperature of 55°C.

11.8 Cable trays and ladders shall be installed as a complete system. Cable trays and ladders shall not have mechanically discontinuous segments of cable trays run.

11.9 Piping shall not be used to support cable trays and ladders.



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Appendix A

Cover

Concrete

Cement

Sand

380 kV Cables

100mm

300mm

1200

mm

Tiles

Grade level

Typical Trench for 380 kV cable routing

ConcreteGutter



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jeres-p-104 wiring methods and materials

Documents