CORPORATE REFERENCE DOCUMENT

STANDARD SPECIFICATION

FOR

POWER AND CONTROL CABLES

Document Number : BRNA-SP-EL-010-02

NOTE

This document contains proprietary information belonging to Brown & Root NA Ltd.
It may neither be wholly or partially reproduced without the prior written permission
of Brown & Root NA Ltd.

Users of this document must always consult the appointed Custodian for advice. The
Custodian should be notified of any errors, omissions and suggested improvements.
 BROWN & ROOT NA LTD
INDEX SHEET FOR REVISIONS

DOCUMENT TITLE DOCUMENT NUMBER

STANDARD SPECIFICATION FOR BRNA-SP-EL-010-02

POWER AND CONTROL CABLES
Page 1 of 16

REVISION HISTORY

REV DATE DESCRIPTION/REASON BY CHK APPROVALS

NO FOR ISSUE
ENGR GEN MD
MGR MGR

00 08/97 Issued for IDC AEA MO

0A 09/97 IDC comments incorporated AEA MO

Issued to finalising Task Group

01 10/97 Issued for Implementation

02 05/00 General Revision MO GJM

Custodian
Name: Discipline: Signature: Date:

M. Owen Electrical
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TABLE OF CONTENTS

Page No.

INDEX SHEET FOR REVISIONS ...................................................................................... 1

TABLE OF CONTENTS ....................................................................................................... 2

1.0 INTRODUCTION...................................................................................................... 3
2.0 SCOPE........................................................................................................................ 3
3.0 DEFINITIONS .......................................................................................................... 3
4.0 REGULATIONS, CODES AND STANDARDS ...................................................... 3
5.0 OTHER REFERENCE DOCUMENTS ................................................................. 5
6.0 TECHNICAL REQUIREMENTS .......................................................................... 5
6.1 Operating and Design Conditions ............................................................................ 5
6.2 General ...................................................................................................................... 6
6.3 66kV Power Cables
6.4 High Voltage Power and Distribution Cable 3.3kV to 33kV ................................... 6
6.5 Low Voltage Power and Control Cables to 1kV ...................................................... 7
6.6 Cable and Drum Marking ........................................................................................ 9
6.7 Materials of Construction and Corrosion Protection Measures ............................. 9
6.8 Works Tests and Inspection ...................................................................................... 10
7.0 DOCUMENTATION TO BE SUBMITTED .......................................................... 11

ATTACHMENTS

1. OWNER DATA SHEET (PROFORMA) ............................................................... 12

2. OFFER DATA SHEET (PROFORMA) . HIGH VOLTAGE POWER AND
DISTRIBUTION CABLE ....................................................................................... 13
3. OFFER DATA SHEET (PROFORMA). LOW VOLTAGE POWER
DISTRIBUTION AND CONTROL CABLES ....................................................... 15

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1.0 INTRODUCTION

This Standard Technical Specification specifies the minimum technical requirements for design,
manufacture, works testing and delivery of power, distribution and control cables for use in
water and waste treatment processes and systems projects.

2.0 SCOPE

Codes and standards are referenced to specify practices to be followed. The Specification
further enhances the codes and standards by defining particular Owner requirements for the
cables. It includes Owner Data Sheet Proforma and Offer Data Sheets Proforma listing
information necessary for the complete design and installation of the power and control cables.

Transmission cables are excluded from this Specification.

3.0 DEFINITIONS

None required.

4.0 REGULATIONS, CODES AND STANDARDS

Unless indicated otherwise in this Specification, the requirements of the following regulations,
codes and standards shall apply:-

British Standards Institution (BSI )

BS 4066 Tests on Electric Cables Under Fire Conditions.

BS 6004 Specification for PVC-insulated Cables (Non-armoured) for Electric
Power and Lighting.
BS 6141 Specification for Insulated Cables and Flexible Cords for Use in High
Temperature Zones.
BS 6207 Mineral Insulated Cables with a Rated Voltage Not Exceeding 750V.
BS 6346 Specification for PVC-insulated Cables for Electricity Supply.
BS 6387 Specification for Performance Requirements for Cables Required to
Maintain Circuit Integrity Under Fire Conditions.
BS 6425 Tests on Gases Evolved During the Combustion of Materials From
Cables. Part 1. Method for Determination of Amount of Halogen

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Acid Gas Evolved During Combustion of Polymeric Materials Taken

From Cables.
BS 6500 Specification for Insulated Flexible Cords and Cables.
BS 6724 Specification for Armoured Cables for Electricity Supply Having
Thermosetting Insulation with Low Emission of Smoke and Corrosive
Gases When Affected By Fire.
BS 6746 Specification for PVC Insulation and Sheath of Electric Cables.
BS 7211 Specification for Thermosetting Insulated Cables (Non-armoured) for
Electric Power and Lighting With Low Emission of Smoke and
Corrosive Gases When Affected By Fire.

International Electrotechnical Commission (IEC)

IEC 227 Polyvinyl Chloride Insulated Cables of Rated Voltages Up to and

Including 450/750V.
IEC 228 Conductors of Insulated Cables.
IEC 245 Rubber Insulated Cables of Rated Voltages Up to and Including
450/750V.
IEC 287 Electric Cables – Calculation of Current Rating
IEC 331 Fire-resisting Characteristics of Electric Cables.
IEC 332 Tests on Electric Cables Under Fire Conditions.
IEC 332-1. Part 1. Test on a Single Vertical Insulated Wire or Cable.
IEC 332-3. Part 3. Tests on Bunched Wires or Cables.
IEC 502 Extruded Solid Dielectric Insulated Power Cables for Rated Voltages
From 1kV Up to 30kV.

IEC 724 Guide to the Short-circuit Temperature Limits of Electric Cables With
a Rated Voltage Not Exceeding 0.6/1.0kV.
IEC 754 Test on Gases Evolved During combustion of Electric Cables. IEC
754-1. Part 1. Determination of the Amount of Halogen Acid Gas
Evolved During the Combustion of Polymeric Materials Taken From
Cables.
IEC 811 Common Test Methods for Insulating and Sheathing Materials of
Electric Cables.
IEC 840 Tests for Power Cables with Extruded Insulation for Rated Voltages
above 30kV up to 150kV.
IEC 885 Electrical Test Methods for Electric Cables.

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IEC 986 Guide to the Short-circuit Temperature Limits of Electric Cables with
a Rated Voltage from 1.8/3 (3.6) kV to 18/30 (36)kV.

International Organisation for Standardisation (ISO)

ISO 9001 Quality Systems - Model for Quality Assurance in Design/

development Production, Installation and Servicing.

5.0 OTHER REFERENCE DOCUMENTS

None.

6.0 TECHNICAL REQUIREMENTS

6.1 Operating And Design Conditions

All power, distribution and control cables covered by this Specification shall be designed to
operate in the environmental conditions stated on the Owner Data Sheet. The cables shall also
be designed to provide the minimum design service life specified on the Owner Data Sheet.
The sheaths of exernally installed cables shall not degradebelow acceptable performance levels
under levels of ultra-violet (UV) radiation occuring within its environment. Where cables are
to be installed within buildings they shall be fire retardant or fire resistant as specified and shall
not support combustion.

Cables required to be flame retardant and designed for low smoke and fume (LSF) emission
shall comply with the following:

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HCl emission - 0.5% maximum to BS 6425 Part 1.

Fire performance - BS 4066: Part 1 and: Part 3, Category C, (1.5 litres of
combustible material per metre).
Oxygen index - 30 minimum.

Where fire resistant (fire survival) cables are specified they shall comply with IEC 331.

6.2 General

All cables shall be new and delivered to site as complete drums or coils with wrappings and
manufacturer's seals intact and with all ends sealed. Cables shall be supplied in the maximum
possible continuous lengths.

6.3 66kV Power Cables

Cables shall be installed in a high voltage trench or ducts beneath the switchgear and between
the switchgear and power transformers.

Cables shall be laid in a trench between the 220/66kV and the 66/11kV power transformers and
the respective 66kV switchgear. Cables shall be suitable for use on a 66kV nominal solidly
earthed system.

Cables shall be single core, annealed, stranded copper conductor, XLPE insulated with
laminated sheath consisting of PE coat, Al tape and PE outer sheath. The cables shall be tested
in accordance with IEC 840.

Cables shall have current carrying capacity in accordance with IEC Publication 287.
Maximum permanent conductor temperature shall be rated at 90°C.

All cable and terminations must be accompanied by complete technical data from the proposed
manufacturer, instances of actual installations, and must be Approved by the Owner prior to
final design.

6.4 High Voltage Power and Distribution Cable 3.3kV to 33kV

Cables shall be constructed in accordance with IEC Publication 502.

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The high voltage power cables shall be single or multi - core type with copper conductors,
extruded cross-linked polyethylene (XLPE) insulated, galvanised steel wire armoured, or in the
case of single core cable, aluminium armoured, polyvinyl chloride (PVC) sheathed or flame
retardant (LSF), as specified. The voltage grades Uo/U shall be 600/1000V, 1900/3300V,
3800/6600V, 6350/11000V, 8700/15000V, 12700/22000V or 19000/33000V as specified on
the Owner Data Sheets, conforming to the applicable codes and standards.

The cable shall be suitable for indoor and outdoor installations, exposed in air on tray or
ladder/racks, or buried either directly in the ground or run in pre-laid conduits or underground
trenches.

The system voltage, frequency and earthing arrangements shall be as stated on the Owner Data
Sheet.

Conductors shall be concentric stranded, plain annealed, uncoated copper with a nominal
conductor size as proposed by Contractor and approved by Owner. The conductor screen shall
consist of extruded semi-conducting polyethylene (PE). A separate tape may be applied to the
conductor before the conductor screen is applied.
Insulation shall be XLPE with insulation thickness complying with the relevant standard. An
extruded semi-conducting polyethylene (PE) screen shall be applied to the surface of the
insulation. An uncoated annealed metallic copper tape shall be applied helically over the semi-
conducting polyethylene (PE) with a suitable overlap.

The cores of the cable shall be laid together with a suitable filler where necessary, and bound
with a suitable tape over the laid-up cores. The bedding shall be of a thermoplastic compound
(PVC) extruded layer, or flame retardant LSF, where specified, in accordance with the
applicable codes and standards.

Armouring of three core cables shall comprise round wires of galvanised steel with the wire
size complying with applicable codes.

The cable shall be sheathed with a durable, moisture resisting, thermoplastic material (PVC),
or LSF sheath where flame retardant cable is specified, suitable for areas where waterlogging
may occur.

The cores of the cable shall be identified by colour as stated on the Owner Data Sheet.

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6.5 Low Voltage Power and Control Cables to 1kV

Low voltage power cable except flame retardant or fire resistant LSF types shall be single or
multi-core with copper conductors, XLPE insulated, or PVC insulated for sizes less than 16
mm2, galvanised steel wire armoured or unarmoured, PVC sheathed, 600/1000 volt grade,
complying with the applicable codes and standards. Minimum conductor size for power cable
shall be 2.5 mm2. Single core power cable armouring shall be non-ferrous.

Control cable shall be multi-core with copper conductors, XLPE or PVC insulated, galvanised
steel wire armoured or unarmoured, PVC sheathed, 600 volt grade, complying with the
applicable codes and standards. Flame retardant LSF sheath shall be provided when specified.

Power and control cables shall be armoured for externally buried installations, either directly in
the ground or, where applicable, run in pre-laid underground conduit system or trench.
PVC insulated (non-armoured) wiring cable to BS 6004 shall generally be used for internal
installations where run in conduit and trunking. Armoured cable shall be used for internal
installations when run on ladder/rack or tray.

For conduit installations, containing power and lighting circuits, cables shall have a minimum
size of 1.5 mm2.

Conductors for low voltage power and control cables shall be solid or stranded, plain annealed,
uncoated copper, and shall conform to IEC 228, Class 2, or equivalent. Nominal cross-
sectional areas shall conform to IEC 228 for the application of metric conductors. Conductors
for power cables larger than 2.5 mm2 shall be stranded.

Control cables shall have a minimum nominal cross-sectional area of 2.5 mm2 and shall be
stranded, plain, annealed, uncoated copper, conforming to IEC 228.

Insulation for low voltage power and control cables shall be XLPE or PVC. The insulation
thickness shall comply with the applicable codes and standards.

The conductors of multi-core cables shall be packed with suitable fillers where necessary to
provide a circular cross-section.

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The packed, insulated, conductors shall be sheathed with thermoplastic material (PVC) or
flame retardant, LSF material to IEC 332-1 and IEC 332-3. The cable sheath shall be suitable
for the proposed installation method: e.g. directly buried, exposed to sunlight, etc., as stated on
the Owner Data Sheet.

The number of cores in a multi-conductor control cable shall be: 2, 3, 4, 7, 12, 19, 27 or 37.
For power cables the number of cores shall be: 1, 2, 3, 4 or 5.

For power cables, core identification shall be by colour as stated on the Owner Data Sheet.

Control cable cores shall be identified with numbers.

6.6 Cable and Drum Marking

Cable information shall be printed at one (1) metre intervals on the entire length of cable such
as voltage rating, number of conductors (or pairs, if applicable), size of conductors, cable type,
suppliers name and year of manufacture. The printing shall be permanent and in a colour
which contrasts clearly with the outer sheath colour.

Cable drums shall each be provided with two 220 mm x 200 mm identification labels made
from aluminium or similar durable material, securely affixed one per side and at the top and
bottom of each drum. Each label shall be engraved with the following information as a
minimum:

 Manufacturer's name.
 Contractor's name.
 Purchase order number/purchase order item number.
 Project number.
 Date of manufacture.
 Batch number.
 Drum number in accordance with the Contractor's drum numbering system.
 Cable type and form.
 Voltage grade.
 Cable size (number of cores and cross sectional area).
 Drummed cable length (metres).
 Nett and gross weights (kg).

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6.7 Materials of Construction and Corrosion Protection Measures

Materials used for cable construction and corrosion protection measures shall be selected to
ensure optimum electrical and mechanical performance and meet the minimum design service
life in the ambient temperatures and installation conditions specified on the Owner Data Sheet.
Cable sheath and armouring shall provide adequate protection against ultra-violet light, water
penetration, corrosion, rodent and insect attack and mechanical damage.

6.8 Works Tests and Inspection

6.8.1 Performance Testing

The Contractor shall perform all routine tests and special tests necessary to
demonstrate the suitability of cables provided.

Cable performance data shall be provided from type tests previously carried out to IEC
and/or British Standards. A copy of all relevant type test certificates shall be provided
by the Contractor for Owner approval.

The cables shall be subject to inspection by the Owner during, and on completion of,
manufacture and during factory testing.

Copies of the relevant routine and/or special test certificates for the cables shall be
submitted by the Contractor to the Owner for approval as soon as practical after the
factory tests.

If any cable fails to comply with the requirements of the appropriate Specification the
Owner reserves the right to reject the cable in question and have it replaced.
The following Section lists specific factory tests which the Owner requires. This does
not preclude the Owner's right to call for further tests or special tests if considered
necessary to verify the suitability of the equipment.

6.8.2 Routine and Special Factory Tests

Tests shall be carried out in accordance with the appropriate IEC and/or British
Standards.

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The following minimum routine and special tests shall be performed:

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a. High Voltage Power Cables:

 Conductor resistance measurement.

 Armour resistance measurement.
 High voltage.
 Partial discharge.
 Insulation resistance.
 Conductor examination.
 Cable dimensions.
 Visual inspection.

b. Low Voltage Power and Control Cables:

 Conductor resistance measurement.

 Armour resistance measurement.
 High voltage.
 Insulation resistance.
 Cable dimensions.
 Visual inspection.

7.0 DOCUMENTATION TO BE SUBMITTED

Contractor shall submit the following documentation to Owner for review and approval:-

 Completed Offer Data Sheets.

 Cable catalogues and full technical data.
 Manufacturing and testing barchart.
 Inspection and Test procedure.
 Copies of all type test certificates.
 Routine test certificates.
 Certified and guaranteed performance data.
 All certified cable dimensions.

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ATTACHMENT 1
OWNER DATA SHEET
(PROFORMA)

General Data

System frequency (Hz) 50 Hz

Maximum system voltage variation (+/- %) +/-10%
Maximum frequency variation (+/- %) 5% (= 2.5Hz)
Outdoor ambient temperature range (°C) 6.1°C to 37.8°C
Indoor ambient temperature range (°C) Outdoor +5°C
Extreme maximum outdoor temperature range 1.7°C to 46.7°C
Summer relative humidity (% / °C) (High / Low) High: 2.5% / 36.1°C
Low: 1% / 37.8 °C
Winter relative humidity (% / °C) (High / Low) High: 99% / 6.1°C
Low: 97.5% / 7.2 °C
Height above sea level (m) Less than 1000m
Application Potable water pumping station
Site Location Libya - coastal

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66kV Cable Specification

Nominal System Voltage 66 kV

System Voltage Range 64 kV - 110 kV

Conductor Annealed Stranded Copper
Cores Single
Insulation XLPE
Standard IEC 840, 287, 228
Sheath PE coat, Al tape and PE outer sheath
Burial In trenches
Sheath colour Black
Core colour Black
Minimum design service life 25

11kV Cable Specification

Maximum System Voltage 15kV

Conductor Annealed Stranded Copper
Cores Three
Insulation XLPE
Standard IEC 502, 228
Armour Galvanised steel wire
Over sheath PVC
Sheath colour Red
Core colours Red, yellow, Blue
Minimum design service life 25

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ATTACHMENT 2
OFFER DATA SHEET
(PROFORMA)
HIGH VOLTAGE POWER AND DISTRIBUTION CABLE

Manufacturer
Country of manufacture:
Substation location
Applicable standards:
Voltage grade: V
Number of cores:

Conductor:
 size: mm²
 Material:
 Outer diameter: mm
 Maximum resistance at 20°C: /m

Conductor Shield:
 Material:
 Thickness: mm

Insulation:
 Material:
 Thickness: mm

Insulation Shield:
 Material:
 Thickness: mm

Tape:
 Material:
 Thickness: mm

Armour:
 Material:
 Thickness: mm

Outer sheath:
 Material:
 Thickness: mm

Diameter under armour: mm

Overall diameter: mm
Net weight of complete cable: kg/km
Maximum weight of cable and drum: kg
A.c. test voltage: kV
Time for test: mins
Minimum insulation resistance: M/m

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Standard drum length: m

Colour:
 Cores:
 Outer sheath:
Flame retardant LSF sheath
Minimum design service life: years
Termination and splice kit (indoor and outdoor):

Note: This Data Sheet shall be provided for each size and
type of cable.

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ATTACHMENT 3
OFFER DATA SHEET
(PROFORMA)
LOW VOLTAGE POWER DISTRIBUTION AND CONTROL CABLES

Manufacturer
Country of manufacture:
Substation location
Applicable standards:
Voltage grade: V
Number of cores:

Conductor:
 size: mm²
 Material:
 Outer diameter: mm
 Maximum resistance at 20°C: /m

Insulation:
 Material:
 Thickness: mm

Armour:
 Material:
 Thickness: mm

Outer sheath:
 Material:
 Thickness: mm

Diameter under armour: mm

Overall diameter: mm
Net weight of complete cable: kg/km
Maximum weight of cable and drum: kg
A.c. test voltage: kV
Time for test: mins
Minimum insulation resistance: M/m
Standard drum length: m

Colour:
 Core:
 Outer sheath:
Flame retardant LSF sheath
Minimum design service life: years
Termination and splice kit (indoor and outdoor):

Note: This Data Sheet shall be provided for each size and
type of cable.

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