KOC_E_023

KUWAIT OIL COMPANY (K.S.C.)

KOC STANDARD FOR

ELECTRICAL POWER CABLES AND WIRING

DOC NO: KOC-E-023

lSSUlNG AUTHORITY:

STANDARDS DIVISION

DOC NO. KOC-E-023

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KOC STANDARD

DOC NO. KOC-E-023

F0.R ELECTRICAL POWER CABLES and WIRING

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DOC NO. KOC-E-023

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I DOC NO. KOC-E-023 I Page 3 of 18 REV - 2 CONTENTS

Page

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCOPE 4

2.0 GENERALIAPPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.0 TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . 4.0 REFERENCE DOCUMENTS & STANDARDS . 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 ENVIRONMENTAL CONDITIONS . 6

. . . . . . . . . . . . . . . . . . . . . . . . . 6.0 MATERIAL DESIGN REQUIREMENTS . 7

GENERAL Voltage Designation Conductors Insulation Filling and Bedding Laying Up Armour (Metallic Covering) Marking and Identification of Cores, Sheath & Drums

CABLE TYPES

7.0 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 SPECIAL APPLICATIONS 13

Flame Retardant Cables Fire Resistant Cables Low Halogen and Smoke Emissions Oxygen Index Additional Tests for Fire Resistant Cables Special Cables - Flexible and Oil Resistant

9.0 DATASHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 DOCUMENTATION . 14

11.0 QUALITYASSURANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.0 APPENDICES .I6

Cable Data Sheet

I DOC NO. KOC-E-023 1 Page 4 of 18 1 REV - 2 SCOPE

This Standard describes KOC's minimum requirements for the Design, manufacture, testing and supply of electric power cables and wiring for use within the company facilities.

'-his Standard does not include cables for instrumentation;

Cables shall conform to the requirements of this standard, except as modified or supplemented by the project specification data sheet. TERMINOLOGY

Abbreviations

KOC: BS: IEC: Ex(d): XLPE: PVC: SWA: EPR: CSP: LC: GSWA: SWBA: MlCS PlCC

Kuwait Oil Company(K.S.C.) British Standard International Electrotechnical Commission Explosion proof Cross-linked Polyethylene Polyvinyl Chloride Single Wire Armouring Ethylene Propylene Rubber Chlorosulphonated Polyethylene Lead Covered Galvanised Steel Wire Armour Steel Wire Braided Armouring. Mineral Insulated Copper Sheathed Paper Insulated Copper Conductors

REFERENCE DOCUMENTS & STANDARDS

In the event of conflict between this standard and the codes referenced herein, the most stringent requirement shall apply, unless otherwise specified.

Any exceptions or deviations from this standard, along with their merits and justifications, shall be brought to the attention of KOC's Controlling Departmentlstandards Division for their review, consideration and amendment (if required) of the standard. International Standards

IEC 228 Conductors of insulated cables. .

IEC 331 Fire resisting characteristics of electrical cables.

IEC 332 Tests on electric cables under fire conditions.

IEC 502

IEC 754 Part 1

IEC 8 1 1

IEC 8 8 5

British Standards

BS 8 0 1

BS 2782 Part 0

BS 5467

BS 6007

BS 6207: Part 1

BS 6425 : Part 2

Extruded solid dielectric insulated power cables for rated voltages from 1 kV up to 30kV.

Tests on gases evolved during combustion of electric cables.

Common test methods for insulating and sheathing materials of electric cables.

Electric test methods for electric cables.

Specification for composition of lead and lead alloy sheaths for electric cables.

Specification for galvanised mild steel wire for armouring cables.

Methods of testing plastics

Specification for armoured cables wi th thermosetting insulation for electrical supplies.

PVC-insulated cables (non-armoured) for electric power and lighting.

Rubber-insulated cables for electric power and lighting.

Mineral insulated copper-sheathed cables with copper conductors.

PVC insulated cables for switchgear and controlgear wiring.

PVC-insulated cables for electricity supply.

Performance requirement for cables required to maintain circuit integrity under fire conditions.

Tests on gases evolved during the combustion of materials from cables.

Specification for impregnated paper insulated lead or lead alloy sheathed electric cables of rated voltages up to and including 33kV.

Specification for cables with extruded cross-linked polyethylene or ethylene propylene rubber insulation for rated voltages from 3.8/6.6kV up to 19133kV.

Specification for armoured cables for electricity supply having thermosetting insufation and low emission of smoke

and corrosive gases when affected by fire. (60011000V & 1900J3300V ratings).

DOC NO. KOC-E-023

BS 6883 Specification for elastomer insulated cables for fixed wiring in ships

BS 6899 Rubber Insulation & Sheath of Electrical Cables

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BS 721 1 Thermosetting insulated cables (non armoured) for electric power and lighting with low emission of smoke and corrosive gases when affected by fire. (450/750V rating.)

REV - 2

U.K. Industry Standards

EEMUA 133 Underground Armoured Cable Protected against Solvent Penetration and Corrosive Attack.

5.0 ENVIRONMENTAL CONDITIONS

The environment of Kuwait, is severe on all equipment and must be considered carefully before procurement of plant and equipment. It must be assumed that, unless otherwise specified, equipment may be subjected to sand and fine particle dust storms, sand laden winds, thunderstorms, heavy rains, chemical contaminants and extreme temperatures.

Humidity can pose a serious problem with long periods of relative humidity levels of 100% being part of the normal weather pattern.

Electrical components and materials shall be designed for continuous operation under ambient temperatures of 50C in the shade.

For buried cables a design temperature of 40C shall be used.

Specific attention shall be given to the following environmental factors:

(i) Exposure to seawater or salt spray.

(ii) Exposure to intense heat radiation from the sun or from a flare.

(iii) Excessively high or low ambient temperatures.

(iv) Exposure to oil contamination and water pressure.

6.0 MATERIAL DESIGN REQUIREMENTS

6.1 GENERAL

6.1.1 Voltage Designation

Power cables and wiring shall be designated for rated voltages (Uo/U) of 4501750V, 0.6/1, 1.913.3 or 6.3511 1 kV rms or other voltages as detailed in the attached data sheet.

6.1.2 Conductors

The conductors shall comply with IEC 228. For power cables the conductors shall be circular stranded or shaped stranded tinned copper. Plain annealed copper conductors shall be used where elastomeric insulation of conductors is not employed providing that the manufacturer confirms that the core insulation material will not corrode the conductors.

6.1.3 Insulation

Insulation of the cores shall be suitable for the specified voltage designation and duty. The insulation shall be applied by an extrusion process t o form a compact homogeneous body. Standard products should be purchased PVC, EPR, PlCC or XLPE all being acceptable as insulation on condition that performance requirements are met. Use of PlCC is subject t o KOC approval as it is being phased out. XLPE should be used in preference.

6.1.4 Filling and Bedding

The cable shall be circular and shall be substantially compact t o meet the requirements for direct entry into Ex(d) equipment. Fillers shall be used in the interstices between each core or pair, and any central voids, where it is not possible t o achieve a substantially compact and circular cross section with the extruded bedding.

6.1.5 Laying Up

The cores of all cables having t w o or more cores shall be laid with a right hand direction of lay. Alternate directions shall be used for successive layers of multicore cables. Twisting of cables shall not be permissable.

6.1.6 Armour (Metallic Covering) The armour specified in the Data Sheets shall be equal or an approved equivalent of that type which is detailed in IEC 92-3, clauses 10.1 9, 10.20 & 10.21. Single core cables shall have non-magnetic armouring such as aluminium.

6.1.7 Marking and ldentification of Cores, Sheaths and Drums.

DOC NO. KOC-E-023

a)CORES Armoured cable:

Non armoured:

b)SHEATH Colour:

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Marking:

REV - 2

Two cores - Red and Black

Three cores - Red, Yellow and Blue.

Four cores - Red, Yellow, Blue and Black.

Five cores and Above: White with black lett core.

Earthing cable: Yellow and Green stripes.

All voltages - Black Earth cable - Yellow and Green

.ering alon g the

To be embossed where practicable approx every metre: Manufacturers Name National/lnternational Standard ldentification Cable Designation: No of cores & core sizes

Voltage rating Sheath & Insulation type

All cable drums shall have their identification reference clearly stencilled on the outside of both flanges. Drum identification labels shall be attached on the outside and inside of the drum flange. Labels shall be robust and non-fading and give the following information.

- Drum identification number. - Voltage grade. - Cable construction (eg XLPE/LC/PVC, PVCISWAIPVC). - Number of cores and cross-sectional area. - Cable quantity. - Order number and item number. - Total weight of cable and drum.

Cables shall be drummed in maximum continuous lengths on non returnable cable drums with cable ends sealed and fixed t o the drums. Cable drums shall be fitted with battens, fixed around the entire periphery of the drum.

6.2 CABLE TYPES

6.2.1 Approved Cable Types

Cables shall have annealed stranded circular or shaped copper or tinned copper conductors and should normally be selected from the types listed below, subject to their being suitable for their operating environment and any special application.

All PVC outer sheaths shall be formed from flame retardant PVC meeting the test requirements set out in IEC 332 Part 3 CAT,A.

The use of paper insulated cables is subject to KOC approval and should only be considered where they can be justified on a cost basis otherwise XLPE insulated cables are to be selected in preference.

XLPE Insulated. PVC lnner Sheath, SWA, PVC Outer Sheath Power Cable to IEC 5021BS 6622 (XLPE/PVCshth/SWA/PVC) Voltage grade: 6.35/11 kV

Conductor Screen: Extruded semi-conductive compound.

Insulation: Cross linked polyethylene.

Core Identification: Coloured red, yellow, blue.

Insulation Screen: Extruded semi-conductive compound, bedding of semi-conductive tape and earth screen of copper tape.

Conductor Lay: Cores laid up with rubber filling to form a circular cable.

Inner Sheath: Plastic tape wrapping and bedding of extruded polyvinyl chloride.

Armouring: Galvanised steel wire.

Outer Sheath: Extruded polyvinyl chloride.

XLPE insulated. lead covered. PVC inner sheath. SWA. PVC outer sheath Power Cable to IEC 502lBS 6622 (XLPEILCIPVCshthlSWA/PVC Voltage grade: 6.3511 1 kV.

Conductor Screen: Extruded semi-conductive compound.

Insulation: Cross-linked polyethylene.

Core Identification: Coloured red, yellow, blue.

Insulation Screen: Extruded semi-conductive compound, bedding of semi-conductive tape and earth screen of copper tape.

Conductor Lay: Cores laid up with rubber filling to form a circular cable.

mer Sheath: Plastic tape wrapping and lead alloy sheath according to EEMUA 133.

3edding: Extruded polyvinyl chloride.

Armouring: Galvanised steel wires.


Paper Insulated, Lead Covered, Steel Wire or Tape Armour. PVC Outer Sheath Power Cable to BS 6480.

Voltage grade: 6.3511 1 kV

Conductor Screen: Semi conductor carbon paper.

Insulation: Paper tape, mass impregnated non-draining.

Insulation Screen: Non-ferrous metallic tape.

Core identification: Coloured red, yellow, blue.

Inner sheath: Plastic wrapping with lead alloy sheath according to EEMUA 133 or BS 801.

Bedding: Extruded polyvinyl chloride.

Armouring: Galvanised steel wires or tape.


XLPE Insulated. Lead Covered. PVC Inner Sheath. SWA. PVC Outer Sheath Power Cable to IEC 5021BS 5467 (XLPE/LClPVCshth/SWA/PVC. Voltage grade: 0.611 kV or 1.913.3 kV.


Core Identification: Up to four core colours (red, yellow, blue and black). Five cores and above coloured white with black numbers along the length of cores.

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Conductor Lay: Cores laid up with extruded PVC filler for up to five cores. For six cores or more wrapping of polyester tape.

Inner Sheath: Plastic tape wrapping and lead alloy sheath according to EEMUA 133.

Bedding: Extruded polyvinyl chloride.

Armouring: Galvanised steel wire. Single-core cables shall have aluminium wire armouring.


PVC Insulated. Lead Covered, PVC lnner Sheath, SWA, PVC Outer Sheath Power Cable to BS 6346 (PVCILCIPVCISWAIPVC. Voltage grade:

Insulation:

Core Identification:

Conductor Lay:

lnner Sheath:

Bedding:

Armouring:

Outer Sheath:

Extruded polyvinyl chloride.

Up to four core colours (red, yellow, blue and black). Five cores and above coloured white with black numbers along the length of cores.

Cores laid up with extruded PVC filler for up to five cores. For six cores or more wrapping of polyester tape.

Plastic tape wrapping and lead alloy sheath according to EEMUA 133.


Galvanised steel wire. Single-core cables shall have aluminium wire armouring.


EPR Insulated. CSP lnner Sheath. Steel or Comer Allov Braid. CSP Outer Sheath Power Cable to BS 6883 or IEC 92-3 for Flexible and Oil Resistant Duties.

Voltage grade: 0.611 kV to 6.3511 1 kV.

Insulation: Ethylene Propylene Rubber or equivalent type OR1 to

Inner Sheath: Chlorosulphinated polyethylene or equivalent as inner sheath and fillers of synthetic rubber compound type RS3 to BS 6899

Armour: Galvanised mild steel, tinned annealed copper or tinned bronze braiding.

Outer Sheath: Chlorosulphinated Polypropyleneorequivalent - Heat, Oil and Fire retardant synthetic rubber compound to BS 6883 type A, B, C or D selection dependent on requirements.

XLPE Insulated. PVC lnner Sheath, SWA, PVC Outer Sheath Power Cable to IEC 502lBS 5467 (XLPEIPVCshthlSWAIPVC Voltage grade: 0.611 kV or 1.913.3 kV.




Inner Sheath: Extruded polyvinyl chloride.

Armouring: Galvanised steel wire. Single-core cables shall have aluminum wire armouring.


PVC Insulated, PVC lnner Sheath. SWA. PVC Outer Sheath Power Cable to BS 6346 (PVCIPVCISWAIPVC Voltage grade: 0.611 kV

Insulation: Extruded polyvinyl chloride.



Inner Sheath: Extruded polyvinyl chloride.

Armouring: Galvanised steel wire. Single-core cables shall have aluminum wire armouring.


Mineral Insulated Comer Sheathed Cable (MICS) to BS 6207 Part 1 Heavy Putv with Moisture Resistant Insulation.

DOC NO. KOC-E-023 I Page 13 of 18

Voltage grade: 750 V

REV - 2

Insulation:

I

Compressed powdered mineral, chemically stable and non-corrosive to copper. A moisture resistant insulation version is now available (AEII.

Sheath: Annealed copper.

Outer Sheath: Extruded polyvinyl chloride. (When required) PVC insulated sinqle core cable for use in conduit and Earthinq cable to BS 6004. 6007 and 6231

Voltage grades: 4501750 V or 600t1000V

Insulation: Extruded polyvinyl chloride (colour to suit service). TESTING

Routine tests shall be carried out as per the applicable standard and certification provided to demonstrate these and any additional requirements stipulated for special applications e.g. Flame Retardant and Fire Resistant cables or Low Smoke and HCL emission.

SPECIAL APPLICATIONS

Flame Retardant Cables

For use in offshore environments. Cable constructed of materials which will not assist the spread of flame when the cable is exposed to combustion, meeting the test requirements set out in IEC 332.

Fire ~es is tant Cables

For use in essential circuits and accommodation in offshore environments. Cable constructed to allow continued normal operation for a period of 3 hours while exposed t o a temperature of 750C in accordance with IEC 331.

Low Halogen Acid and Smoke Emission

For use in manned offshore environments. A sample of each constituent component of the insulation, bedding and sheathing of the cable shall be tested in accordance with IEC 754 part 1. and the manufacturer shall state the total mass of acidic product released in the

data sheet and provide an analysis of the gas in compliance with BS 6425 Pt 2. Where low smoke emission and acid evolution are a requirement cables shall be specified to comply with the requirements of BS 6724, 721 1 & 6883 type D.

Oxygen lndex

For use in offshore environments. All non metallic material components of the cable shall be tested for Oxygen lndex according to the requirements of a National Standard such as BS 2782 P t l , Method 1410. The manufacturer shall state the value achieved and the standard used. A value of 28 or greater is required.

1

Additional tests for Fire Resistant Cables

DOC NO. KOC-E-023 1 Page 1 4 of 18

Fire and Impact Resistance

REV - 2

Fire resistant cable shall be capable of operating when exposed to a source of heat as detailed in IEC 331 and sustaining a degree of mechanical impact as detailed in BS 6387.

Water Resistance During a Fire

Fire resistant cables shall be capable of operating when exposed to a water spray during a fire as detailed in BS 6387. Cable ends are to be sealed to prevent ingress of moisture during the test. The insulation resistance of the cable during the test shall be not less than 1 megohm.

All tests are to be carried out on the same piece of cable.

Special Cables

Special cables for use in marine environments, as trailing cables or for submersible pump applications require additional features such as flexibility, resistance to pressure, heat and oil and flame retardancy. These should be selected from cables with synthetic rubber insulation and sheaths to suit the particular application.

DATA SHEETS

The information detailed on the data sheets (Appendix 1 .) shall be provided for each type and size of cable. Sheet 1 is for completion by the purchaser and the remaining sheets are for completion by the manufacturer.

10.0 DOCUMENTATION

All correspondence, drawings, instructions, catalogues, data sheets, design calculations or any other written information shall be in the English Language. All dimensions, units of measurements, physical constants, etc. shall be in'the SI units, unless otherwise specified.

11.0 QUALITY ASSURANCE

The manufacturer shall operate a quality system t o ensure that the requirements o f this Standard are achieved. The quality system shall be preferably based on I S 0 9000. Certification may be done by internationally reputed inspection agencies. Verification of a Vendor's quality system is normally part o f the pre- qualification procedure, and is therefore not detailed in the core text of this standard.

12.0 APPENDICES APPENDIX 1

CABLE DATA SHEET (KOC-E-023)

Data sheets for indent and purchase of cable To be completed in block capitals by purchaserfvendor

pHEET 1: TO BE COMPLETED BY THE PURCHASER

ITEM REF No: Type Refketter): Cable Type: Standard D Low Smoke & Acid Emission (Tick appropriate)

D Flame Retardant Fire Resistant 0 Special (see schedule) 1. Nominal Voltage D 4501750V 0.611 kV

2. Type: D DC 0 Single Phase a.c. O 3 Phase a.c. Other

DOC NO. KOC-E-023

3. Number of cores and Construction (See attached schedule)

4. Nominal cross sectional area of cores (See attached schedule)

t Page 1 6 of 18

5. Lengths (See attached schedule)

REV - 2

6. Conductors:

7. Insulation:

8. Bedding:

9. Sheath:

10. Armour:

11. Installation

Copper

0 As per attached schedule

0 As per attached schedule

As per attached schedule

0 SWA GSWA D SWBA

D Other

Other

0 Other

Other

D Other

D Tray D Buried D Unfilled Trenches

12. Certification: 0 None Routine Type

SHEETS 2 & 3: TO BE COMPLETED BY THE MANUFACTURERISUPPLIER

DOC NO. KOC-E-023

ITEM REF No:

1. Current Ratings in:- (Vendor standard ratings for standard conditions) Air:

Duct:

Ground:

Please supply details of standard conditions for temperatures, thermal resistivities, proximity other cables, etc.

2. Resistance (ohmlkm):

1 Page 17 of 18

Max d.c. at 20C Max a x . at 20C

REV - 2

3. Volt drop (per amp per metre) for each cable type:

4. Fault current (KA) for each cable type: Duration 2 5 0 degC

I

5. Diameter (mm): under arrnour

1.0 sec

0.5 sec 0.2 sec

over armour

overall

Conductor

6. Weight (kgikm) for each cable type:

Armour

For each cable type

7. Bending radius (mm) for each cable type:

8. Materials Used for each cable type:

Insulation:

Bedding:

Sheath:

Armour

9. Oxygen index for each cable type (where specified): (minimum 28)

10. Halogen Acid Evolution (where specified):

DOC NO. KOC-E-023 I Page 18 of 18 REV - 2

KOC_E_023

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