TNM-DS-806-0843

Issue 2.0 Dec-01

Cable Systems Standard

TO BE READ IN CONJUNCTION WITH AMENDMENT NO. 1

APPROVED
COPYRIGHT TRANSEND NETWORKS PTY LTD ALL RIGHTS RESERVED
This document is protected by copyright vested in Transend Networks Pty Ltd. No part of the document may be reproduced or transmitted in any form by any means including, without limitation, electronic, photocopying, recording or otherwise, without the prior written permission of Transend. No information embodied in the documents which is not already in the public domain shall be communicated in any manner whatsoever to any third party without the prior written consent of Transend. Any breach of the above obligations may be restrained by legal proceedings seeking remedies including injunctions, damages and costs.

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CONTACT

This document is the responsibility of the Technology & Standards Group, Transend Networks Pty Ltd, ABN 57 082 586 892. Please contact Transends Performance Improvement Manager with any queries or suggestions.

REVIEW

DATE

This document is due for review not later than Dec-02

MINIMUM

REQUIREMENTS

The requirements set out in Transend's documents are minimum requirements that must be complied with by contractors, including designers and other consultants. The contractor is expected to implement any practices which may not be stated but which can reasonably be regarded as good practices relevant to the objective of this document. Transend expects contractors to improve upon these minimum requirements where possible and to integrate these improvements into their procedures and quality assurance plans.
AUDITS

Periodic audits to establish conformance with this document will be conducted by Transends Performance Improvement Department.

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CONTENTS
1. GENERAL 1.1. Purpose 1.2. Scope 1.3. Objective 1.4. Certificate of conformance 1.5. Precedence 1.6. Deviation 1.7. References GENERAL REQUIREMENTS 2.1. Service Conditions 2.2. Performance CABLE SYSTEMS 3.1. Design of cable systems 3.2. Design of Cables INSTALLATION OF CABLE SYSTEMS 4.1. Cable segregation 4.2. Underground installations 4.3. Above ground cable installation 4.4. Labelling and identification 4.5. Conduits 4.6. Cable route 4.7. Cable length 4.8. Cable bending radii 4.9. Cable laying 4.10. Cable supports 4.11. Cable fittings 4.12. Earthing of cable sheaths and screens 4.13. Dimensioning of cable installation EXTRA HIGH VOLTAGE AND HIGH VOLTAGE CABLE SYSTEMS 5.1. Design requirements for EHV and HV cable systems 5.2. Installation requirements for EHV and HV cable systems LOW VOLTAGE CABLE SYSTEMS 6.1. Preferred multicore cable types 6.2. Segregation of cables 6.3. Wiring standards 6.4. Wire numbering 6.5. Wiring and connection diagrams/tables FIBRE OPTIC CABLES 7.1. Installation of fibre optic cables INSTALLATION OF COMMUNICATIONS AND DATA CABLES CABLE SCHEDULES CIVIL WORKS DATA FOR ASSET MANAGEMENT INFORMATION SYSTEM TESTING 5 5 5 5 5 6 6 6 6 7 7 7 7 7 8 8 9 10 10 11 11 11 11 12 12 13 13 13 13 13 14 15 15 16 16 17 20 20 20 21 21 21 21 22

2.

3.

4.

5.

6.

7. 8. 9.

10. 11. 12.

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12.1. Type tests 12.2. Routine tests 13. INFORMATION TO BE PROVIDED WITH TENDER 14. 15. DELIVERABLES HOLD POINTS

22 22 23 23 23

LIST OF TABLES
Table 1 : EHV and HV cable system requirements Table 2 : Preferred multicore cable types Table 3 : Circuit Function Letters 14 15 18

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1. 1.1.

GENERAL
PURPOSE To define the requirements from cable systems under the responsibility of Transend Networks Pty Ltd (hereafter referred to as "Transend").

1.2.

SCOPE This standard applies to all cable systems under the responsibility of Transend. This standard contains requirements for design, engineering, manufacture, construction, testing at manufacturers works, secured packaging, supply, transportation, delivery to site, testing and commissioning with complete documentation of cable systems and is to be applied to new installations as well as redevelopment of part or all of existing installations. This standard applies to all extra high voltage, high voltage and low voltage cables under the responsibility of Transend.

1.3.

OBJECTIVE Transend requires design, construction, installation and commissioning of equipment and services as covered in this standard to ensure: a) that relevant Australian legal requirements are met. b) that the requirements of the Tasmanian Electricity Code and National Electricity Code are met. c) personnel and public safety. d) safety of Transend's assets. e) ease in operation and maintenance. f) reliability and continuity of the AC supply. g) minimum disruption to the AC supply following a fault. h) that the requirements of Transend business plan are met. i) that the exposure of Transends business to risk is minimised.

1.4.

CERTIFICATE OF CONFORMANCE a) Before any new and/or modified Cable system is put into service in Transends system, certificate of conformance with this standard must be submitted to Transend. The certificate of conformance must be duly supported with documents, drawings, test results, test reports, test certificates, completed check lists and other documents as applicable. Where Transend has approved deviation to specific requirements of this standard, all such approvals must be included with the certificate of conformance. b) Transend will supply blank proforma for certificate of conformance, to be completed by the Contractor. c) Cable system will be put in service only after the certificate of conformance has been accepted by Transend.

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1.5.

PRECEDENCE Any conflict between the requirements of the codes, specifications, drawings, rules, regulations and statutory requirements or various sections of this standard and other associated documents must be brought to the attention of Transend for resolution.

1.6.

DEVIATION Special approval for a deviation to this standard may only be accorded, if it does not reduce the quality of workmanship and does not deviate from the intent of the standard. A request for a deviation must follow a designated procedure that involves approval from Transend. Deviations if any, must be specifically requested, and approved in writing by Transend before award of Contract.

1.7.

REFERENCES As a component of the complete specification for a system, this standard is to be read in conjunction with other standards and documents as applicable. In particular this includes the project specifications and the following: AS 1429.1 AS 1824.2 AS 2067 AS 2373 AS 2395 AS 2648 AS 3000 AS 3147 CIGRE SC36 WG04 1997 IEC 840 Electric cables polymeric insulated Insulation coordination, Application Guide Switchgear assemblies and ancillary equipment for alternating voltages above 1 kV Electric cables for control and protection circuits Terminals for switchgear assemblies for alternating voltages above 1 kV Underground marking tape SAA Wiring rules Approval and test specifications for electric cables elastomer insulated for working voltages upto and including 0.6/1 kV Guide on EMC in Power Plants and Substations. Power cables with extruded insulation and their accessories for rated voltage above 30 kV upto 150 kV test methods and requirements Substation Civil Infrastructure Standard. General Substation Requirements Standard. Testing, Commissioning and Training Standard. Cable Systems information to be provided with tender. Cable Systems deliverables. Substation Ancillary Systems Standard. Glossary for Standards (terms and definitions are defined in this document)

TNM-DS-806-0832 TNM-DS-806-0837 TNM-DS-806-0841 TNM-DS-806-0843-001 TNM-DS-806-0843-002 TNM-DS-806-0845 TNM-DS-809-0846

2.

GENERAL REQUIREMENTS
Project specific requirements for the cable systems will be listed in the project specifications.

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2.1.

SERVICE CONDITIONS a) Environmental conditions and any specific design criteria for particular works will be stated in the project specifications. Minimum service conditions for cable systems are stated in document TNM-DS-806-0837. b) All equipment must be capable of operation at its specified rating without assisted means, for example, forced cooling will not be permitted to achieve the rated capacity.

2.2.

PERFORMANCE a) Cable systems must ensure reliability, security and redundancy. b) The selection of the equipment constituting cable systems must be appropriate to satisfy the design criteria and to meet or exceed the specified performance. c) The selection of equipment, design and all works associated with the cable systems must conform to the requirements as specified in document TNM-DS-806-0837. d) The selection of the equipment must be based on most severe of: (i) (ii) (iii) requirements mentioned in this standard; project specifications; or results from system TNM-DS-806-0837. analysis and requirements as stated in document

3. 3.1.

CABLE SYSTEMS
DESIGN OF CABLE SYSTEMS a) The design of the cable systems must ensure that: (i) (ii) the reliability requirements TNM-DS-806-0837 are met. and service life as stipulated in standard

adequate provision is made for future expansion as defined in the project specifications.

b) The design and design calculations must include, but not be limited to: (i) (ii) (iii) (iv) (v) (vi) cable size and sheath size calculation. cable sheath, single or double point-bonding system. voltage rise under fault conditions for single point bonding. type of installation, (eg. in ground: direct buried/conduit /cable trenches/cable ducts; above ground; cable tunnel). selection of cable route. for extra high voltage and high voltage cables, thermal performance of the cable installation.

3.2.

DESIGN OF CABLES Design and selection of cable sizes and cable types must take into consideration the requirements mentioned below. a) Cables must be suitable for most onerous of: (i) outdoor installation;
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(ii) (iii)

indoor installation in ducts; or exposed to direct sunlight.

b) To meet the design requirements, electrical and mechanical design of the cable circuits must be undertaken. c) Cables must be rated and installed to support the circuit maximum input and output powers, taking into account the maximum overloads that may occur, without any overheating and without any degradation to the service life. d) Appropriate de-rating factors must be applied in the cable sizing calculations for factors that are different to the conditions nominated by the cable manufacturer in determining the standard cable current ratings. The de-rating factors must compensate for without limitation: (i) (ii) (iii) (iv) (v) (vi) the variations in the ambient; the variations in soil temperatures; group heating effect; depth of underground installation; cable laying formation; and spacing.

e) the cable oversheath must be designed to withstand the extremely high UV index pertaining to Tasmania.

4.

INSTALLATION OF CABLE SYSTEMS

The cable systems must be installed such that: a) Their installation is in accordance with manufacturers recommendations. b) Cables must be installed in cable ducts for interior routes or conduits elsewhere. c) Outdoor cables are laid in ducts unless otherwise specified in project specifications. d) Cables are not direct buried unless specifically allowed in the project specifications. e) The installation will withstand any vehicular loading that may occur. f) All cables are installed for easy access throughout the entire length for future replacement and repair. g) All cable supports, ducts and conduits are filled to no more than 50 percent of their working capacity to permit future expansion or modification. h) Cables damaged during installation are replaced in their entirety. If Transend has reason to doubt the integrity of the cable system, Transend reserves the right to reject the cable system even if there is no sign of it being damaged. i) Details of the cable installation must be included in the design documentation submitted to Transend for review and approval before commencement of works.

4.1.

CABLE SEGREGATION a) All cables must be grouped and segregated by type and function. b) All cables must be grouped and segregated, based on voltage level, to eliminate the possibility of induced voltages or static over voltages. Grouping must be made as follows without limitation:

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(i) (ii) (iii) (iv) (v) (vi)

separate groups of extra high voltage cables for each voltage present. separate groups of high voltage power cables for each voltage present. 415V/240V cables. control cables including CT/VT cables. DC cables. communication and instrumentation cables.

c) If some instances the number of low voltage power cables and control cables installed on a site may not warrant the installation of a separate duct or support system. For these installations, special approval must be sought from Transend to allow for cable installation without segregation in ducts. If Transend does not approve the suggested installation, cables must be segregated and installed in separate ducts. Where cables are approved to be installed without segregation in ducts suitable, means must be provided to eliminate possible induced voltage.

4.2.

UNDERGROUND INSTALLATIONS

4.2.1. Excavation
a) Excavation must be performed by hand, unless it can be demonstrated with certainty that no underground services exist. b) Care must be exercised at all time to ensure that no underground utilities are damaged during the excavation process. c) The Contractor is responsible for the repair of any damaged underground utilities at the Contractor's cost.

4.2.2. Cable protection

a) The duct must not be reinstated until Transend has inspected the cables. b) In all locations where cables may be exposed to mechanical damage, suitable means must be provided to protect the cables. c) All cables, where they rise from ground, must be mechanical protected by suitable means for an appropriate height above the ground level. d) Cables may use the inside of structures as a method of protection. e) Underground cables and conduits must be protected from mechanical damage by one, or a combination, of the methods specified in AS 3000 for Category B systems. f) Cable protection must be placed at a minimum of 300 mm above the cables and must overlap the cables by at least 100 mm on each side. g) Where vehicle access is permitted, a heavy-duty traffic barrier must be erected. h) Cable laid below vehicular pavements and access roads require additional protection. Such cables must: (i) (ii) (iii) be laid within electrical conduits, or by protection, allowing for future replacement and/or maintenance access. be laid such that access does not require the excavation of the road pavement. allow access from a location at least 1000 mm, but no more than 2000 mm, from the edge of the road pavement.

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i)

Backfilled soil must be free from wastes, metals and large debris. Each layer of backfill must be consolidated by hand until dense and firm consolidation is obtained.

j) The cables must be additionally protected from future excavations by placing and identification electrical cable marker tape over the full width of the cables. The marker tape must: (i) (ii) (iii) (iv) be a continuous length, orange in colour, complying with AS 2648. be positioned at not more than 200 mm above the mechanical protection. be lettered with WARNING, or "DANGER ELECTRICAL CABLE" or similar wordings. faithfully follow the route of the cable.

k) Approved surface markers must be provided to indicate the position of the cables laid directly in the ground and conduits. The markers must (i) (ii) (iii) (iv) be erected immediately on completion of the laying of the cable. be placed at a maximum interval of 10 metres to indicate the position of the buried cables. be placed at every position where the cable changes direction. be placed as required by Transend.

4.3. ABOVE GROUND CABLE INSTALLATION 4.3.1. Cable installation and support
a) All cables installed above-ground must: (i) (ii) (iii) (iv) (v) (vi) be well supported without visible sag. be adequately protected against damage. not be loosely bundled in air. be installed in parallel as far as practicable. be easily identified throughout its entire route. They are not to be bunched or crossed. be free from kink and unnecessary bends.

b) The number of layers on each level of support system must be kept to a minimum to facilitate future work. Separation between each level of support must be provided for easy access to the furthest cable at each level.

4.3.2. Cable installation sealing

a) Used and unused cable conduits and openings must be sealed with vermin-proof, waterproof and fire resistant sealant material. The sealing materials must be easily removable and resealable to facilitate future modifications to the cabling. b) Cable entries at transformer pits, including all duct lids where used, must be sealed with an approved fire resistant and oil compatible sealant to minimise entry of water and other foreign material.

4.4.

LABELLING AND IDENTIFICATION a) They are identified throughout its entire length.

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b) all equipment is adequately labelled to provide for safe and convenient operation and maintenance. c) Adequate quantities of cable markers are installed to ensure safe operation of the cables. Approved surface markers must be provided to indicate the position of the cables laid. The markers must: (i) (ii) (iii) be placed at least every 10 metres to indicate the position of the buried cables. be placed at every position where the cable changes direction. be placed as required by Transend.

4.5.

CONDUITS a) Cable conduits must be heavy duty orange PVC. b) All cable conduit openings and cable entries in transformer pits, whether used or unused must be sealed with approved type of fire and oil resistant breakable sealant material to avoid entry of water or any other foreign material. a) The conduit entrances at both ends must be completely sealed as necessary to prevent the ingress of moisture after the installation. c) There must be no sharp edges in conduits.

4.6.

CABLE ROUTE a) The cable route must be selected after a careful consideration of conditions on site and must factor the implementation process of the work to avoid minimal disruptions and avoid risks. b) All cable installation must be neat and follow a most direct, straight route with minimum number of crossings and minimum number of bends. c) There must be no sharp bends along the cable installation route. d) A layout drawing showing the proposed cable route with an illustrative description of the method of cable installation must be submitted to Transend for review and approval. This must include, as a minimum, the formation, depth in ground and support above ground.

4.7.

CABLE LENGTH a) Cable must be of sufficient length for their purpose and selected route. b) While calculating the cable lengths allowance must be given to the following: (i) (ii) (iii) terminations, possible route deviations that may be found necessary during laying of the cable. provision of a spare loop at each end of the cable where the cable length is greater than 2.0 metres. The spare loop must be sufficient for one re-termination of the cable.

c) All cables must be run in continuous lengths between connected devices. In line joints to make up for shortfalls in lengths are not acceptable.

4.8.

CABLE BENDING RADII a) The requirements from maintaining the bending radii as discussed in this section apply to both conditions: (i) (ii) during the installation process while the cable is being laid; and the installed cable.

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b) The minimum cable bending radii must not be less than the recommended bending radii by the cable manufacturer. c) If the cables are bent to a radius below the recommended radii in the installation process or in final configuration, the cables must be replaced in their entirety.

4.9.

CABLE LAYING a) While laying the cables, the cables must be pulled by both the conductor and sheath. b) Pulling of the cables must use methods and procedures as recommended by the cable manufacturer. c) The maximum pulling tension and maximum sidewall force as recommended by the cable manufacturer must not be exceeded during any process of cable laying. d) The cable ends must be sealed before it is laid. e) Suitable means, such as pulleys, rollers at bends and proprietary brands of pulling lubricant must be used to reduce friction and tension exerted on the cable. The lubricants must: (i) (ii) (iii) (iv) be compatible with the cable outer sheath. not set or harden during cable installation. not set in future. not consist of oil or grease.

f) Free running rollers must be positioned on the trench bottom to minimise frictional forces. The curvature of the roller must match that of the cable to ensure that the cable is not deformed. g) Skid plates must be installed at bends and maintain a smooth effective curvature not less than the cable minimum bending radius. h) The cable must not be used as a means of turning the reel in the laying process, and must be prevented from being subjected to a reverse bend as it is pulled from the reel.

4.10.

CABLE SUPPORTS a) Cables in buildings and switchyard must be supported by a suitable proprietary cable support system. The system must: (i) (ii) (iii) (iv) (v) consist of tray type supports. comply with NEMA Standard No VE-1. use hot-dipped galvanised steel for indoor installation. be designed to carry a safe working load, including allowance for future expansion, with a minimum design safety factor of not less than 1.5. be provided with expansion fittings at appropriate spacing for each continuous straight run where required.

b) Overhead cable support systems must not impede the movement of personnel, vehicle and equipment. c) Outdoor cable support systems must not rely on other civil structures for supporting the load. Freestanding support systems are preferred.

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4.11.

CABLE FITTINGS Cable glands must be of the non-ferrous type designed for armoured or non-armoured cables.

4.12.

EARTHING OF CABLE SHEATHS AND SCREENS a) Earthing of cable systems must as a minimum comply with document TNM-DS-806-0845. b) Where cables enter or pass through the switchyard or at locations possibly subject to electromagnetic or electrostatic interference, they must be screened. c) Screens must be bonded to earth according to the document (CIGRE SC36 WG04 1997). d) Where single point bonding of sheaths is used, the maximum standing voltage developed at the cable sheaths at the open-end must be limited to a maximum of 65V. e) A dedicated earth bar must be fitted within HV cable boxes for earthing of cable sheaths and screens terminated within the boxes. f) For protection, control and metering cables, single copper braid/tape must be used for the screens. g) Earthing points must be shown on the cable layout drawings, schematics and the wiring diagrams.

4.13.

DIMENSIONING OF CABLE INSTALLATION The position of all cables must be identified on a drawing. This drawing must detail the position of the cables including dimensions. All dimensions must be taken from survey or from structures/boundaries etc. Dimensions must be taken from points that are reasonably expected to remain in service for the life of the cables.

5. 5.1.

EXTRA HIGH VOLTAGE AND HIGH VOLTAGE CABLE SYSTEMS

DESIGN REQUIREMENTS FOR EHV AND HV CABLE SYSTEMS a) EHV and HV cables must be provided with the following: (i) (ii) (iii) (iv) (v) copper conductor with XLPE insulation. copper wire or tape screen incorporated with semi conducting water swellable material to prevent moisture ingress. a lead alloy or alternative metallic moisture barrier. This is not required for cables operating below 33 kV unless specified in the project specifications. a PVC oversheath to prevent the metallic sheath from corrosion. oversheath forms the outer sheath then it must be orange coloured. If the PVC

a HDPE outer oversheath for additional mechanical protection must be provided as required. The oversheath must be black, embossed and coated with graphite.

b) The design of the EHV and HV cable systems must ensure: (i) (ii) (iii) that the over-sheath is fire proof. all transformer cables are rated at 1.5 times the maximum MVA rating of the transformer, considering the most unfavourable system voltage. that where single point bonding is used, the maximum standing voltage developed at the cable sheaths at the open-end must be limited to a maximum of 65V. A removable

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connection or link must be provided at the earth end to facilitate testing of the cable oversheath. (iv) (v) (vi) cables operating at 88 kV or above must be provided with explosion proof link boxes if required by the design. voltage parameters must be in accordance with the point of installation and project specifications. cable technical parameters must be in accordance with Table 1.

Table 1 : EHV and HV cable system requirements

Sr. No. 1. 2. 3. Description Design conductor temperature Maximum conductor temperature Short time current withstand ratings Conductor Copper screen including metallic over-sheath Short circuit duration (seconds) Maximum conductor temperature designed for the short circuit rating Unit C C Requirement 90 105 Refer to Project Specifications Refer to Project Specifications 250

4. 5.

sec C

5.2.

INSTALLATION REQUIREMENTS FOR EHV AND HV CABLE SYSTEMS

5.2.1. EHV and HV cable installation

The cable systems must be installed such that: a) the length of cables installed in air must be kept to a minimum. Where portions of cables are installed in air, ventilation and / or shading must be provided. b) all cable tails must have highly visible coloured phase identification marking on them. Where single core cables are installed, the cables must be marked with permanent phase identification marks at least every 10 metres of a constant run and at every change of cable direction. c) where conduits are used, they must have an internal diameter not less than twice the cable overall outer diameter. d) appropriate trench base and back filling materials are used, taking into account thermal conductivity requirements. e) a continuous layer of marker tape is installed at a depth of 150 mm below ground level.

5.2.2. Cable accessories

All accessories necessary for the effective and efficient implementation of the cable systems must be supplied. As a minimum the following accessories must be provided: a) Outdoor cable sealing ends. EHV cable sealings must: (i) (ii) (iii) be suitable for outdoor installation have a creepage distance greater than 50mm per kV in accordance with AS1824-2. have a rated 1 minute power frequency withstand (dry) and lightning impulse withstand voltage of magnitude as stated in the standard TNM-DS-806-0831 and

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TNM-DS-806-0844, depending on the nominal voltage of the power system where the cable is installed. (iv) (v) have primary line terminal compliant with AS2395. have a support that maintains the minimum ground safety clearance as specified in AS2067.

b) Cable terminations. c) Earthing cables. Earthing cables must be: (i) (ii) constructed of stranded copper. appropriately rated for greater of:

the future maximum earth fault rating at site; and 25kA, 0.5s.

d) Sheath voltage limiters. e) All bonding leads and cabling. f) Link boxes. g) Support structures.

6.

LOW VOLTAGE CABLE SYSTEMS

Low voltage cable systems include all cable installations within the boundary of the works, including those for protection, control, metering and power circuits. Multicore cables must have a minimum of 10 % spare cores. Spare cores must have sufficient length to allow termination on any terminal in the cubicle terminal strip.

6.1.

PREFERRED MULTICORE CABLE TYPES a) Multicore cables for low voltage applications must be circular, stranded, plain annealed copper conductor, 0.6/1kV PVC insulated, PVC sheathed and screened. Preferred sizes are given in the Table 2. b) Multicore cables with white sheath, must have core numbers inscribed on the sheath. Table 2 : Preferred multicore cable types
Cores mm2 Strands Screen Cores Sheath Standard

Instrumentation Cables 2 pr 6 pr 10 pr 0.5 0.5 0.5 7/0.3 Cu 7/0.3 Cu 7/0.3 Cu Al Electrostatic Al Electrostatic Al Electrostatic W Bk W Bk W Bk Bk PVC Bk PVC Bk PVC

Control Cables 2 1.5 1.5 4 8 16 1.5 1.5 7/0.5 Cu 7/0.5 Cu Single Cu Tape Single Cu Tape W W Bk PVC Bk PVC AS 2373.1 AS 2373.1 7/0.5 Cu 7/0.5 Cu Single Cu Tape Single Cu Tape W W Bk PVC Bk PVC AS 2373.1 AS 2373.1

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Current and Voltage Transformer Cables 4 4 4 4 2.5 4 6 16 7/0.67 Cu 7/0.85 Cu 7/1.04 Cu 7/1.7 Cu Single Cu Tape Single Cu Tape Single Cu Tape Single Cu Tape W W W W Bk PVC Bk PVC Bk PVC Bk PVC AS 2373.1 AS 2373.1 AS 2373.1 AS 2373.1

6.2.

SEGREGATION OF CABLES a) Cable runs must not give rise to induced voltages or build up of static overvoltages. Where parallel runs are unavoidable, the control and auxiliary cables should be separated from the busbars by the maximum practicable distance. b) Switchyard cables entering the control building must be physically separated from the internal cables and from cables containing low-level signal circuits. c) Separate individual cables must be used for each of the following purposes: (i) (ii) (iii) (iv) (v) (vi) AC Voltage Transformer secondary circuits. AC Current Transformer secondary circuits. DC controls. DC supplies. analog control signals. revenue metering.

d) AC and DC circuits must not be combined in the same cable.

6.3.

WIRING STANDARDS

6.3.1. General
a) Secondary wiring must be terminated in clamp type screw tightened terminals where screw does not bear a direct pressure on the wire. b) Looping connections between three or more devices on a panel must be arranged to achieve the shortest route length. c) Where DC bus positive supplies are required in panels, the corresponding negative must be included on an adjacent terminal irrespective of whether it is required in the internal wiring. d) If a panel contains terminals or other items connected to 415/240 volts AC then these parts must be shrouded, a danger label provided and a note to this effect must be placed on the wiring diagram. e) Wiring is to be designed to be protected from heat damage or be heat resistant where required. This applies for example for wiring to anti-condensation heaters.

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6.3.2. Standard wire sizes

a) Both panel internal wiring and external control/auxiliary cabling must be sized and rated to fit for the application purpose in regard to normal voltage and current ratings, voltage drop, and short-circuit rating. b) Minimum of V-90 grade insulation. c) The minimum standard for wiring sizes is: (i) (ii) (iii) (iv) Current transformer wiring and earth wiring are 7/0.67 (2.5mm2). All other wiring is 30/0.25 (1.5mm2). Wiring for circuits carrying data must be 7/0.030 shielded pairs Only non-standard wire sizes must be shown on the wiring diagram.

6.3.3. Standard wire colours

The standard for wiring colours is: a) DC wiring must be grey. b) AC wiring must be red, white, blue or black as required. c) Earth wiring must be green/yellow. d) Only wire colours other than grey must be shown on the wiring diagram.

6.3.4. Wire termination

a) Both ends of each wire must carry wire numbers as shown on the wiring diagram or in the wiring /connection table. b) Wires connected to the equipment side of a trip link must be fitted with red PVC sleeving or white ferrule with red letter T (approximately 10mm in length) located between the link and the wire number. c) Conductors of more than 7 strands which terminate at tunnel type terminals must be fitted with Klippon Boot Lace ferrules or similar. d) Ferrules must be fitted firmly on the insulation as close as possible to the terminal. Clip on ferrules or printing direct onto the insulation will not be permitted.

6.4.

WIRE NUMBERING New wire numbers must be used. The wire number schedule must be marked up for the station with any new numbers used in the design. The wire number schedule is in a hard copy format and must be updated by hand.

6.4.1. Wire number code

a) The alphanumeric code for small current wire marking comprises: (i) (ii) (iii) A prefix letter, indicating function. A number, giving wire identity. A suffix letter, indicating association with repetitive main circuit.

b) The code markings must be put on both ends of each wire, and must be unique such that in any one station, no two wires of different origin will have the same code marking. Every uninterrupted branch of any connection must bear the same code marking. Intervening terminals do not require a change of wire code marking.

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c) In each circuit the code marking must change when the circuit passes through a device which affects, or is affected by, the operation of the device. Links that are integral with terminals but not identified as links must not require a change of wire code marking. d) Where it is necessary to identify branches which are common, for example the neutral of a CT, different code markings must be used if the branches are common through identified links or are connected to separate terminals which are then common by removable connections.

6.4.2. Wire number prefix letter

a) Each wire must have a prefix letter to denote its circuit function, for example secondary circuit of a CT for primary protection, VT supply for instruments, closing and tripping circuits for a circuit breaker. These are given in the column under Circuit Function Letters. b) Wires originating from apparatus that serves more than one function in series must bear the prefix letter of the first function in the circuit. c) Where relays are used, the coil and contact circuits do not necessarily bear the same function letter. This should be determined by the function of the individual circuit containing them. For example, the coil circuit of an interposing relay may be W, but the contact circuits could bear prefix letters such as K, L or N as appropriate. d) Current and voltage transformer function letters must follow through any interposing and auxiliary current and voltage transformers, including such transformers when used for light current circuits. Where an AC supply, reflecting the primary quantities and derived from a current or voltage transformer, is rectified for the operation of instruments or relays, the DC circuits may carry the same function letter as the AC circuit. e) Circuits with functions not included in Table 3 must not have prefix letters.

6.4.3. Wire number numerals

Each wire must have a number identifying the individual wire in its function. This may consist of one or more digits as required. For functions, A to G the numbers must be confined as indicated in Table 3. If more than 100 are required then multiples thereof should be added, thus 29 may be extended to 129 or 229. Positive wires from a DC source must bear odd numbers and negative wires must bear even numbers. Where coils or resistors are connected in series, the change from odd to even numbers must be made at the coil or resistor end nearest to the negative pole of the supply.

6.4.4. Wire number suffix letter

In certain cases, a wire must have a suffix letter to identify its association with a main circuit. This will apply in cases of repetitive main circuits such as occur in installations of multiple machines, transmission lines, station batteries etc. Table 3 : Circuit Function Letters
CIRCUIT FUNCTION LETTERS A. B. C. Current transformers for primary protection, excluding overcurrent. Current transformers for busbar protection. Current transformers for overcurrent protection (including combined earth-fault protection and instruments). WIRE NUMBERS * 10-29 30-49 50-69 70-89 Red phase White phase Blue phase Non phase specific,

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TNM-DS-806-0843
Issue 2.0 Dec-01 CIRCUIT FUNCTION LETTERS D. E. F. G. H. J. K. L. Current transformers for metering and voltage control. AC reference voltage for instruments, metering and protection AC reference voltage for voltage control. Reference voltage for synchronising AC and AC/DC supplies. DC main battery buses. Closing and tripping control circuits. Alarms and indications initiated by auxiliary switches and relay contacts excluding those for remote selective control and for general indication equipment Auxiliary and control motor devices eg. governor motor, rheostat motor, generator AVR control, spring charging motors, transformer cooler motor control, motors for disconnector operation. Tap change control, including AVC, tap position and progress indications. An indication that the ferruling is not in accordance with the general scheme and that if it is not altered double ferruling will be required for coordination with the remaining equipment in the station. DC tripping circuits used solely for busbar protection Interlock circuits not covered above. DC instruments and relays, exciter and field circuits for generators. Pilot conductors (including directly associated connections) between panels, independent of the distance between them, for pilot-wire protection, for inter-tripping or for both. Spare cores and connections to spare contacts. Any number from one upwards Wire numbers should preferably increase from the source so that low numbers are a general indication of importance to the circuit.} Spare cores must be numbered from one upwards in each cable, and must be so arranged that they can be readily identified on site with the cable containing them. This must be achieved by suitable grouping, and unless the location of each group is clear from the diagram, the groups must be labelled. Alternatively, the core number must be preceded by the cable number. WIRE NUMBERS * residual circuits & neutral CTs 90 Earth wires directly connected to the earth bar. 91-99 Test windings normally inoperative.

Any number for one upwards. Wire numbers should preferably increase from the source so that low numbers are a general indication of importance to the circuit

M.

N. O.

P. R. S. T.

U.

W. X. Y.

Connections to and from light current control equipment. Generally, all circuits to and from remote terminal units. Telephones and Communications (Fibre Optic) Any number from one upwards.

Transend Networks Pty Ltd

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TNM-DS-806-0843
Issue 2.0 Dec-01 CIRCUIT FUNCTION LETTERS * WIRE NUMBERS *

If, for functions A to G, more numbers are required, add multiples of one hundred. (For example, 10-29 may be extended to 110-129, 210-229 etc.)

6.5.

WIRING AND CONNECTION DIAGRAMS/TABLES a) The connection of all equipment must be shown on wiring connection diagrams/tables. b) Termination diagrams must be combined with equipment wiring diagrams. c) Wiring diagrams must show the following details for each cubicle, cabinet, device or other equipment to which the Contract cabling is to be connected: (i) (ii) (iii) (iv) (v) The cubicle designation. All terminal strips or terminals in there correct relative location. A wire number (or blank space in the case of a spare terminal) against each side of a terminal. For each cable, the cable identification numbers, the total number of cores and the number of spare cores and the designation of the cable. The wire number of each core in each cable.

d) Equipment removed from service must be deleted from any existing drawing/table. e) When removing equipment from service it must be ensured that looping of signals to other equipment that is to remain in service is maintained. Tee-offs or in-line joins on looping wires are not acceptable. Rewiring is required.

7. 7.1.

FIBRE OPTIC CABLES

INSTALLATION OF FIBRE OPTIC CABLES a) All fibre optic cables must be installed in telecommunications conduits (white) with a minimum diameter of 32 mm, so that cables will be protected from the weight of other cables, crushing, ground disruption or any other environmental abuse. The conduit should be identified suitably at regular intervals. Such identification will be provided at a minimum of 3 metre intervals. b) A draw wire must be provided in each conduit for future use. c) Cable pits must be provided at every bend and other suitable locations. d) Any fibre optic cable run indoors must be installed in flexible telecommunication conduit to prevent mechanical damage. The conduit must not be laid under other cables. e) All fibre optic cables must be installed using proper installation techniques with particular care exercised during the installation. f) Cables must not be subject to excessive pulling tension, sharp jerks, kinks or twists that may damage the cables. There must be no sharp bends along the installation route or sharp edges in conduits. g) There must be no more than three 90 degree changes in direction for any single cable pull. If so then the cable must be pulled through to an intermediate point after the third 90 degree change of direction and the cable must then be backed. h) The minimum bending radii of the fibre optic cable must be in accordance with those recommended by the cable manufacturer during installation and at the as-installed position.

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i)

The cable must be under minimal tensional stress at the completion of the installation.

j) No joints must be allowed along the length of the fibre optic cables. k) The cable must be sufficiently covered in pulling lubricant and the cable end must be completely sealed and made waterproof before it is pulled into the conduit. l) The conduit entrances at both ends must be completely sealed to prevent the ingress of moisture after installation.

m) Sufficient length of spare fibre optic tail must be left for termination.

8.

INSTALLATION OF COMMUNICATIONS AND DATA CABLES

A qualified communications officer must carry out all communications and data cable installation. The qualified communications officer must have proven experience in accordance with good engineering practice. Transend has the right to reject the work which, in Transend's opinion, has not conformed to this standard and associated documents, or the workmanship is substandard.

9.

CABLE SCHEDULES
a) New or updated existing cable schedules must be prepared to show all cables added or modified for the works. b) Cable schedules must show for each cable: (i) (ii) cable identification number. from/to information, showing the location of the two cable ends in separate columns by cubicle designation or device description with, where applicable, the device number as shown on the circuit diagrams. brief description of route, listing cable trays, trenches, etc. by identification number or letter. details of cable (type, conductor size, number of cores, route length in metres). type and size of cable glands.

(iii) (iv) (v)

10.

CIVIL WORKS
All civil works associated with Cable System must be in accordance with document TNM-DS-806-0832.

11.

DATA FOR ASSET MANAGEMENT INFORMATION SYSTEM

a) Transend maintains a comprehensive Asset Management Information System (AMIS) that contains all design, test results and the condition of all Transend assets. The AMIS also contains maintenance regimes for all assets. b) The Contractor must provide information required to maintain the currency of AMIS for each asset in standard proformas. The proformas will be provided by Transend to the selected Contractor. Proformas are required to be filled for new assets and for decommissioned assets. c) The filled up proformas must be filled in and submitted to Transend as below: (i) Design information and maintenance regime information for all assets must be submitted to Transend before commencing installation on site.
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(ii)

Information on test results for all assets must be submitted before commissioning.

12.

TESTING
a) Testing, installation and commissioning must comply with the requirements of the document TNM-DS-806-0841. b) All components of Cable systems must be duly tested in accordance with relevant applicable Australian and International standards. Where tests are optional in the standards, it will be considered that these tests are required by Transend, unless otherwise requested by Contractor and agreed in writing by Transend before the award of Contract. c) All test reports must be forwarded to Transend for approval and acceptance. The tests will be considered as completed, only after, an approval and acceptance of test results by Transend in writing. A list of the tests to be conducted on the Cable systems is given below.

12.1.

TYPE TESTS a) Type tests are intended to prove the soundness of design of the systems and their suitability for operation under the conditions detailed in the specifications. Type tests must be carried out before the delivery of the system. A certified test report, detailing the results of such tests along with the procedures followed, must be provided to Transend. These tests must have been made applied to a system of identical design with that offered, or on a system of a design which does not differ from that offered in any way which might influence the properties to be checked by the type test. b) Where such tests have already been performed, a copy of type test reports that qualifies for the exemption from conducting these tests must be provided with the tender. c) For voltages 88 kV and above, relevant type tests for cables as specified in IEC 840 will apply and for voltages below 88 kV, relevant type tests for cables as specified in AS 1429.1 will apply.

12.2.

ROUTINE TESTS a) The routine tests must be conducted on the complete system to prove quality of manufacture and conformance with the relevant performance requirements of the applicable standards. Splitting of routine tests into separate phases for individual components of the system is not acceptable. Routine testing must be performed at the manufacturers works before delivery. d) Procedures for routine tests with supporting documentation must be submitted to Transend for approval and acceptance. Routine tests will not be conducted unless the routine test procedures have been accepted and approved by Transend. d) Routine test results and certificates must be submitted to Transend for approval and acceptance. Routine tests will not be considered as completed only after Transend approves and accepts the test results. e) f) Routine factory test results must be approved and accepted by Transend before dispatch of equipment to site. As a minimum, the tests stated below must be conducted.

12.2.1. Site tests

Site installation and commissioning tests must be conducted on the installed system after erection on site and before it is put into service to prove that it has not been damaged during transportation or erection. The site test procedures must be submitted to Transend for approval.

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Site test reports must be approved and accepted by Transend before placing equipment in service. As a minimum the tests stated below must be conducted: (i) (ii) (iii) (iv) (v) (vi) Phasing / continuity check. Oversheath bonding contact resistance measurement where applicable. 10 kV DC oversheath test. Insulation resistance test. High voltage DC or AC test. Sheath voltage limiter test where applicable.

13.

INFORMATION TO BE PROVIDED WITH TENDER

Requirements for information to be submitted as part of the tender are outlined in document TNM-DS-806-0843-001.

14.

DELIVERABLES
Requirements for project deliverables are outlined in document TNM-DS-806-0843-002.

15.

HOLD POINTS
The requirement of documentation is listed in the deliverable schedule in document TNM-DS-806-0843-002. The hold points for Cable system include: a) "Analysis and preparatory documentation" must be submitted before "detailed design" for Transend's review, comments and approval. b) "Detailed design documentation" must be submitted before manufacturing or procurement of equipment, for Transend's review, comments and approval. c) "Inspection and Test Plan" must be submitted before any testing of equipment, for Transend's review, comments and approval. d) "Invitation to witness testing" must be submitted before any testing of equipment, for Transend's arrangements to witness. e) Complete updated design documentation, operations and maintenance manuals must be submitted before "Factory Acceptance Testing (FAT)" for Transend's preparation to attend FAT. f) Draft training manuals must be provided at least three months before training, for Transend's review, comments and approval. g) Final training manuals must be provided at least two weeks before training, for use of training team. h) "FAT" must have been witnessed by Transend and FAT results approved by Transend, before "pre-commissioning tests". i) All non-conformances as identified during FAT must have been completed before commencing any pre-commissioning tests.

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j) Information required for AMIS pertaining to design and maintenance regimes must be submitted to Transend before commencing installation. k) "Pre-commissioning tests" must have been witnessed by Transend and test results approved by Transend, before "commissioning tests". l) All non-conformances as identified during pre-commissioning tests must have been completed before commencing any commissioning tests.

m) Results of commissioning tests must have been approved by "System Controller", other code participants and relevant testing authorities as per the requirements of the Code, before commissioning. n) "Commissioning tests" must have been witnessed by Transend and test results approved by Transend, before "energisation". o) All non-conformances as identified during commissioning tests must be completed before commencing any energisation. p) "Training" must have been completed before energisation. q) Information for AMIS pertaining to test results must have been submitted to Transend before energisation. r) Certificate of conformance with contract specifications, standard specifications, codes and standards with associated documents, drawings, test results, test reports, test certificates, completed check lists and other documents must be submitted and will have been accepted and approved by Transend prior to energisation. s) Transend must have completed the Inspection of each asset before its energisation. t) All as-built documentation, software licences, operation and maintenance manuals, test results and test certificates must be submitted to Transend and be accepted by Transend prior to practical completion.

u) Conduits must not be reinstated until Transend has inspected the cables. v) Location of all buried services must be established before commencing any excavations.

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Form No: TNM-GS-809-0101/012 (October 2004)

Date Published: 05/12/2005

AMENDMENT NO. TO DOCUMENT #:

TNM-DS-806-0843Issue # 2

TITLE:

CABLE SYSTEMS STANDARD

AMENDMENTS

Insert new section: 4.14 Removal of Redundant Cables

Before removing redundant cables and wiring, both cable ends must be appropriately identified, disconnected and decommissioned. Wherever possible, redundant cables should be completely removed from the duct, tray, tunnel, conduit or other storage medium within which the cable resides. In some cases full removal may not feasible due to: interwoven cables preventing removal of a single redundant cable large number of cables installed in a single location causing cables to wedge tightly In these situations where it is deemed that damage may occur to adjacent cables, the redundant cable must be terminated as close as practicable to the transition point between cable storage mediums. For example, where a redundant cable passes from a tray into a conduit and the cable can not be pulled clear of the conduit without damaging adjacent cables, the redundant cable must be cut as close as practicable to the conduit end. Where cables are stored in ducts, all duct covers must be removed before commencing cable removal. This will ensure that the assessment of the likelihood of damage to adjacent cables is performed with greater accuracy prior to any removals occurring. Unless requested otherwise by Transend, where the redundant cable is direct buried the cable will be cut below the substation ground level (SGL). All redundant cables will be disposed of by the Contractor unless otherwise specified by Transend. Ducts, cable trays, conduits or other cable storage mediums must be left in a tidy, orderly and secure condition. Redundant inter-panel cabling and wiring must be removed completely. Under some circumstances it may be difficult for the contractor to identify the decommissioned cable requiring removal (eg. where numerous cables are in close proximity within an enclosed space). If, after making all reasonable attempts the Contractor believes they are unable to identify the correct cable then, after approval by Transend the cables may be cut and capped at an alternative location as agreed with Transend. All cables that have been cut off are to be treated as follows: All cuts are to be square through the cable; Cable ends are to have a heat shrink cap fitted; Original cable numbers are to be retained on sealed cable ends. If the original cable numbers are illegible or in poor condition then the Contractor must reapply the cable number. Additional marking to indicate redundant (eg Large red R on number tag) must also be fitted to the cable.

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