VALDEL ENGINEERS & CONSTRUCTORS PVT LTD

STANDARD SPECIFICATION FOR CABLE SYSTEM INSTALLATION WORK

DOC. No. : SS 75 6028 REV. No. : 1

ISSUED BY

QUALITY DIVISION .............................................................

DATE OF ISSUE

ISSUED TO

...............................................................

[ ] [ ]

CONTROLLED COPY UNCONTROLLED COPY

COPY No. ..................................

VALDEL ENGINEERS & CONSTRUCTORS PVT LTD Meghdooth Mansion, No.9 Civil Station, Hosur Road Bangalore 560 025 - INDIA
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VALDEL ENGINEERS & CONSTRUCTORS PVT LTD

STANDARD SPECIFICATION FOR CABLE SYSTEM INSTALLATION WORK

DOC. No.: SS 75 6028

REVISION RECORD

REVISION DESCRIPTION CHANGE OF COMPANY NAME

REV. No. 1

DATE 30.09.05

PREPARED BY SURI SREENIVAS

APPROVED BY SELVAKUMAR.S

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VALDEL ENGINEERS & CONSTRUCTORS PVT LTD MEGHDOOTH MANSION 9, CIVIL STATION HOSUR ROAD BANGALORE-560025 (INDIA)

DOCUMENT No. DOCUMENT TITLE

: :

SS 75 6028 STANDARD SPECIFICATION FOR CABLING SYSTEM INSTALLATION WORK

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STANDARD SPECIFICATION VALDEL ENGINEERS & CONSTRUCTORS PVT LTD FOR CABLE SYSTEM INSTALLATION WORK

PAGE No.: 2 DOC.No.: SS 75 6028 SHT. 1 OF 1 REV. 1

CONTENTS

1. 2. 3. 4. 5. 6. 7.

INTRODUCTION CODES AND STANDARDS GENERAL TECHNICAL REQUIREMENTS PAINTING OF CABLE TRAYS AND ACCESSORIES TESTING AND COMMISSIONING AS BUILT DRAWINGS

PREPARED BY APPROVED BY AUTHORISED BY

: ........................................................ DATE : SURI SREENIVAS : ........................................................ DATE : SELVAKUMAR S : ......................................................... DATE : SELVAKUMAR S

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1.0 1.1

INTRODUCTION The intent of this specification is to define the requirements of supply, installation, testing and commissioning of the cabling system. The installation, testing and commissioning of complete cabling system shall be carried out in accordance with the General & Technical requirements and installation procedures enumerated in this specification for cable trays, cable accessories like cable glands, lugs, termination/jointing kits, junction boxes, conduits & pipes etc. Also installation of cables, cable trays & other accessories shall be carried out as per the Purchasers / Engineers typical and specific project drawings and data sheets. All deviations from this specification shall be clearly brought out in the bid. In the absence of this it shall be construed that the bidders offer is in full conformity with this specification without any exception. CODES AND STANDARDS The cabling system installation work shall comply with the latest applicable standards, regulations and safety codes of the locality where the installation is being carried out. Nothing in this specification shall be construed to relieve the contractor of his responsibility. The installation work shall conform to the latest applicable codes of practices, electricity rules, fire insurance regulations and other specific standards indicated in the data sheet. GENERAL The scope and supply shall cover the requirements of cabling accessories such as lugs, glands, termination and jointing kits, junction boxes, marshalling boxes, cable trays, conduits and pipes etc. Bidder shall quote for supply & installation of above items. The cost of supply and cost of installation shall be segregated. Supply of cables is not a part of this specification. (scope of cable supply is specified elsewhere). However, the installation work shall include unloading, storing, laying, fixing, jointing / termination, testing, commissioning of cables and any other work items necessary for completing the job. The contractor shall arrange for all labours, supervisors, welding equipment, tools & tackles and testing equipment as required for installation work. All incidental hardware & miscellaneous items such as saddles, spacers, nuts, bolts, washers, anchor fasteners, cable route & joint markers and protective covers for buried cables, cable identification tags and ferrules, nylon cord, GI wire etc. as required for the cable installation shall be deemed to be included in contractors scope as a part of this specification. Civil works for construction of built-up cable trenches / tunnels / duct banks, cable carrier supports on main pipe rack structure, provision of embedded conduits / pipes in RCC / masonry structures and across roads / railway tracks shall be excluded from the cable installation contractors scope unless otherwise specified. However, minor civil works such as patch up of any holes made by the contractor on the walls in an approved manner,

1.2

2.0 2.1

2.2 3.0 3.1

3.2

3.3

3.4

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embedding of short lengths of conduits in floors, walls, etc. (if not already done by Civil contractor) shall be included in the contractors scope of work. The contractor shall work in coordination with the civil, air-conditioning, piping and equipment installation contractors at site. 3.5 The manufacturers / purchasers / engineers drawings, cable schedules, instructions and recommendations shall be strictly followed by the contractor while handling, laying, testing and commissioning of the cabling system. In case of any doubts or misunderstanding as to correct interpretation of drawings / instructions, contractor shall obtain necessary clarifications from the engineer / purchaser. Any changes in routes of cables which are required to be made to suit site conditions shall be carried out by the contractor in consultation with the engineer / purchaser. All such changes shall be marked by the contractor on relevant project drawings / in cable and conduit schedule for approval by the consultants site / design office. All thefts and damage of cables or equipment to which cables are to be connected, till the installation is handed over to the purchaser, shall be made good by the contractor. The site engineer / purchaser shall arrange to clear the area / cable routes / trenches to facilitate the contractor to proceed with cable laying work without any obstructions. It will be the responsibility of the contractor to clean the trays/tunnels, remove cable drums, surplus/waste materials & all other similar items after the installation work is completed. CONTRACTORS LICENCE It shall be the responsibility of the contractor to obtain necessary Licence / Authorisation / Permit for work from the Licensing Board of the locality / State where the work is to be carried out. The persons deputed by the contractor should also hold valid permits issued or recognised by the concerned Licensing Board of that locality / State where the work is to be carried out. 3.10 WORKMANSHIP The contractor shall ensure workmanship of good quality and shall assign qualified Supervisors / Engineers, skilled & competent labours experienced in the several trades of similar nature. The purchaser / engineer shall reserve the right to reject non-competent persons employed by the contractor, of the workmanship is not of good order. 4.0 4.1 TECHNICAL REQUIREMENTS CABLE TRAYS

3.6

3.7 3.8

3.9

4.1.1 The cable trays shall be fabricated out of mild steel sheets free from flaws and conforming to any international / national codes / standards. The cable trays shall be either prefabricated hotdip galvanised, sheet steel trays or fibreglass (FRP) or site fabricated steel trays, as specified elsewhere. 4.1.2 The cable trays shall be ladder type and perforated type.
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4.1.3 The ladder type cable trays shall consists of side rails and ladder rungs fabricated out of 2mm thick sheet steel. Each straight section shall be approximately 2.5m length. The rungs shall be spot welded to the elbows, reducers, tees, crosses etc. shall be formed out of 2mm thick mild steel sheets having similar side rails and ladder rungs. Details of cable trays and fittings shall be in accordance with the drawings wherever applicable. 4.1.4 The perforated type cable trays shall be fabricated out of 2mm thick sheet steel. All burrs and sharp edges shall be ground and filed after perforations are made. The trays shall have smooth surfaces for easy cable laying / pulling. The fittings like elbows, tees, crosses etc. shall also comprise 2mm thick sheet steel. 4.1.5 Cable trays shall have standard widths of 150mm, 300mm, 450mm, 600mm and 800mm or as indicated in the drawings / data sheets enclosed elsewhere. 4.1.6 In certain cases it will be necessary to site fabricated portion of trays and fittings like nonstandard bends to suit particular layout. Normal prefabricated trays and accessories may not be useful there. In such cases, contractor shall fabricate at site suitable sections of trays and accessories for the specific purpose. 4.2 CABLE GLANDS

4.2.1 Cable glands shall be of double compression type, robust construction capable of clamping cable and cable armour (for armoured cables) firmly without injury to insulation. The cable glands shall be tested as per BS-6121 or equivalent standards. These cable glands shall be of heavy duty brass, machine finished and tinned to avoid corrosion and oxidation. Rubber components used in cable glands shall be of neoprene and of tested quality. The maximum and minimum overall diameter and diameter under armour of the cables will be furnished to the successful contractor. 4.2.2 The make of cable glands shall be as approved by the Client/Purchaser. 4.3 CABLE LUGS

4.3.1 Cable lugs shall be tinned copper solder-less crimping type suitable for aluminium or copper conductor cables (as applicable). Solder-less, crimping of terminals shall be done by using corrosion inhibitory compound. The cable lugs shall suit the type of terminals provided on the compound. 4.3.2 The cable lugs shall be Dowells make or Equivalent make approved by the Client / Purchaser. 4.3.3 Crimping tool used shall be of approved design and make. 4.4 CABLE TERMINATION / JOINTING KITS

4.4.1 Cable termination and jointing kits shall be of proven design and fully type tested. 4.4.2 The termination kits shall be suitable for termination of the cables to an indoor switchgear or to a weatherproof cable box of an outdoor mounted transformer / motor. The terminating kits shall
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be preferably be as of the following types or equivalent make approved by the Client / Purchaser: a) b) c) d) TAPEX of M-seal make using non-linear resistance material for stress grading. PUSH-ON type of CCI make using factory moulded Silicon rubber insulators. TROPOLINK type, of CCI make. Heat - shrinkable type Sleeve, of Raychem make.

For outdoor installations, weather shields / sealing ends and any other accessories required shall also form part of the kits. 4.4.3 The straight through jointing kits shall be suitable for underground buried installation with uncontrolled backfill and possibility of flooding by water. The jointing kit shall be one of the following types or equivalent make approved by the Client / Purchaser: a) b) c) TAPEX of M-seal make TROPOLINK type, of CCI make Heat - shrinkable type Sleeve of Raychem make.

4.4.4 Make of kits other than those specified above may be considered, provided the contractor furnishes type test certificates along with his offer. 4.5 JUNCTION BOXES

4.5.1 The junction boxes shall be weather, dust and vermin proof and of 2mm thickness with min. IP55 enclosure protection. The junction boxes shall be duly galvanised. The cover shall be provided with a suitable neoprene rubber gasket. The junction box shall be provided with four knockout plates for cable / conduit connection and a weeping hole at the bottom plate. Junction Boxes shall be provided with two earthing terminals suitable for connecting GI earthing strips. Suitable locking and sealing arrangement shall be provided for the junction boxes. 4.5.2 The terminal blocks used in the junction boxes shall be rated for 1100V shall be of clip on type. Each terminal shall be suitable for connecting 2 nos., 2.5mm copper conductors on each side. All the terminals shall be complete with insulated barriers, galvanised terminal studs, washers, nuts, lockouts, identification strips etc. The terminals shall be made of copper alloy and shall be of box clamp type. 4.5.3 Stud type terminals shall be provided for higher size cables. 4.6 CONDUITS AND PIPES

4.6.1 Rigid, flexible, steel/non-metallic conduits/pipes, fittings as required in the data sheet and project layout drawings conforming to relevant standards shall be supplied. 4.6.2 The rigid conduits and pipes shall be supplied in standard lengths of 5M and flexible conduits in 20M.
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4.6.3 Steel conduits and pipes shall be manufactured by Electric Welding Resistance process and they shall be galvanised unless otherwise specifically indicated in the data sheet. 4.6.4 The ends of steel conduits / pipes shall be threaded. One end shall be supplied with coupler / socket and cap and the other end with cap only. 4.6.5 Flexible conduits shall be made of bright, cold-rolled, annealed and electro-galvanised mild steel wires. 4.6.6 Flexible conduit / pipe shall be provided with end adapters for termination. 4.7 CABLE LAYING

4.7.1 The contractor shall install, test and commission power and control cables as per the cable schedule which will be furnished by the Purchaser. The quantities, sizes and types of cables shall be indicated in the cable schedule or in data sheet. 4.7.2 The cables shall be laid in built-up trenches, directly buried in ground, on cable trays, vertical raceways, clamped on structures / walls / ceiling, pulled through pipes and conduits etc., as per the relevant cable installation practice notes and typical / project drawings. 4.7.3 The scope of cable laying shall include laying, pulling cables as above, proper dressing of cables on cable trays, racks, vertical raceways and supply and installation of cable fixing saddles, spacers and nylon cord for tying as required. Supply of trefoil clamps for single core cables shall be quoted separately. However, the installation of trefoil clamps for clamping the cables shall be included in the installation cost of relevant cables. 4.8 CABLE TERMINATION AND JOINTS

4.8.1 All cables that will be laid by the contractor shall be connected at both ends to switch gear, panels, equipment, local pushbuttons, instruments or junction / marshalling boxes terminals as the case may be. 4.8.2 The termination and jointing of cables shall be done strictly in accordance with cable and termination kit manufacturers instruction, drawing and / or as directed by the client. 4.8.3 All cable terminations and joints shall be done by skilled and experienced persons. 4.8.4 The scope of jointing of various sizes and types of power cables indicated in the data sheet shall include all necessary special tools and incidental accessories and H.V. pressure testing of the joints. 4.8.5 The scope of termination at each end shall include dressing, bunching and connection of all the cores of the cables. The following shall be included in the scope of work: a) Making the requisite holes at the bottom / gland plate of the switch gear for cable boxes / glands, fixing the cable boxes / glands, terminating the cables in the cable boxes / glands, crimping the cable lugs on each core, neatly clamping the cables inside switch gear / panels,
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cable alleys, wiring troughs and connecting to correct terminals as per the purchasers / manufacturers wiring diagrams and cable schedules. The cable and core identifying lugs and ferules respectively shall be supplied and installed by the contractor as a part of cable termination work. 4.8.6 All cable terminations shall be solder-less crimping type. Proper crimping tools of reputed / approved make shall be used by the contractor. The crimping tools used shall be subject to the purchasers / engineers approval. 4.8.7 Supply of lugs, glands, cable-boxes, junction boxes shall be included in contractors scope unless otherwise specified in the specification / data sheet. 4.8.8 Spare cores of control cables shall be connected to spare terminal blocks, where available, with appropriate ferrules. If there are no spare terminal blocks, the spar cores shall be properly insulated and bunched together and shall be neatly kept inside the panel. 4.9 CABLE TRAYS INSTALLATION

4.9.1 The contractor shall install the type and sizes of cable trays as indicated in Project layout drawings. The trays shall be welded or bolted to the mounting / carrier structures. 4.9.2 The scope of cable trays installation shall include the supply and installation of the associated accessories like coupler plates, elbows, drop-outs, tees and bends as required in project layout drawings. The contractor shall also include earthing of the cable trays at distances not exceeding 10M length by means of minimum size 25 x 3mm GI flat unless otherwise noted or as specified elsewhere in the contract document. 4.9.3 Supply of trays and accessories shall be indicated separately as per specification. 4.10 CABLE TRAYS COVERS INSTALLATION

4.10.1 All vertical raceways / trays and outdoor trays shall be generally covered by 16 gauge painted / galvanised MS sheet covers unless otherwise specified. The estimated lengths and widths of these covers shall be included in the data sheet. The scope of work shall include the installation of these covers including necessary screws when required for fixing to vertical raceways. 4.10.2 Supply shall be indicated separately as per specification. 4.11 CABLE TRAYS MOUNTING ARRANGEMENTS, VERTICAL RACEWAYS AND CABLE CARRIER STRUCTURES

4.11.1 The contractor shall fabricate, install and paint the following as per relevant enclosed drawings / general notes: a) Mounting arrangements for cable trays. Any cable trays, junction bends, which are nonstandard, shall be fabricated as racks to suit installation drawings.
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b) Vertical cable raceways and steel accessories (angles and plates) required to seal the floor openings in the case of indoor raceways. c) Cable carrier structures (racks) for cable trenches and tunnels. d) Supporting steel for junction / marshalling boxes, pushbuttons, vertical structures for clamping trefoil cables, cable boxes if mounted below switchgear etc., as required. 4.11.2 The cable tray mounting structures / cable racks shall be fabricated from standard structural steel members as indicated in enclosed drawings (channels, plates, angles and flats). The estimated quantity of steel shall be as indicated in the data sheet. The supply of steel if required, to be furnished by the contractor will be indicated in the data sheet and the rate for the same shall be stated separately in his quotation. 4.11.3 The scope of installation of structural steel shall include fabrication, installation, painting, earthing to system grid of all vertical raceways and cable carrier structures in tunnels / trenches by minimum size 25 x 3mm GI flat(unless noted otherwise), as indicated in enclosed drawings / notes, supply of all incidental accessories like anchor fasteners, bolts, nuts, washers, welding works as required for fabrication and installation. Normally civil contractor will do all floor plate inserts / steel embodiments in walls required for welding the cable support structures to the same. However, if any extra floor plates are required in certain locations for convenience of cable routing, the same shall be fitted by means of anchor fasteners by the contractor. 4.11.4 All structural steel shall be painted as per instructions given in enclosed drawings / notes on cable tray mountings, trenches, tunnels and cabling practices. Where any cuts or holes are made or welding is done on painted / galvanised steel work / cable-trays, these shall be painted in the original manner. 4.12 ASSOCIATED WORK FOR DIRECT BURIAL OF CABLE, CONDUITS AND PIPES

4.12.1 The contractors scope of work required for directly buried cables shall include excavation, preparation of riddled soil bedding, supply and installation of protective covers, back-filling, ramming, supply and installation of route markers and joint markers. The details of construction work and provision of protective covers and markers shall be as indicated in the enclosed drawings of installation practice for directly buried cables. 4.12.2 The contractors scope of construction work for directly buried pipes / conduits shall be excavation and back filling as per varying depths / widths required in project drawings. The BIDDER to indicate this scope as per cubic metre basis. 4.13 CONDUITS / PIPES INSTALLATION

4.13.1 The contractor shall install all conduits / pipes required for the cable work as per enclosed drawings / notes. The sizes and quantities shall be as indicated in the data sheet. 4.13.2 The scope of installation of conduits / pipes shall include supply and installation of all accessories like tees, elbows, pull-boxes, conduit end plugs, bell-mouths, GI wire for cable
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pulling, GI saddles, spacers, screws, nuts and bolts. 4.14 SEALING OF FLOOR OPENINGS

4.14.1 All floor openings for vertical cable trays / raceways shall be sealed by fireproof and waterproof compound as specified in the contract documents. 4.14.2 The scope of work shall include preparing and laying of the compound. The supply rate for the compound and installation shall be indicated separately by the contractor. 4.15 JUNCTION / MARSHALLING BOXES / PUSHBUTTON STATION INSTALLATION

4.15.1 The contractor shall install the junction / marshalling boxes wherever indicated in the project drawings for the convenience of marshalling several cables at a local point near a equipment or central to various field mounted equipments. The estimated sizes and quantity of these boxes shall be indicated in the data sheet. 4.15.2 Unless otherwise specified, the contractor shall install the Pushbutton stations local to motors as per relevant enclosed typical cabling practices drawings. The quantity of these Pushbutton stations shall be indicated in the data sheet. 4.15.3 The scope of installation of junction / marshalling boxes and Pushbutton stations shall be mounting on walls, columns, structures, including necessary bolts, nuts, screws and welding work as necessary. 5.0 5.1 PAINTING OF CABLE TRAYS AND ACCESSORIES Cable tray supports and mounting structures and all other non-galvanised parts shall be brushed before giving one coat of red lead primer, one coat of oil primer followed by two finishing coats of aluminium alloyed paint. Cable trays fabricated out of mild steel material shall be painted with the above procedure, however the colour shade of finish coat shall be light grey as per RAL 7032 or equivalent unless specified, otherwise. 5.2 Junction boxes shall be given one coat of red primer, one coat of oil primer followed by two finishing coats of shade dark grey for the exterior and glossy white for interior surface unless otherwise specified elsewhere. TESTING AND COMMISSIONING TESTS ON CABLE TERMINATIONS AND JOINTS Type tests to be carried out at manufacturers works to prove the general qualities and design of a given type of termination / jointing system. The type test shall include the following tests conforming to the latest IEC 502.2, 466 and VDE 0278 specifications. The type test certificates shall be submitted by the contractor along with the offer for the jointing system considered. The charges for conducting these tests shall be quoted separately.
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6.0 6.1

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a) AC Voltage with stand dry test for 1 minute. b) Partial discharge test (for screened cables with solid dielectrics only). c) Impulse with stand test. d) AC high voltage test following load cycling test with conductor temperature at 95C. e) Thermal short-circuit test of 250C for 1 second. f) DC Voltage with stand test for 30 minutes. g) Humidity test. h) Dynamic short-circuit withstand test. i) Salt log test. j) Impact test.

6.2

COMMISSIONING The contractor shall carryout the following tests and checks after erection at site. In addition, the contractor shall carryout all other checks and tests as recommended by the manufacturers. a) Cable i) Check for physical damage. ii) Check for insulation resistance before termination / jointing and after termination / jointing. The following meggers shall be used for the purpose : 1100V grade cable 6600V/11,000V grade cable 33,000V grade cable 1000 kV Megger 2500 kV Megger 5000 kV Megger

iii) 6.6kV grade XLPE cables shall be pressure tested before commissioning. This test voltage shall be as per international / national codes and standards. iv) D.C. high voltage test shall be conducted on all 1100V grade cables in which strength through joints have been made and cables above 1100V grade after cables shall be installed in final position with all the straight through joints complete. Terminations shall be kept unfinished so that motors, switch gear, transformers etc. are not subjected to test voltage. The test voltage shall be as under : For 3.3 kV grade cables For 6.6 kV grade cables For 11 kV grade cables
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v) Check for continuity of all cores of the cables. vi) Check for correct polarity and phasing of cable connections. vii) Check for proper earth connections of cable glands, cable boxes, cable armour, screens etc. viii) b) Check for provision of correct cable tags, core ferrules, tightness of connections.

Cable Trays / Supports and Accessories i) Check for proper galvanising / painting and identification number of the cable trays / supports and accessories. ii) Check for continuity of power and control cable trays over the entire route. iii) Check that all sharp corners, burrs and waste materials have been removed from the trays / supports. iv) Check for earth continuity and earth connection of cable trays.

7.0

AS BUILT DRAWINGS The contractor shall submit one(1) set of drawings to the owner duly marked with all the changes / modifications made at site during erection / commissioning for preparation of AS BUILT drawings.

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