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1.5.1.3.5.03-Rev.

AUXILIARY AND CONTROL CABLES

INDEX

SECTION TITLE

1 General
1.1 Cable Design
1.2 Conductors
1.3 Insulation
1.4 Core Identification
1.5 Laying of Multicore Cables
1.6 Armour Bedding Multicore cables
1.7 Armour
1.8 Outer Protective Covering
1.9 Voltage Identification
1.10 Jointing Accessories & Termination
1.11 Sealing and Drumming
1.12 Termination of Auxiliary cables and
Identification of cores
1.13 Terminal Colouring and Labelling
1.14 Terminal Boxes
2 Installation of cables & Accessories
2.1 Depth of laying
2.2 Cable Segregation and Fire risk
2.3 Cable supports
2.4 Earthing and Bonding Multicore Cables
3 Routine, Type and Functional Tests at Manufacturer's
3.1 General
3.2 Auxiliary Power and Control Cables
4 List of standards

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1.5.1.3.5.03-Rev.1

AUXILIARY AND CONTROL CABLES

1 General
All PVC insulated multicore auxiliary cables shall be 600/1000 V
grade with stranded copper conductors. They shall conform to an
approved National Specification, IEC Recommendations, and to all
the applicable requirements of this Specification dealing with the
construction of power cables unless otherwise specified 2hereunder.
Conductors shall be stranded and not less than 2.5 mm in cross
section unless otherwise approved.
All auxiliary cables shall be PVC sheathed, wire armoured and PVC
sheathed overall unless otherwise specified.
1.1 Cable Design
This Specification applies to XLPE/PVC insulated single core and
multicore cables which shall be generally manufactured to IEC 502
or BS 5467.
1.2 Conductors
Conductors shall be of plain stranded annealed
2
copper wires to IEC
228 or BS 6360. Conductors less than 16 mm cross section shall be
of copper made up of seven strands. Single strand conductor is not
permitted.
1.3 Insulation
The insulation shall be of XLPE for auxiliary supply and for all
other cables it should be PVC insulated.
1.4 Core Identification
Cores shall be identified by colours in accordance with BS 5467.
The cores of control cables shall be identified in accordance with
clause 6 of BS 6346. When numerals are used, they shall be printed
in black on the white core insulation at intervals not greater than
70 mm throughout the length of the core. The print shall be
permanent and not easily removed.
1.5 Laying Up Multicore Cables

Cores shall be laid up in accordance with BS 5467.


1.6 Armour Bedding Multicore Cables
The armour bedding shall be of extruded PVC type ST1 or TM1.
1.7 Armour
The armour shall consist of a single layer of galvanised steel
wires complying with the requirements of BS 1442 or aluminium wires
for single core cables.

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1.8 Outer Protective Covering


The outer covering shall be of extruded PVC to meet the
requirements of BS 6746 or equivalent IEC Standard incorporating
fire retardant characteristics to meet the requirements of BS 4066
and IEC 332.
1.9 Voltage Identification
The outer covering shall be embossed with the name of the
manufacturer followed by: ELECTRIC CABLE 600/1000 VOLTS or LV
CONTROL CABLE in accordance with BS 6346 or BS 5467. The size of
cable, year of manufacture and type of insulation shall also be
included.
1.10 Jointing Accessories and Termination
Cables shall be terminated and jointed with accessories which have
successfully been type tested.
Straight through jointing of short cable lengths is not normally
permitted but, in exceptional circumstances may be allowed subject
to the Engineers' approval.
All cables entering or leaving terminal boxes shall be provided
with separate terminations so that any cable out of a number of
such cables can be removed or replaced without disturbing the
remainder.

1.11 Sealing and Drumming


Immediately after the Works Tests both ends of every length of
metal sheathed cable shall be sealed by means of a metal cap fitted
over the end and plumbed to the sheath. Other cables shall be
sealed by enclosing the ends in approved caps, which shall be tight
fitting and adequately secured to prevent ingress of moisture.
The ends of factory lengths of cable shall be marked "A" and "Z",
"A" being the end at which the sequence of core numbers is
clockwise and "Z" the end at which the sequence is anti-clockwise.
The cable end which is left projecting from the drum shall be
adequately protected against damage.
Cable drums shall be non-returnable and shall be made of timber,
pressure impregnated against fungal and insect attack or made of
steel suitably protected against corrosion. They shall be arranged
to take a round spindle and be lagged with strong closely-fitting
battens of minimum 40 mm thickness and in accordance with BS 1559.
Each drum shall bear a distinguishing number, either printed or
neatly chiselled on the outside of the flange.
Particulars of the cable, i.e., voltage, length, conductor size,
number of cores, finish, section and length number, gross and nett
weights, shall be clearly shown on one flange of the drum. In
addition the words "Running End "A"" or "Running End "Z"" shall be
marked on the flange and the direction for rolling shall be
indicated by an arrow. The method of drum marking shall be to the
Purchaser's approval.

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All cables and accessories shall be carefully packed for transport


and storage on Site in such a manner that they are fully protected
against all climatic conditions, particular attention being paid to
the possibility of deterioration during transport to the Site by
sea or overland and to the conditions prevailing on the Site.
Wooden drums shall be suitably constructed to avoid problems due to
shrinkage, rot and attack by insects.
Drums, cartes, cases, etc., for maintenance spares shall be non-
returnable. Cable maintenance lengths and spare lengths shall be
wound onto steel drums before they are handed over to the
Purchaser's stores. Particulars of the cable (as stated above)
shall be clearly marked.
The cables shall be wrapped on drums of suitable diameter such that
the radius of bend of the innermost layers is not less than the
minimum radius of bend stipulated in relevant BS/IEC for
installation of the cables. A steel boss shall be fixed over the
central lifting hole of the cable drum.

1.12 Termination of Auxiliary Cables and Identification of cores


The ends of each cable shall be terminated in brass, compression
type cable glands of the correct size, which shall secure the cable
inner sheath and ensure effective electrical continuity between the
cable armouring wires and the metal enclosures on which the cable
is terminated. Cable glands fitted on outdoor equipment shall also
incorporate suitable compression seals to secure the outer sheath
and shall be so designed and fitted that water cannot enter the
cable or the equipment via the cable termination. Where required, a
barrier shall be incorporated to prevent ingress of moisture via
the interstitial spaces in the cable. At all rising terminations,
the cable inner sheath shall pass through the gland to terminate
approximately 6 mm above the gland. Insulated glands and glands not
in an environmentally controlled atmosphere, shall be supplied
complete with close fitting insulating shrouds.
Where multicore cables provided under this contract connect with
plant and equipment supplied under another Contract, the Cable
Contractor shall leave sufficient lengths of tails to connect up to
the terminal boards. The Contractor shall also strip, insulate,
ring through and identify the tails with temporary tags, and shall
provide, fit and install the cable glands in accordance with the
requirements specified above.

1.13 Terminal Colouring and Labelling


Phase identification shall be marked in an approved manner on cable
boxes, tail ends and single core cables and at all connecting
points. Cable boxes shall be marked with stamped brass labels
indicating the purpose of the supply where such supply is not
obvious.

1.14 Terminal Boxes


The outer case of terminal boxes shall be constructed of steel
sheet or weather resistant reinforced plastic subject to approval
and fitted with one or more hinged covers provided with fasteners

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and padlocking facilities. The boxes shall be of IP56 for outdoor


installations and IP51 for indoor installations.
The case shall be adequately ventilated also dust and vermin proof.
Removable gland plates shall be provided at the top and bottom.
They shall be supplied complete with suitable insulating material
capable of withstanding the climatic conditions and test voltages
specified herein where the glands are required to be insulated from
the terminal boxes. If the width of the box necessitates the
provision of two hinged front covers they shall close on to a
centre post which shall be removable to facilitate cable
termination. The depth of the outer case shall be not less than 200
mm unless otherwise approved.
The outer cases shall be treated before painting to prevent
corrosion and shall be finished in glossy enamel to an approved
colour externally and white internally. Where terminal boxes are
required for installation outdoors or in damp situations, they
shall be of water tight construction and galvanized.
Terminal boards shall comprise banks of rail mounted, screw clamp,
spring loaded insertion, solder lug or stud type terminals as
required to suit the design and duty of the cables to be
terminated, arranged in pairs horizontally and grouped in vertical
formation to provide a rigid assembly. Each pair of terminals shall
be connected together at the base with a fixed or plug type link as
specified. Insulating material of self extinguishing or resistant
to flame propagation and substantially non-hygroscopic type shall
be moulded around the base of the screws or studs, links connecting
pairs of screws or studs or plug sockets to prevent exposure of
live metal at the back of the terminal boards and to secure the
terminals against rotation and displacement.
Stud type terminal boards shall have screws or studs of 5 mm dia.
for phosphor bronze or stainless steel, and 6 mm dia. for high
tensile brass, unless otherwise approved. They shall be complete
with the appropriate clamps, springs, nuts, locknuts and washers.
Terminal boards shall be complete with approved means for securing
the wires, identification ferrules, insulating barriers between
pairs of terminals and removable transparent non-inflammable
terminal covers fitted with marker strips for identifying the
terminals. All nuts, washers, links and other components provided
for securing the wires shall be electro-tinned. Springs shall be
aged and shall withstand corrosion.
The clearance between adjacent terminal boards and from the sides
of the case shall not be less than 100 mm. The minimum clearance
between terminal boards and the top and bottom of the case shall be
150 mm.
All terminal boxes and boards shall meet the associated cable site
tests.

2 INSTALLATION OF CABLES AND ACCESSORIES


2.1 Depth of Laying
The depth of laying cables for tendering purposes shall be as
stated in the latest revision of General Design Standard
1.1.0.0.0.01 of this Specification. Variation may be necessary to

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satisfy the requirements of the local and other authority or to


suit particular installation requirements. Any variations from the
specified depth shall be subject to approval.
2.2 Cable Segregation and Fire Risk
All cables shall be routed and connections designed to reduce fire
risk, outage and damage to other plant and buildings.
Cables shall be segregated to reduce damage if fire occurs and
avoid faulty operation of equipment due to induced voltages as
follows:-

i) Control and protection cables shall be separated from power


cables to avoid damage in the event of a power cable fault.
ii) Telephone, communication, analogue and digital system cables
shall at no point be less than 600 mm away from power
cables.
iii) All cable holes through walls and floors shall be sealed
with approved silicone foam fire seals or other approved
materials after the cables have been installed and the cost
thereof is deemed to be included in the Contract.
Each cable shall be run in one continuous length, straight through
joints will not be permitted unless specifically authorised by the
Engineer in writing.

2.3 Cable Supports


The Contractor shall supply and install all the supports, racks,
trays, cleats, saddles, clips and other parts required to carry and
secure the cables, without risk or damage, in a neat and orderly
manner. The spacing of all supports, racks, cleats, saddles and
clips shall be agreed by the Engineer. No cable shall be laid on
the trench floor. They shall be run in a neat and orderly manner
and the crossing of cables within the trench shall be avoided as
far as possible. Where cable runs unavoidably cross a suitable
ramp shall be provided so that the runs do not touch.
The design of all such items shall ensure freedom from rough edges,
burrs and sharp corners, and the materials used for the
construction and fixing thereof shall be approved by the Engineer.
No materials shall be supplied which will promote electrolytic or
other corrosive action in contact either between the various parts,
or with the cable sheaths or the building surfaces and other
materials with which they may make contact.
The cable supports required for installation with single core
cables, forming a three phase circuit, shall be so designed as to
permit the cables to be laid flat touching or spaced, or in close
trefoil or quadrature formation. Metal cleats may be used for this
purpose but in such cases approved insulation shall be provided
between the cable and the cleats.
Where single core cables in trefoil or quadrature formation are not
secured in cleats, binders of approved material and construction
shall be fitted around the formation to prevent the cables
separating under fault conditions. The binders shall consist of a
non-ferrous strap secured around the cables by means of a bolted
connection. The spacing of binders shall be approved by the

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Engineer. Single core and multicore cables shall be clamped to


the racks with smooth finish split packing pieces or cleats with
bores of the correct size for the cable diameters.
The design of cable support for cables installed in air in cable
tunnels, basements, etc., shall consist of vertical steel members
spaced at approved intervals and secured to the walls, floors and
ceilings as necessary by means of bolts either cemented in position
or expanded into cored holes. Each vertical support shall have
bolted to it a number of steel brackets spaced at the intervals and
designed to support and retain trays constructed of galvanized
sheet steel of adequate section to carry the weight of the cables,
plus space for an additional quantity of future cables not less
than 25% by weight and dimensions in excess of the cables installed
under this Contract and an additional load of 100 kg at the
extremity without distortion. The trays shall be designed with
raised edges to retain the cables and shall incorporate an
interlocking feature so as to prevent movement between supports.
Solid sheet steel trays shall have drainage holes and shall be
drilled to accommodate cable cleats at an agreed spacing to support
single core cables in the desired formation.
The design of support for situations where trays are not required
shall in general consist of a metal rack within which is contained
one or more pairs of cleats shaped to suit the formation of the
cables. Cable cleats shall be of an approved non-corrosive material
having no deleterious effect on cable coverings or supporting steel
work. Aluminium or aluminium alloy cleats shall not be used. Cleats
for carrying a single core cable shall be non-magnetic and the
arrangement shall not permit any closed magnetic circuit around the
cable.
The steel used in construction of cable supports shall be
galvanized.
The design and construction of all cable cleating and supporting
arrangements shall suit the cable system design. The spacing of
cable supports shall be approved by the Engineer.
Where cables are cleated to the floor of cable tunnels or
basements, they shall be protected by heavy gauge galvanized steel
shrouds with steep sloping top, and firmly secured to the floor.
The shrouds shall be adequately ventilated. Where a cable circuit
is protected by a shroud and occupies a width greater than 450 mm,
a suitable heavy duty steel step shall be provided over the cables
to allow personnel to easily cross the obstruction.
Cable trays shall be of perforated steel subsequently galvanised in
accordance with BS 729 with a heavy duty flange. Cable ladders
shall be of galvanised steel. All trays and ladders shall be to
the approval of the Engineer and shall be supported on steelwork or
masonry as required. Multicore power cables shall be tied to the
tray or ladder with plastic ties to the approval of the Engineer.
Cable cleats shall be spaced as follows:-.
600mm for cables up to 40 mm overall diameter
1000mm for cables between 40 mm and 60 mm overall diameter
2000mm for cables exceeding 60 mm overall diameter on horizontal
runs and
1200mm on vertical runs.
Cables run on trays shall be neatly dressed and where not provided
with cleats shall be secured by heavy gauge, type approved metal
reinforced, clips or saddles. Not more than six cables shall be

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embraced by one clip and not more than two layers of cables run on
one tray. Care shall be exercised to ensure a "Reduced Fire
Propagation" installation.
Every cable shall be supported at a point not more than 500 mm from
its termination.
2.4 Earthing and Bonding Multicore Cables
The metallic sheath and armour of multicore cables shall be bonded
together and earthed.
Cable
2
earthing conductors shall be copper strip of not less than 95
mm section laid in formed cable trenches or ducts, or fixed to
walls, concrete or steel work, by means of clamps or claw type
cleats, appropriately secured into suitable wall plugs or tapped
holes. The spacing of fixings shall not be greater than 1 m. Where
earth strip is buried or laid in positions in which there is danger
of corrosion it shall be provided with a corrosion-proof serving of
extruded thermo-plastic or self-adhesive PVC tape which for short
lengths may be hand applied on Site.
The Contractor shall connect, unless otherwise instructed, all
cable sheaths and armour, supporting steel work and the metal
enclosure of sealing boxes, joints, etc., to the main earth bar by
suitable branch connections which may be of bare or insulated
stranded conductor as required to suit the cable system.
Concentric type bonding leads of suitable impedance shall be
employed where necessary . The bonding and earthing system shall be
subject to the approval of the Engineer and shall be designed to
meet the subsequent maintenance requirements.
3. ROUTINE, TYPE AND FUNCTIONAL TESTS AT MANUFACTURER'S
WORKS
3.1 General
The works tests shall include all routine electronic, electrical
and mechanical tests when relevant in accordance with the
appropriate IEC Standard, and in addition any tests called for by
DEWA to ensure that the individual plant or equipment being
supplied meets the requirements of the Specification.
Acceptance tests during inspection by DEWA's engineer in the works
of manufacturer shall comprise all the routine tests specified for
the items under inspection on samples which will be selected by
DEWA's engineer. In addition, any of the specified type tests may
be required to be carried out in his presence, if satisfactory
evidence of carrying out such tests is not available.
3.2 Auxiliary Power and Control Cables
Routine tests in accordance with IEC.227 or BS.6346:1969, or
BS.5467:1967 and subject to approval of DEWA.
Tests at site
Voltage test to B.S. 6346 Appendix B6 or alternatively cables may
be tested with a 2000V Megger insulation tester

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4. LIST OF STANDARDS
BS1442 Specification for galvanised mild steel wire for armouring
cable.
BS2484 Specification for straight concrete and clayware cable
covers.
BS 4066 Part 3: Tests on electric cables under fire conditions.
BS 5467 Cables with thermosetting insulation for electricity
supply for rated voltages of up to and including
600/1000V and up to and including 1900/3300V.
BS 6004 Specification for PVC insulated cables (non
armoured) for electric power and lighting.
BS 6121 Mechanical cable glands.
BS 6234 Specification for polythene insulation and sheath of
electric cable.
BS 6360 Specification for conductors in insulated cables and
cords.
BS 6346 PVC-insulated cables for electricity supply
BS 6746 Specification for PVC insulation and sheath of
electric cables.
IEC 189-2 Cables in pairs, triples, quads, quintuples for
inside installations.
IEC 228 Conductors of insulated cables.
IEC 332 Tests on electric cables under fire conditions.
IEC 287 Calculation of continuous current rating of cables
(100% load factor).
IEC 502 Extruded solid dielectric insulated power cables for
rated voltages from 1 kV up to 30 kV.
IEC 840 Tests for power cables with extruded insulation for
rated voltages above 30kV upto 150kV.
IEC 885 Electrical test methods for electric cables.
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