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Lauren Engineers & Constructors, Inc.

Abilene, Texas

Section No. 26 05 13.16 Rev. 0

High Tension Single- and Multi-Core Cables

January 9, 2012

For

GGEL Solar Plant

Rajasthan, India

Godawari Green Energy Limited

LEC Job No. LCC001-200

Interdiscipline Reviews
Discipline Reviewer Date
Process E Vermillion 12/15/11
Civil/Structural J Buxkemper 12/15/11
Electrical D Joiner 1/09/12
I&C R Heard 12/13/11
Mechanical B Anders 12/23/11

Name Company - Title Date


Originator David Joiner, P.E. LEC – Sr. Electrical Engineer 11/08/11
Verifier Kevin Hargis, P.E. LEC – Sr. Electrical Engineer 11/08/11
Project Engineer David McWright, P.E. LEC – Project Engineer 12/23/11
Owner Approval
LCC001-200 GGEL SOLAR PLANT
January 9, 2012 RAJASTHAN, INDIA

TABLE OF CONTENT

PART 1 GENERAL 1 
1.01  SUMMARY 1 
1.02  REFERENCES 1 
1.03  SUBMITTALS 2 
1.04  QUALITY ASSURANCE 2 
1.05  DELIVERY, STORAGE, AND HANDLING 2 
PART 2 PRODUCTS 3 
2.01  EQUIPMENT 3 
2.02  CABLE MARKINGS 3 
2.03  6.6 KV POWER CABLE 3 
2.04  11 KV POWER CABLE 4 
2.05  SOURCE QUALITY AND CONTROL 5 
PART 3 EXECUTION 5 
3.01  INSTALLATION 5 
3.02  CONNECTIONS AND TERMINATIONS 6 
3.03  SITE QUALITY CONTROL 7 
3.04  ATTACHMENTS 7 

DAVID JOINER, P.E. HIGH TENSION SINGLE- AND MULTI-CORE CABLES


REVISION 0 26 05 13.16 - i
LCC001-200 GGEL SOLAR PLANT
January 9, 2012 RAJASTHAN, INDIA

SECTION 26 05 13.16
HIGH TENSION SINGLE- AND MULTI-CORE CABLES

PART 1 GENERAL

1.01 SUMMARY

A. Section Includes:

Specific requirements, products, and methods of execution relating to high tension power
cable. Cables furnished shall be single-core or multi-core, copper or aluminum conductor
as specified, XLPE insulated, armoured, with PVC outer sheath. Cables shall be suitable
for installation in cable tray, in conduit, and in underground duct bank.

B. Related Requirements:
1. Section 01 31 19 – EXISTING CONDITION INFORMATION
2. Section 01 33 00 – SUBMITTAL PROCEDURES
3. Section 26 05 33.19 – RACEWAYS FOR ELECTRICAL SYSTEMS
4. Section 26 05 36 – CABLE TRAYS FOR ELECTRICAL SYSTEMS
5. Section 26 05 06.29 – ELECTRICAL CABLE INSTALLATION IN CONDUIT
6. Section 26 05 53 – IDENTIFICATION FOR ELECTRICAL SYSTEMS

1.02 REFERENCES

A. Abbreviations and Acronyms:


1. International Electrotechnical Commission (IEC)
2. Bureau of Indian Standards (BIS)
3. Oil Industry Safety Directorate (OISD)
4. Polyvinyl Chloride (PVC)
5. Cross-Linked Polyethylene (XLPE)
6. Flame Retardant (FR)
7. Flame Retardant – Low Halogen Smoke (FR-LHS)

B. Definitions:
1. Vendor – Recipient of award of any Purchase Order or Contract for supply of the
equipment specified herein.
2. Purchaser – Lauren-Jyoti JV
3. Contractor – The Company that has a contract with the Owner to perform the work.
4. Subcontractor – The Company that has a contract with the Contractor to perform
certain portions of the work.
5. Engineer – Lauren CCL Engineers Pvt. Ltd.
6. Owner – Godawari Green Energy Limited.

C. Reference Standards (latest issue):


1. BIS SP 30 - National Electrical Code
2. IS 1255 – Code of Practice for Installation and Maintenance of Power Cables Up To
and Including 33kV Rating
3. IS 3961 – Recommended Current Ratings for Cables
4. IS 3975 – Mild Steel Wire, Formed Wires and Tapes for Armouring Cables
5. IS 5561 – Specification for Electric Power Connectors

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6. IS 5831 – Specification for PVC Insulation and Sheath of Electric Cables


7. IS 7098 ( Part 2) – Specification For Cross-Linked Polyethylene Insulated PVC
Sheathed Cables For Working Voltages From 3.3 kV Up To and Including 33kV
8. IS 8130 – Specification for Conductors for Insulated Electric Cables and Flexible
Cords
9. IS 10810 (Part 43) – Method of Test for Cables: Part 43 Insulation Resistance
10. IS 10810 (Part 45) – Method of Test for Cables: Part 45 High Voltage Test
11. IS 13573 – Joints and Terminations for Polymeric Cables for Working Voltages from
6.6 kV up to and Including 33kV.
12. IEC 60228 – Conductors of Insulated Cables
13. IEC 60332 – Test for Electric Cables Under Fire Conditions
14. IEC 60501 – Power Cables with Extruded Insulation and their Accessories for Rated
Voltages from 1kV (Um = 1,2kV) up to 30kV (Um = 36kV)
15. IEC 60502 – Extruded Solid Dielectric Insulation Power Cables for Rated Voltages
from 1kV to 30kV
16. IEC 60754 – Test on Gases Evolved During Combustion of Electrical Cables
17. IEC 61034 – Measurement of Smoke Density of Cables Burning Under Defined
Conditions
18. IEC 60811 – Common Test Methods for Insulating and Sheathing Materials of
Electric Cables
19. OISD 147 – Inspection and Safe Practice During Electrical Installation
20. OISD 173 – Fire Prevention and Protection System for Electrical Installation

1.03 SUBMITTALS

A. Product data for electrical wires, cables, and connectors.

B. Manufacturer’s recommended installation procedures.

1.04 QUALITY ASSURANCE

The products of each type shall be designed, manufactured and tested in facilities registered to
ISO 9001 quality standards.

1.05 DELIVERY, STORAGE, AND HANDLING

A. Storage and Handling Requirements:


1. Handling:
a. The cable, with or without drum or reel, shall not be thrown or dropped on the
ground during unloading from the carrier trucks.
b. The cable drums or reels shall be unloaded with the use of cranes or forklifts,
using proper ramp having inclination of 1:3 to 1:4 in order to avoid mechanical
damage to the outer layers of the cable.
c. The cable drums or reels shall always be lifted or stored with their flanges
vertical.
d. The cable drum or reel shall be rolled in the direction of arrow only in order to
avoid loosening of cable winding. The drum or reel shall not be rolled on rocky,
uneven surfaces or for long distances, as this may damage the drum or reel and
cable.

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January 9, 2012 RAJASTHAN, INDIA

e. Remove all nails and staples from the reel flanges before moving a reel, and
avoid all objects that would crush, damage, or impact the cables when moving.
Never use the cable as a means to move a drum or reel.
f. When unreeling, observe recommended cable bending radii, use swivels to
prevent twisting and avoid over runs.

B. Storage:
a. The cables shall be stored in dry covered places having concrete or firm surface
capable of bearing the load of the drum.
b. The cable ends shall be sealed properly in order to prevent moisture ingress.
c. Anti-rodent/termite repulsion treatment shall be applied to the site where the
drums are stored for an extended period of time.

PART 2 PRODUCTS

2.01 EQUIPMENT

A. Approved Manufacturers:
1. Finolex Cables Ltd.
2. Gemscab Industries Ltd.
3. Gloster Cables Limited
4. Havells India Ltd.
5. Helukabel India Pvt. Ltd.
6. KEI Wires & Cables
7. Nicco Corporation Limited
8. Torrent Cables Ltd.
9. Universal Cables Ltd.
10. Engineer approved equal.

2.02 CABLE MARKINGS

The outer sheath of each cable shall be marked as described by IS 7098 (Part 2) Section 20.
The cables shall be flame retardant rated and be marked “FR.”

2.03 6.6 KV POWER CABLE

A. Description
1. Cable shall be armoured having both conductor and insulation screening and shall
have an overall outer sheath. Cable shall conform to IS: 7098 (Part 2) for cross-linked
polyethylene insulation (XLPE). Cable shall be suitable for operation on a 6.6kV
+5%/-10%, 50 Hz., 3-phase, 3 wire, electrical system earthed through a transformer
neutral grounding resistor. Cable core configuration, conductor type and conductor
sizes shall be provided for each circuit in accordance with the project Circuit
Schedule.
2. Voltage grade: 6.6/6.6kV.
3. Conductor: stranded compacted circular copper or aluminum wires complying with
IEC 60228 and IS: 8130. Conductor type shall be as listed in the project Circuit
Schedule.
4. Conductor Strand Screen: Extruded semi-conducting XLPE, meeting or exceeding
requirements of IEC 60502 and IS: 7098 (Part 2).

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RAJASTHAN, INDIA January 9, 2012

5. Insulation: Cross-linked polyethylene (XLPE), not less than 3.6 mm average


thickness, meeting or exceeding requirements of IEC 60502 and IS: 7098 (Part 2).
6. Insulation Screen: Extruded semi-conducting XLPE insulation screen applied directly
over the insulation, meeting or exceeding requirements of IEC 60502 and IS: 7098
(Part 2).
7. Individual cores on multi-core cables shall be identified by applying coloured strips
(red, yellow, blue) or by printing numerals (1, 2, 3) on the cores.
8. Insulation Shield: 0.125 mm thickness, coated copper tape, helically applied.
9. Filler and Inner Sheath: Material shall be thermoplastic material and shall not be
harder than the insulation or outer sheath. The materials shall be chosen to be
compatible with temperature rating of the cable.
10. Armouring: The armour material for single-core cables shall be metallic non-
magnetic wire/strip only; armour material for multi-core cables may be either
galvanized round steel wire/strip or metallic non-magnetic wire/strip. The galvanized
steel wires/strips shall comply with the requirements of IS: 3975.
11. Outer Sheath: Material shall be black polyvinyl chloride (PVC). Outer sheath shall be
sunlight resistant, suitable for cable tray installation, and flame retardant. The outer
sheath shall pass the vertical flame test requirements of IEC 60332.
12. Temperature Rating:
90 degrees Celsius Conductor Temperature Continuous
250 degrees Celsius Conductor Temperature at Short Circuit Conditions
13. Factory Tests: Cable shall conform to the requirements of IS: 7098(Part 2). Routine
acceptance tests including conductor resistance test, partial discharge test, and high
voltage 17 kV AC test shall be performed on each core of every cable.

2.04 11 KV POWER CABLE

A. Description
1. Cable shall be armoured having both conductor and insulation screening and shall
have an overall outer sheath. Cable shall conform to IS: 7098 (Part 2) for cross-linked
polyethylene insulation (XLPE). Cable shall be suitable for operation on a 10.5kV +/-
10%, 50 Hz., 3-phase, 3 wire, electrical system either unearthed or earthed through a
generator/transformer neutral grounding resistor. Cable core configuration, conductor
type and conductor sizes shall be provided for each circuit in accordance with the
project Circuit Schedule.
2. Voltage grade: 11/11kV.
3. Conductor: stranded compacted circular copper or aluminum wires complying with
IEC 60228 and IS: 8130. Conductor type shall be as listed in the project Circuit
Schedule.
4. Strand Screen: Extruded semi-conducting XLPE, meeting or exceeding requirements
of IEC 60502 and IS: 7098 (Part 2).
5. Insulation: Cross-linked polyethylene (XLPE), not less than 5.5 mm average
thickness, meeting or exceeding requirements of IEC 60502 and IS: 7098 (Part 2).
6. Insulation Screen: Extruded semi-conducting XLPE insulation screen applied directly
over the insulation, meeting or exceeding requirements of IEC 60502 and IS: 7098
(Part 2).
7. Individual cores on multi-core cables shall be identified by applying coloured strips
(red, yellow, blue) or by printing numerals (1, 2, 3) on the cores.
8. Insulation Shield: 0.125 mm thickness, coated copper tape, helically applied.

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LCC001-200 GGEL SOLAR PLANT
January 9, 2012 RAJASTHAN, INDIA

9. Filler and Inner Sheath: Material shall be thermoplastic material and shall not be
harder than the insulation or outer sheath. The materials shall be chosen to be
compatible with temperature rating of the cable.
10. Armouring: The armour material for single-core cables shall be metallic non-
magnetic wire/strip only; armour material for multi-core cables may be either
galvanized round steel wire/strip or metallic non-magnetic wire/strip. The galvanized
steel wires/strips shall comply with the requirements of IS: 3975.
11. Outer Sheath: Material shall be black polyvinyl chloride (PVC). Outer sheath shall be
sunlight resistant, suitable for cable tray installation, and flame retardant. The outer
sheath shall pass the vertical flame test requirements of IEC 60332.
12. Temperature Rating:
90 degrees Celsius Conductor Temperature Continuous
250 degrees Celsius Conductor Temperature Short Circuit
13. Factory Tests: Cable shall conform to the requirements of IS: 7098 (Part 2). Routine
acceptance tests including conductor resistance test, partial discharge test, and high
voltage 28 kV AC test shall be performed on each core of every cable.

2.05 SOURCE QUALITY AND CONTROL

A. Tests and Inspections:


1. Routine Tests - The following shall constitute routine tests that shall be made on all
finished cable lengths to demonstrate the integrity of the cable:
a. Conductor resistance tests
b. High voltage test at room temperature
c. Partial discharge test
2. Type Tests including flammability tests shall be made before supply on a general
commercial basis on each type cable in accordance with IS: 7098 (Part 2) Section
18.1.
3. Acceptance Tests including flammability tests shall be made on lot samples of cables
in accordance with IS: 7098 (Part 2) Section 18.2.

PART 3 EXECUTION

3.01 INSTALLATION

A. System Integration:

Install all cables in accordance with IS: 1255, manufacturer’s recommendations and
project installation specifications and drawings.
1. High tension cable shall be installed in cable tray or conduit in accordance with IS
1255 and with Section 26 05 06.29 – ELECTRICAL CABLE INSTALLATION IN
CONDUIT. All required lugs, connectors, terminators, insulating materials, etc., shall
be furnished by the Contractor.
2. Prior to pulling, all cables installed in conduits shall be lubricated with an approved
pulling lubricant that is compatible with cable materials. Cables shall be pulled
through conduits using a rotating eye swivel, which shall be separate from the means
of cable attachment. Pulling attachment to cable shall include attachment to both
conductors and armour.
3. Cable glands shall be provided for armoured cable entry into all equipment
enclosures. Cable glands shall be nickel- plated brass unless shown otherwise on the
project drawings. Single compression type cable glands shall be used for indoor

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panels and equipment. Cable glands for outdoor equipment shall be weather-
protected double compression type. The size of cable glands shall be appropriate for
the size of the cable to ensure sealing and shall be rated for hazardous areas where
applicable. Entry thread of cable gland shall match threading of equipment where
provided or adapters shall be provided.
4. All high tension power cables shall have the cable shield and armour connected to
earth through an earthing strap at the source end cable termination. The Contractor
shall ensure that the earthing straps on cables installed through zero-sequence type
current transformers are passed through the current transformer window to earth for
proper operation of earth fault relays.
5. Earthing of metallic shields shall be accomplished by a solderless connector enclosed
in a watertight rubber housing covering the entire assembly. The earthing device and
splice or terminator shall be of same manufacturer to insure electrical integrity of the
shielded parts.
6. Each circuit installed by the Contractor shall have the cables permanently marked
with the appropriate feeder identified on the one-line diagrams and project Circuit
Schedule. Identification of the cables shall be by both feeder name, and circuit
number. Marking shall be provided on each phase of single core cables, at each end
termination and in each manhole or vault.
7. All cables pulled into manholes, vaults or cable trays shall be laid in a neat, orderly
manner. Cables shall be parallel and not intertwined. Cables in cable trays shall be
installed with all three phases for a given circuit in trefoil configuration or adjacent to
each other. If, in the Purchaser’s judgment, the Contractor does not comply with this
requirement, the Contractor shall remove all cable and reinstall the cable under the
direction of the Purchaser, without additional cost to the Purchaser.
8. Cables shall be installed in a manner to provide as much slack in manholes and vaults
as practicable.

3.02 CONNECTIONS AND TERMINATIONS

A. System Integration:
1. All high tension cable connections and terminations shall be installed by individuals
trained in the installation of the type of terminators used.
2. Terminations and connections shall be made with approved molded rubber kits
meeting IS: 13573 requirements that are suitable for the cable voltage and type.
Submit manufacturers' data and instructions for approval. Installation shall closely
follow the manufacturer’s instructions.
3. Terminate all power cables with minimum 2-hole, long barrel, tin-plated compression
lugs suitable for the voltage. Copper lugs shall be provided for copper conductor and
aluminum lugs shall be provided for aluminum conductors.
4. Cable splices shall be made with approved splice kits meeting IS: 13573
requirements that are suitable for the cable voltage and type. Submit manufacturers'
data and instructions for approval. Installation shall closely follow the manufacturer’s
installation instructions.
5. The Contractor shall drill all holes, where not drilled by the equipment manufacturer,
in the equipment connection terminals to accommodate the lugs specified herein.
Holes shall be free of filings and other debris.
6. Cables terminating on switchgear bus, transformers, or other equipment shall be
provided with a Raychem type HVBT or approved equal heat shrink kit to
completely insulate the equipment and cable connection.

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LCC001-200 GGEL SOLAR PLANT
January 9, 2012 RAJASTHAN, INDIA

3.03 SITE QUALITY CONTROL

A. Site Tests and Inspections:


1. After installation of the cables, and prior to the high potential test specified below,
the Contractor shall perform a simple continuity test on each core of the cables. The
continuity test shall test the shield and conductor to ensure continuity of each.
2. After the continuity test, the Contractor shall perform an insulation resistance test
using a 5000-volt megger.
3. After successful continuity and megger tests, the Contractor shall perform high
potential tests in accordance with IS: 1255 and per manufacturer’s instructions on
each high tension cable in the system, with terminations in place but disconnected
from the equipment on each end. The test voltages shall be applied in accordance
with IS: 1255 and the cable manufacturer’s recommendations.
4. The installation shall withstand, for a minimum of five minutes, a DC test potential
as follows:

INSULATION INSULATION FIELD DC ACCEPTANCE


RATED THICKNESS (mm) TEST VOLTAGE
VOLTAGE

6.6/6.6 kV 3.6 18 kV

11/11 kV 5.5 30 kV

5. If the test voltage applied is increased continuously, the rate of increase shall be
approximately uniform, increasing to maximum voltage in not less than 10 seconds
and in not more than 60 seconds.
6. If the test voltage is applied in steps, the rate of increase of test voltage from one step
to the next shall be approximately uniform. The duration at each step shall be long
enough for the absorption current to attain reasonable stabilization (one minute
minimum). Current and voltage readings shall be taken at the end of each step
duration. The number of steps shall be from three to five depending on cable rating.
7. After high potential testing is completed, cable terminations shall be connected to the
equipment. Phase rotation testing of equipment shall be made, if applicable.
8. All high tension cable terminal lug bolt torque levels shall be checked with a torque
wrench and recorded for each circuit. Torque wrench testing shall be witnessed by
Purchaser’s representative. Torque levels shall be in accordance with equipment
manufacturer’s recommendation.

3.04 ATTACHMENTS

Submit the attached high potential test report completed for each cable.
WARNING: A hazardous voltage may still exist on the cable after the above testing has
been completed. Therefore, before handling the cable, the conductor shall be grounded to
permit any charge to drain to earth.

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REVISION 0 26 05 13.16 - 7
GGEL SOLAR PLANT LCC001-200
RAJASTHAN, INDIA January 9, 2012

HIGH TENSION CABLE – DC HIGH POTENTIAL VOLTAGE TEST REPORT


Date: Job No.: Location:
Conduit Cable No.: Rated kV: Cable Size:
Cable Insulation: Manufacturer: Reel No.: Cable
Equipment From: Equipment To:
Test Equipment: Serial No.: Model No.:
Ambient Humidity: Environmental Conditions:
Type of Splice: No. ___ of ___ Type of Termination: No. __ of ___
LEAKAGE CURRENT Time vs. Current Data
Test kV Time
(Macro- AMPS) For Graph

15 Phase Phase Phase LEAKAGE CURRENT


6.6kV 11kV
Min. L1 to L2 to L3 to Time
Cable Cable Phase Phase
Max Shield Shield Shield Phase L3
L1 L2
5 5 15 sec
10 10 30 sec
15 15 45 sec
18 20 1 Min.
25 2 Min.
30 3 Min.
4 Min.
5 Min.
6 Min.
7 Min.
8 Min.
Remarks: 9 Min.
10 Min.
12 Min.
13 Min.
14 Min.
15 Min.

Performed By _________________________ Contractor Date __________________


Witnessed By _________________________ Purchaser Date __________________
Accepted By _________________________ Purchaser Date __________________

- End of Section -

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26 05 13.16 - 8 REVISION 0