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SJjCTION 16055:

GUIDELINE SPECIFICATION FOR GENERAL PROVISIONS OF LOW VOLTAGE ELECTRICAL WORKS

0 REV

31/01/06 DATE

I Issued for Use

DESCRIPTION

~ PREPARED BY RC APPROVED

KINGDOM OFSAUDI RABIA A

Royal Commission lorJubail Yanbu &

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SECTION 16055 GENERAL PROVISIONS OF LOW VOLTAGE ELECTRICAL WORKS

TABLE OF CONTENTS Item No Title Page No

PART 1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 PART 2 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10 2.11 Rev 0

GENERAL............................................................................................................ 1 DESCRIPTION OF WORK .................................................................................. 1 SECTION INCLUDES .......................................................................................... 1 RELATED SECTIONS ......................................................................................... 1 REFERENCES..................................................................................................... 2 DEFINITIONS....................................................................................................... 4 SUBMITTALS....................................................................................................... 5 QUALITY CONTROL ........................................................................................... 6 HEALTH AND SAFETY CONSIDERATIONS...................................................... 6 FACTORY TESTING ........................................................................................... 6 SERVICE CONDITIONS...................................................................................... 7 DELIVERY, HANDLING AND STORAGE ........................................................... 8 PRODUCTS ......................................................................................................... 9 GENERAL ............................................................................................................ 9 RACEWAY AND BOXES ..................................................................................... 9 CABLE TRAYS .................................................................................................... 9 WIRING DEVICES ............................................................................................. 11 WIRES AND CABLES........................................................................................ 11 CONNECTORS, TERMINALS, SPLICES AND TAPES .................................... 13 DISCONNECT AND SAFETY SWITCHES........................................................ 15 CIRCUIT BREAKERS ........................................................................................ 15 PANELBOARDS ................................................................................................ 15 LOW VOLTAGE SWITCHBOARDS .................................................................. 15 MEASURING INSTRUMENTS .......................................................................... 15 i Contract No:

SECTION 16055 GENERAL PROVISIONS OF LOW VOLTAGE ELECTRICAL WORKS

TABLE OF CONTENTS (Contd.) Item No 2.12 2.13 PART 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09 3.10 3.11 3.12 3.13 Title Page No

INSTRUMENT TRANSFORMERS .................................................................... 17 LIGHTING AND POWER DISTRIBUTION TRANSFORMERS ......................... 17 EXECUTION ...................................................................................................... 18 GENERAL .......................................................................................................... 18 EXCAVATION AND BACKFILLING................................................................... 19 FOUNDATIONS AND SUPPORTS ................................................................... 20 EQUIPMENT ERECTION .................................................................................. 21 INSTALLATION OF CABLE TRAYS.................................................................. 21 INSTALLATION OF ELECTRICAL CONDUITS ................................................ 23 INSTALLATION OF BOXES, CUBICLES AND WIRING DEVICES .................. 25 INSTALLATION OF DUCT BANKS AND MANHOLES ..................................... 27 INSTALLATION OF LOW VOLTAGE DIRECT BURIED CABLES.................... 28 INSTALLATION OF CONDUCTORS................................................................. 28 EQUIPMENT CONNECTIONS .......................................................................... 30 PAINTING .......................................................................................................... 31 TESTING AND COMMISSIONING .................................................................... 31

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SECTION 16055 GENERAL PROVISIONS OF LOW VOLTAGE ELECTRICAL WORKS

PART 1

GENERAL

1.01 DESCRIPTION OF WORK A. This Section specifies the minimum technical requirements for design engineering, furnishing, manpower, installation and supervision of General Provision of Low Voltage Electrical Works as per the Contract Documents. The Contractor shall, as part of his full responsibility and scope, check all the General Provision of Low Voltage Electrical Works as specified in the Contract Drawings and Documents. When this check indicates that the specified electrical works are not adequate, the Contractor shall notify the Royal Commission and take the necessary action/changes with prior approval by the Royal Commission. The Contractor shall also check and verify all requirements, aspects and details necessary for coordinating with new or existing systems of electrical works. These Specifications define the minimum requirements for low voltage electrical works with either IEC/SASO or North American based standards, as specified in par. 1.04. Where works interface with Saudi Electricity Company (SEC), the equipment/materials and installation system shall comply with latest revision of SEC standards and shall be reviewed and approved by SEC.

B.

C.

D.

E.

1.02 SECTION INCLUDES A. This Section specifies furnishing, installing, connecting and testing of General Provision of Low Voltage Electrical Works.

1.03 RELATED SECTIONS A. B. C. D. E. F. G. H. I. Section 01320 Section 01330 Section 01410 Section 01450 Section 01650 Section 01660 Section 02315 Section 02580 Section 03310 Construction Progress Documentation Submittal Procedures Regulatory Requirements Quality Control Product Delivery Requirements Product Storage and Handling Requirements Excavation and Fill Electrical and Communication Structures Structural Concrete

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SECTION 16055 GENERAL PROVISIONS OF LOW VOLTAGE ELECTRICAL WORKS

J. K. L. M. N. O. P. Q. R. S. T.

Section 09910 Section 09960 Section 09970 Section 16060 Section 16075 Section 16120 Section 16130 Section 16140 Section 16270 Section 16410 Section 16440

Painting High Performance Coatings Coatings for Steel Grounding and Bonding Electrical Identification Conductors and Cables Raceway and Boxes Wiring Devices Transformers Enclosed Switches and Circuit Breakers Switchboards, Panelboards and Control Centers

1.04 REFERENCES A. The referred codes and standards are intended to provide an acceptable level of quality for materials and products. In case of conflict between these standards and the text of this Specification, the Specification text shall govern. The latest revision of the referred codes and standards shall be used wherever applicable. In case of conflict, the Contractor shall propose equipment conforming to one group of codes and standards. SASO 1. SASO 55 Saudi Arabian Standards Organization PVC Insulated Conductors Cables with Circular Copper

B.

C.

D.

ANSI 1. 2. ANSI C80-1 ANSI C80-3

American National Standards Institute Specification for Rigid Steel Conduit, Zinc-Coated Specification for Electrical Metallic Tubing, ZincCoated Specification for Aluminum Conduit Grey Finishes Equipments for Industrial Apparatus and

3. 4.

ANSI C80-5 ANSI Z55-1

E.

ANSI/IEEE

American National Standards Institute/Institute of Electrical and Electronics Engineers

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1.

ANSI/IEEE C39.1

Requirements Instruments

for

Electricity

Analog

Indicating

2. F. ASTM 1.

ANSI/IEEE C57.13

Instrument Transformers

American Society for Testing and Materials ASTM A123M Standard Specification for Zinc (Hot Dip Galvanized) Coatings on Iron and Steel Products Standard Specification for Steel Sheet and Strip, High-Strength, Low Alloy, Columbium or Vanadium, or Both, Hot-Rolled and Cold Rolled Standard Specification for Steel Sheet Zinc Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvanized) by the Hot Dip Process Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coating Standard Specification for Soft and Annealed Copper Wire Standard Specification for Aluminum and AluminumAlloy Drawn Stainless Tubes [Metric] Standard Specification for Aluminum and AluminumAlloy Seamless Pipe and Seamless Extruded Tube Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel Standard Test Method for Pressure Adhesive Coated Tapes Used for Insulation Sensitive Electrical

2.

ASTM A607

3.

ASTM A653

4.

ASTM A780

5.

ASTM B3

6.

ASTM B210M

7.

ASTM B241M

8.

ASTM B633

9.

ASTM D1000

G.

ICEA 1.

Insulated Cable Engineers Association ICEA S-66-524 Cross Linked Thermosetting Polyethylene Insulated Wire and Cable for the Transmission and Distribution of Electric Energy Ethylene Propylene Rubber Insulated Wire and Cable for the Transmission and Distribution of Electric Energy

2.

ICEA S-68-516

H.

IEC 1. 2. 3. IEC 60051-3 IEC 60051-4 IEC 60227

International Electro-Technical Commission Special Requirements for Wattmeters and Varmeters Special Requirements for Frequency Meters Polyvinyl 3 of 32 Chloride Insulated Cables of Rated

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SECTION 16055 GENERAL PROVISIONS OF LOW VOLTAGE ELECTRICAL WORKS

Voltages up to and Including 450/750 V 4. 5. IEC 60228 IEC 60502-1 Conductors of Insulated Cables Power Cables With Extruded Insulation and their Accessories for Rated Voltages from 1 kV to 30 kV Part 1: Cables for Rated Voltages of 1 kV and 3 kV Alternating Current Watt Hour Meters Institute of Electrical and Electronics Engineers IEEE 383 Standard for Type Test of Class IE Electrical Cables National Electrical Manufacturers Association Panelboards Dead Front Switchboards Metallic Cable Tray System Metallic Cable Tray Installation Guidelines National Fire Protection Association NFPA 70 National Electrical Code Underwriters Laboratories UL 1 UL 6 UL 62 UL 83 UL 486A Flexible Metal Conduit Electric Rigid Metal Conduit-Steel Flexible Cord Fixture Wire Thermoplastic Insulated Wires and Cables Wire Connectors and Soldering Lugs for Use With Copper Conductors Dead Front Switchboards

6. I. IEEE 1. J.

IEC 60521

NEMA 1. 2. 3. 4. NEMA PB-1 NEMA PB-2 NEMA VE-1 NEMA VE-2

K.

NFPA 1.

L.

UL 1. 2. 3. 4. 5.

6.

UL 891

1.05 DEFINITIONS A. circuit breaker: A device designed to open and close a circuit by non-automatic means and to open the circuit automatically on a predetermined over-current without damage to itself when properly applied within its rating. conductor (general): Any carrier of electric current. In practical terms, a wire or cable design electric current. A conductor can be insulated or un-insulated depending on application. Examples include wire, cable and bus bar.

B.

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C.

insulation (general): Non-conductive material that is applied over a conductor (e.g. cable, wire) to insulate a conductor from other conductors or ground. jacket (underground): The outer covering of a cable. A tough plastic material that provides physical protection for the cable. Jacketed cable protects against physical damage and corrosion, thus reducing the risk of damage to the primary neutral. low voltage (general): Voltage less than 1000 V is generally termed as Low voltage. panelboard: A single panel, or a group of panel units designed for assembly in the form of a single panel, including buses and automatic over-current devices, and equipped with or without switches for the control of light, heat, or power circuits; designated to be placed in a cabinet or cutout box placed in or against a wall, partition, or other support; and accessible only from the front. raceways: Raceways include, but are not limited to, rigid metal conduit, rigid nonmetallic conduit, intermediate metal conduit, liquid tight flexible conduit, flexible metallic tubing, flexible metal conduit, electrical non-metallic tubing, electrical metallic tubing, under floor raceways, cellular concrete floor raceways, cellular metal floor raceways, surface raceways, wire ways, and busways. splice: A device to connect together the ends of bare conductor or insulated cable. switchboard: A large single panel, frame, or assembly of panels on which are mounted on the face, back, or both, switches, over-current and other protective devices, buses, and usually instruments. Switchboards are generally accessible from the rear as well as from the front and are not intended to be installed in cabinets.

D.

E.

F.

G.

H. I.

1.06 SUBMITTALS A. The Contractor shall submit to the Royal Commission, under the provisions of SECTION 01330, the following items for review and approval before commencing Work: 1. Shop Drawings and product data, including the following: a) b) List of manufacturers. Manufacturers literature including installation instructions for electrical materials. Operation and maintenance (O&M) manuals. Quality Control Program as specified in SECTION 01450. Factory test reports. Samples of electrical materials for approval by the Royal Commission. Certificate of compliance

c) d) e) f) g)

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h)

Calculations for sizing of circuit breakers, switches and cables to justify appropriateness of the proposed electrical equipment and materials.

2.

The Contractor shall submit the field test reports after the completion of testing and commissioning.

1.07 QUALITY CONTROL A. The Contractor shall be responsible for quality of work and shall develop and propose programs and methods of construction and testing such as to achieve the specified quality to the approval of the Royal Commission in accordance with SECTION 01450.

1.08 HEALTH AND SAFETY CONSIDERATIONS A. All work undertaken in relation to this specification are to be completed in full accordance with the respective health and safety requirements established by the following: 1. Kingdom of Saudi Arabia a) 2. Legislation, Regulation, Standards and Codes.

Royal Commission Regulations a) Standards, Contractual Conditions, and Health & Safety systems.

3.

Contractor a) Health and Safety Standards and Systems as accepted by the Royal Commission.

B.

In the absence of any of the above, best accepted industry practice shall be employed throughout.

1.09 FACTORY TESTING A. General 1. All the electrical equipment and materials shall be tested at the factory in accordance with the latest approved manufacturing codes and standards. The Contractor shall notify the Royal Commission in writing not less than 30 days prior to the scheduled starting date of the factory tests. The Royal Commission reserves the right of deputing their representatives for witnessing the factory testing. Upon completion of factory tests, and before shipment of the electrical equipment/materials, the Contractor shall submit 5 certified copies of test reports not later than 10 days after the completion of all factory tests for review and approval by the Royal Commission.

2.

3.

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1.10 SERVICE CONDITIONS A. All the electrical equipment and materials installed indoors shall be suitable for continuous operation under the following service conditions: 1. Ambient Air Temperature a) b) c) A maximum of 40C. A minimum of 0C. Average temperature, measured over a period of 1 month, of a maximum of 35C.

2.

Relative Humidity (Average Value) a) b) For a period of 24 hours, not exceeding 95%. For a period of 1 month, not exceeding 90%.

B.

All the electrical equipment and materials installed outdoors shall be suitable for continuous operation under the following service conditions: 1. Ambient Air Temperature a) b) A maximum of 50C. A minimum of 0C, unless a lower temperature is specified in Contract Drawings. Average temperature, measured over a period of 1 month, of a maximum of 45C.

c)

2.

Altitude a) Less than 1000 m, unless a higher altitude is specified in Contract Drawings.

3.

Relative Humidity (Average Value) a) b) c) For a period of 24 hours, not exceeding 95%. For a period of 1 month, not exceeding 90%. Relative humidity may be temporarily 100%.

C.

All the equipment or materials to be installed in classified areas as indicated on the Contract Drawings shall be suitable for such installation as per NEC Article 500.

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1.11 DELIVERY, HANDLING AND STORAGE A. The Contractor shall deliver, handle and store material and equipment in accordance with SECTIONS 01650 and 01660, as well as following requirements: 1. Deliver equipment and materials to site originally packed, securely wrapped and labeled by manufacturer in unopened containers. Protect materials during delivery to comply with manufacturers direction. Store materials at building site strictly according to manufacturers instruction. Store products or equipment in dry and ventilated place. Avoid damage or distortion of the materials during handling and shipment or transportation. The Contractor shall be held responsible for any damage to the electrical equipment/materials during storage or transportation.

2.

3.

4.

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PART 2

PRODUCTS

2.01 GENERAL A. All goods and products covered in this Specification shall be procured, when available, from an in-Kingdom manufacture. However, procurement of all goods and products manufactured out-of-Kingdom or in-Kingdom must be approved by the Royal Commission. Quality of the equipment shall be of the best grade for each type of class, even though such quality may not be stated specifically in the specifications. All equipment and materials shall be new and manufactured by well known firms and shall be sound and uniform in quality, size, ratings, shapes, color and texture. All equipment and material shall be free from cracks, warpage or other defects. Each major component of the equipment shall have the manufacturers name, address, model number and rating on a plate securely fixed in a conspicuous place. The only nameplate of the distributing agent will not be acceptable. NEMA code ratings or other data which are die-stamped into the surface of the equipment shall be stamped in an easily visible location. Procured materials and equipment shall be of the type specified. Materials and equipment shall be the manufacturers standard products in compliance with the referenced standards and adequately described by published product information. Procured materials to be used in hazardous classified areas shall be rated for the specific classification of each area.

B.

C.

D.

E.

2.02 RACEWAY AND BOXES A. For more details refer to SECTION 16130.

2.03 CABLE TRAYS A. Metallic Cable Trays 1. Metallic cable trays shall be standard approved type and shall have suitable strength and rigidity to provide adequate support without undue sag. The cable tray system shall be manufactured in accordance to NEMA VE-1 and VE-2 standards. Cable tray shall be fabricated either from corrosion resistant metal such aluminum or metal with corrosion resistant coating. Steel cable trays shall protected against corrosion by hot-dip galvanizing after fabrication accordance with ASTM A123M and shall have coating of Grade 65, with average zinc coating of thickness 0.065 mm per side. as be in an

2.

3.

Carbon steel trays intended for installation in highly corrosive environments with severe alkaline and acidic conditions shall be PVC coated. Minimum coating thickness shall be 0.38 mm (15 mils). The PVC used for coating shall be UV stabilized. Galvanized steel trays shall not be coated with PVC.

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4.

Allowable loading capacity of the metallic cable tray shall be the static weight of cables plus an allowance of 20% spare and a concentrated load of 90 kg at mid-span. The metallic cable tray load safety factor shall be at least 1.5. The next nearest higher tray designation per NEMA VE-1 shall be selected when the allowable loading capacity falls within NEMA range. Cable tray shall be designed to provide a minimum of 25% spare space for future expansion. Cable tray deflection shall be restricted to a maximum of 12 mm for all spans. Cable trays shall not have sharp edges, burrs or projections that could damage insulation or jackets of the cable. Types of Cable Trays a) Ladder Type 1) Ladder tray shall be a prefabricated structure of 2 longitudinal side rails connected by individual transverse members. Spacing of the rungs shall be 150 mm, as per NEMA VE-1. When the number of cables to be accommodated per tray is limited, then the spacing of the rungs can be 230 or 300 mm per NEMA VE-1.

5.

6.

7.

b)

Trough Type 1) Trough tray shall be a prefabricated structure greater than 102 mm in width consisting of a ventilated/perforated bottom within integral or separate longitudinal side rails.

c)

Solid-Bottom Type 1) Solid bottom tray shall be a prefabricated tray consisting of a bottom with no openings within integral or separate longitudinal side rails.

d)

Channel Type 1) Channel tray shall be a prefabricated structure consisting of a 1-piece ventilated bottom or solid-bottom channel section, or both, and not exceeding 150 mm in width.

8.

Cable Trays Dimensions a) Dimensions for various types of trays shall be as per Table 2A.
TRAY DIMENSIONS

TABLE 2A:

Type of Tray Ladder Trough Solid Bottom

Length (mm) 3660 or 7320 3660 or 7320 3660 or 7320

Width (mm) 150, 300, 450 600, 750 or 900 150, 300, 450 600, 750 or 900 150, 300, 450 600, 750 or 900

Depth (mm) 75, 100, 125 or 150 75, 100, 125 or 150 75, 100, 125 or 150

Radii (mm) 300, 600 or 900 300, 600 or 900 300, 600 or 900

Degree of Arc for Elbows 30, 45, 60 or 90 30, 45, 60 or 90 30, 45, 60 or 90

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Type of Tray Channel 9.

Length (mm) 3660 or 7320

Width (mm) 75,100 or 150

Depth (mm) 75, 100, 125 or 150

Radii (mm) 300, 600 or 900

Degree of Arc for Elbows 30, 45, 60 or 90

Finish Touch-Up a) Cable trays that have a hot-dip galvanized coating applied after fabrication need to be re-touched after cutting, drilling or de-burring. These operations leave bare metal edges that will begin to corrode immediately. Touch-up of the galvanized finish shall be done as per practices given in ASTM A780. Zinc-rich paint used for touch up shall meet the requirement of ASTM A780. An area up to 26 mm beyond the bare metal shall always be painted to prevent corrosion.

10.

Fittings, Connectors and Accessories a) All fittings used to change the direction or size of cable trays such as horizontal and vertical elbows, crosses, tees and reducers shall be of the same material as the straight section of the tray. Approved expansion joint fittings shall be provided where trays cross building expansion joints. All adjustable, expansion, reduction and earth continuity connectors and couplers shall be of approved make. Accessories shall cover items that are needed as supplement to straight sections and fittings to complete the cable tray system. Accessories include drop-outs, covers, conduits, adaptors, hold-down devices (clamps), anchors, barriers strips and dividers. They shall be supplied by the manufacturer for a complete cable tray system.

b)

c)

2.04 WIRING DEVICES A. For details refer to SECTION 16140.

2.05 WIRES AND CABLES A. General 1. Low voltage wires and cables (600 V nominal) shall be suitable for installation in conduits or ducts above and below ground, as well as for exposed installations in cable trays. Cables shall be suitable for operation in locations with alternately wet or dry conditions. If exposed cable tray installations are used, cables shall be suitable for operation in a sandy and salty atmosphere without affecting its physical and electrical characteristics. All the wires and cables shall conform to the industry codes and standards.

2.

3.

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4.

Conductors a) Conductors shall be uncoated, annealed, solid or stranded copper in accordance with IEC 60228. Single core cable shall not be larger than 300 mm2. Sizes 6 mm2 and smaller shall be solid or stranded and sizes 10 mm2 and larger shall be stranded.

b) c)

5.

Insulation a) Insulation shall be a heat, oil, moisture and ozone resisting compound, suitable for 85/90C maximum conductor temperature under normal operating conditions. Cable insulation systems and materials shall be as follows: 1) 2) 3) 85C PVC in accordance with SASO 55, IEC 60227 and IEC 60502-1, or other applicable standards. 90C Cross-Linked Polyethylene (XLPE) in accordance with ICEA S-66-524 or equivalent standards. 90C Ethylene Propylene Rubber (EPR) in accordance with ICEA S-68-516 or equivalent standards.

6.

Jackets a) The jacket compound shall consist of a thermosetting, fire retardant and a heat, oil, moisture and ozone resistant material such as neoprene, PVC or hypalon, or approved equal.

7.

Tests a) Cable shall be tested in accordance with the latest requirements of ICEA S-66-524 and S-68-516, or relevant IEC standards. Cables shall be tested to determine the capability of preventing propagation of fire and to determine its self-extinguishing characteristics. The flame-retardant capability of the cable shall be demonstrated by subjecting samples of the cable to be furnished to the vertical cable tray flame test described in IEEE 383, par. 2.5. Individual insulated conductor or 3-conductor cable shall satisfactorily pass the Underwriters Laboratories, Inc. (UL) vertical flame test as described in UL 83 and the flame test described in ICEA S-66-524, Section 6.12.5. All cables used in cable trays and underground duct banks shall have flame retardant characteristics.

b)

c)

d)

8.

Application a) Cable applications shall be as shown on the Contract Drawings and shall comply with the following:

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1)

Building interior power wiring shall be in conduits or closed raceway systems and shall be single core, non-sheathed PVC, XLPE or EPR insulated cables. The cable voltage rating shall be 600 V/1000 V. Minimum conductor size shall be 4 mm2. Building interior control and instrumentation wiring shall be in conduits or closed raceway systems and shall be either single core, non-sheathed or multi-core with overall sheath PVC, XLPE or EPR insulated cables. Outdoor above grade wiring in conduits or closed raceway systems shall have the same requirements as for building interior wiring. Below grade circuits in ducts shall use single core PVC, XLPE or EPR insulated cables. XLPE and EPR cables shall be rated 600 V. Cables shall be rated for wet locations and maintain 85C rating for PVC and 90C rating for XLPE and EPR. Cables used in cable trays shall be XLPE or EPR, single or multicore, 90C, 600 V and rated for use in cable trays.

2)

3)

4)

5)

9.

All cables shall be permanently marked in accordance with the requirement of NEC Article 310. Factory tests shall be performed in accordance with requirements of the applicable standards. Color code cables for phase identification as per NEC Article 210 and as specified herein. Use color bands of tape on exposed ends of cable insulation to code cables, if correct color scheme is not available. Feeder and circuit neutral conductors shall be the same size as phase conductors. Fixture Wire a) UL 62 with the following additional requirement: 1) 2) Insulation: SF-2 silicon rubber. Conductor: Stranded copper conductor 1.5 mm2 or larger as shown on the Contract Drawings.

10.

11.

12.

13.

14.

Bare Conductor a) ASTM B3 Class B stranded annealed copper conductor, unless otherwise indicated on the Contract Drawings.

15.

For more details refer to SECTION 16120.

2.06 CONNECTORS, TERMINALS, SPLICES AND TAPES A. General 1. Rev 0 Connectors and splice caps shall be in accordance with UL 486A. Connectors 13 of 32 Contract No:

SECTION 16055 GENERAL PROVISIONS OF LOW VOLTAGE ELECTRICAL WORKS

shall only be used for joining two or more 6 mm2, and smaller conductor cables. Connectors shall be compression type tin plated copper, with nonflammable and self-extinguishing insulation, and temperature rating equal to that of the conductor insulation. 2. All the connectors, terminals, splices and tapes shall conform to the industry codes and standards. a) 3. Solder type connectors shall not be used for connecting the cables.

The connectors used for terminating cables of size 95 mm2 and above shall be 2 holes pad type connector conforming to NEMA design. All compression connectors for 10 mm2 and larger conductors shall have a manufacturers reference compression die number and the conductor size printed or stamped on the connector. The cable splicing or termination shall be in strict compliance with the manufacturers instructions. Splicing and terminating operations shall not be performed when the relative humidity exceeds 40%. The splice insulation material can be heat-shrinkable, pre-molded type. For splicing copper to copper conductor, a copper connector shall be used. Splices shall be tin-plated copper (compression type) only. Splicing materials shall be in kits or individual, composite units; complete with insulation equal to the cable insulation. Provide only splicing materials approved for the specific application. Splices in wet locations shall provide a moisture seal equal to the cable insulation. Compression splices in ground cables shall only be permitted above ground and shall be non-insulated. Conductor terminals or lugs required for termination on bolt or screw terminals shall be tin plated copper compression type only. For 10 mm2 and smaller conductors, the terminals shall be ring tongue with a nylon insulating sleeve. For conductors between 10 to 120 mm2, the terminals shall be 1 or 2 bolt holes tongue, as required by the application. For conductors larger than 120 mm2, the terminals shall have a 2 bolt holes tongue. Bolt hole sizes shall be suitable for the application. Bundling Straps a) Self-locking tapered strap of self-extinguishing nylon to 120C temperature rating. For outdoor use, straps shall be ultraviolet resistant nylon strap with the above characteristics.

4.

5.

6.

7. 8. 9.

10.

11.

12.

13.

b)

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14.

Insulating Tape a) Plastic Tape 1) Vinyl plastic tape with rubber based pressure-sensitive adhesive, pliable at low temperature and having the following minimum properties when tested in accordance with ASTM D1000: (a) (b) (c) (d) b) Thickness: Breaking Strength: Elongation: Dielectric Breakdown: 0.18 mm (7 mils) 8 kg/25 mm 125% 7,000 V

Rubber Tape 1) Silicon rubber tape with silicon pressure sensitive adhesive and having following minimum properties when tested in accordance with ASTM D1000: (a) (b) (c) (d) (e) Thickness: Breaking Strength: Elongation: Dielectric Breakdown: Insulation Resistance: 0.128 mm (5 mils) 1.5 N/m (width) 525% 13,000 V 1,000,000 Mega Ohms

2.07 DISCONNECT AND SAFETY SWITCHES A. For details, refer to SECTION 16410.

2.08 CIRCUIT BREAKERS A. For details, refer to SECTION 16410

2.09 PANELBOARDS A. For details, refer to SECTION 16440.

2.10 LOW VOLTAGE SWITCHBOARDS A. For details, refer to SECTION 16440.

2.11 MEASURING INSTRUMENTS A. General 1. The maximum current and voltage of the meters and instruments shall match the rated extended, secondary current and voltage of the relevant instrument 15 of 32 Contract No:

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transformers. 2. The nominal current and voltage ratings of meters and instruments (used with CTs and PTs) shall be 1A or 5A as specified in the scope of work, technical specifications and 115 V AC respectively. Instrument scales shall indicate primary quantities when used in conjunction with CTs and PTs. All instruments shall be provided with a zero adjustment accessible from outside the case and located in front. All meters and instruments shall be calibrated for 60 Hz operation and according to the CT and PT ratio and accuracy ratings. All meters shall indicate the test calibration values used for full scale deflection.

3.

4.

5.

B.

Ammeter 1. Ammeters, suitable to operate on a current transformer for the measurement of line current shall be provided. The ammeter shall be provided with maximum demand indicator and shall have accuracy Class 1. The size of ammeter shall be approximately 114 mm2, and shall have graduations as indicated on drawing with black figures on white background. The ammeters shall be provided with shorting links. All ammeters shall be provided with a 4 position selector switch, including OFF.

2.

3.

4.

C.

Voltmeter 1. Voltmeters shall conform to ANSI C39.1 and shall be panel-mounted, heavy duty type, suitable to operate on a potential transformer with voltmeter selector switch. The selector switch shall be robust 6-way rotary type switch to measure phase-to-phase and phase-to-neutral voltage. The size of voltmeter shall be approximately 114 mm2, graduated from zero to 600 V with black figures on white background. The accuracy class of voltmeter shall be Class 1. The voltmeter shall be protected with a 2 A fuse.

2.

3.

4.

D.

Frequency Meter 1. Frequency meters shall be of the vibration type and shall comply with IEC 60051-4. Voltage variations of 20% shall have no influence on the indicated frequency.

2.

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E.

Power Factor Meter 1. Power factor meters shall be of the totally iron enclosed electro dynamic cross coil meter movement type and shall comply with IEC 60051-4. 20% of the rated current must guarantee a proper indication at the rated voltage.

2.

F.

Watt Meter 1. Watt meters shall be of the totally iron enclosed electro dynamic type and shall comply with IEC 60051-3. They shall be capable of carrying 1.2 times the continuous full load current.

2. G.

Watt Hour Meter 1. Watt hour meters shall comply with IEC 60521 and may be either for direct or current transformer connection. Maximum rating for direct connection shall be 10 A. For connection through current transformers, either 1 or 5 A secondary current windings may be used. Kilowatt hour meters used for official accounting purposes will normally be supplied by, or in accordance with, the specifications of the supply company.

2. 3.

4.

2.12 INSTRUMENT TRANSFORMERS A. The potential transformers shall conform to ANSI C57.13 and shall be wound-type with polarity markers suitable for operating meters and relays. The isolation transformer shall have voltage ratio as indicated on the Contract Drawings. The current transformers shall be provided in the application of instruments, meters, and relaying as shown on the single line diagrams. The Contractor shall be responsible for checking burdens to be in compliance with ANSI/IEEE C57.13. The current transformers shall be insulated for the full voltage rating of the equipment, and shall be rated to withstand the maximum short circuit rating of the equipment. Primary CT current rating shall be the nearest standard rating equal to not less than 125% of the normal primary current in the circuit. Shorting links shall be provided to short CT terminals before the removal of connected load. CTs to be fully rated for outdoors ambient conditions.

B.

C.

2.13 LIGHTING AND POWER DISTRIBUTION TRANSFORMERS A. For details, refer to SECTION 16270.

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PART 3

EXECUTION

3.01 GENERAL A. The Contractor shall provide all materials, equipment and labor as deemed necessary to show proper execution of the work. Enclosures, equipment, controls, controllers, circuit protective devices and other like items shall be protected during installation against entry of foreign matter. The aforementioned shall be vacuum cleaned both inside and outside before testing and operating, as well as before repainting, if required by the Royal Commission. All the work shall be performed in a first class workmanlike manner, in conformance with the applicable codes and standards, the best electrical engineering practices and as per the manufacturers instruction. Work shall be performed by skilled workers equipped to produce satisfactory results in a safe and substantial manner so as to avoid undue stresses. Damaged equipment, as determined by the Royal Commission, shall be placed in first class operating condition or be returned to the source of supply for repair or replacement. The Contractor shall be responsible for the proper coordination of all phases of the work and equipment as specified herein, with the work to be performed and equipment to be furnished under the other Sections of the Specifications, in order to assure a complete and satisfactory installation. The Contractor shall furnish and install all temporary electrical facilities, including lamps, required for construction and safety operation. All such equipment shall remain the property of the Contractor and shall be removed when permanent connections have been completed. If it is determined during construction that the temporary facilities, as installed, interfere with other construction operations, the Contractor shall relocate said facilities in an approved manner to an approved location. No wire, bus or electrical equipment which is part of any of the permanent electrical systems may be used for temporary electrical service during the construction operations. Temporary connections shall be safe and in accordance with accepted practices. The Contractor shall be responsible for any damage to equipment, materials, or injury to personnel caused by improperly protected temporary installations. All costs for materials and installation for temporary electrical facilities and energy for their operation shall be at the expense of the Contractor. Electrical welders used in the erection and fabrication of the building and its equipment shall be provided with an independent grounding cable connected directly to the structure on which the weld is being made, rather than to an adjacent conduit. After the installation is complete and properly adjusted, the Contractor shall conduct operating tests. The various equipment and systems shall be demonstrated to

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operate in accordance with the requirements of the specifications. Tests shall be performed in the presence of the Royal Commissions representative. The Contractor shall provide electric power, instruments and personnel necessary for performing the various tests. 3.02 EXCAVATION AND BACKFILLING A. General 1. Prior to the start of excavation, the Contractor shall submit a request for an excavation permit and this permit shall be obtained from Royal Commission, Saudi Electricity Company (SEC), Saudi Telecommunication Company (STC), and MARAFIQ, as applicable. The trench layout drawings and other relevant documents, showing coordinates and elevations, as well as any crossings with existing pipe and cables, shall be attached to the request for permit. No excavation shall take place until the permit is issued. The Contractor shall survey the cable routes according to the Drawings. If obstructions are located on the cable routes, either the obstructions shall be removed or the cable shall be re-routed after obtaining consent from the Royal Commission. During excavation, the material suitable for backfilling shall be stored aside at a sufficient distance from the trench border. Excavated materials not required or not suitable for backfilling shall be hauled off to an authorized dump, or placed at a location determined by the Royal Commissions representative. General excavation and backfilling of trenches required for the installation of all electrical services and conduit systems within the building and for connections with exterior underground electrical services shall be performed as shown and noted on the Contract Drawings, and in accordance with SECTION 02315. Trenches shall be excavated to the required depth and grade. The bottom of the trench shall be sloped as specified on the Contract Drawings for the installation of conduits and ducts. Rock or existing concrete, where encountered, shall be excavated to a minimum depth of 150 mm below the bottom of conduit, duct or concrete envelope, if so encased. Where mud or otherwise unstable soil is encountered at the bottom of the trench that is incapable of supporting the conduit, duct or concrete envelope, such soil shall be removed to a firm bearing and the trench shall be backfilled with sand to the proper grade and tamped to provide firm, uniform support. The Contractor shall be responsible for coordinating the trenching work with other disciplines underground work, so as to resolve conflicts in level or space allocation. The Contractor shall repair any damage to existing services which may occur during trenching operations.

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3.03 FOUNDATIONS AND SUPPORTS A. General 1. The Contractor shall provide concrete pedestals, bases, pads, curbs, anchor blocks, anchor bolts, slab inserts, hangers, channels, cradles and saddles for the installation of electrical equipment and apparatus, as shown on the Contract Drawings. Concrete pads shall be 150 mm high, complete with steel reinforcing and the necessary bolts and anchors. Where concrete pads are set directly on the concrete floor, the Contractor shall provide dowels to tie the base to the floor. These pads shall be extended at least 100 mm beyond the equipment outline on all 4 sides. Individual hangers, trapeze hangers and riser clamps shall be provided for supporting conduit. All parts and hardware shall be zinc coated (galvanized). Pipe straps and hanger rods shall be fastened to concrete by means of inserts or expansion bolts; to brickwork by means of expansion bolts and to hollow masonry by means of toggle bolts. Wooden plugs and shields shall not be used for fastening pipe strips and hangers. Under no circumstance shall ductwork, piping and mechanical equipment be used for supporting electrical facilities. For more details, refer to SECTIONS 03310.

2.

3.

4. 5.

6.

7. B.

Chases and Openings 1. The Contractor shall provide necessary chases and openings for all electrical works where required and through walls, partitions, ceilings and floors to accommodate the electrical works as per the Contract Drawings. The chase sleeves and openings in firewalls and floors for telephone, electrical closets and instrumentations facilities shall be packed with acceptable or approved flexible barriers designed for this purpose.

2.

C.

Cutting and Patching 1. The Contractor shall execute the cuttings of walls, partitions, floors and ceilings for installation of all sleeves and inserts required for electrical works as per the Contract Drawings. Before cutting any portion of the walls or partitions, the Contractor shall obtain a written approval from the Royal Commission and he shall be responsible to coordinate the work with that of other disciplines. The Contractor shall be responsible for the careful repair and patching up of openings with applicable and suitable sealants and packing compounds.

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3.04 EQUIPMENT ERECTION A. General 1. All electrical equipment shall be erected or installed in accordance with applicable codes and standards, manufacturers instructions, good electrical engineering practice and the relevant drawings. Bolted electrical connection shall be thoroughly cleaned before assembly. The bolted connections shall be tightened with manual torque wrenches as per manufacturers instruction and according to the UL 486A, the values of tightening torque for screws shall be measured in N.m (Newton.meter). The tightened bolts shall be tested in presence of the Royal Commissions representative and the results shall be submitted to the Royal Commission. Sufficient access and working space shall be provided and maintained around all electric equipment to permit ready and safe operation and maintenance of such equipment. For working space requirement, refer to NEC Article 110.

2.

3.

4.

3.05 INSTALLATION OF CABLE TRAYS A. Cable trays shall be installed both indoors and outdoors, as applicable. It will be subjected to severe desert conditions and corrosive plant atmospheres. The metallic cable tray shall be designed, manufactured and tested in accordance with NEMA VE-1. Cable trays shall be installed in locations where aesthetic looks are of secondary importance such as suspended ceiling. Only cables and insulated sheathed multicore wiring shall be installed on cable trays. A minimum of 25% space for future cable installation shall be provided. The installation shall conform to recommendations of NEMA VE-2. Cable tray load performance shall be designated in accordance with NEMA load/span designations and shall meet the requirements of NEMA Class 20B (111.6 kg/m) for uniformly distributed loads. In addition to uniformly distributed load requirement, cable tray shall support a concentrated load of 90 kg applied at midspan and at centerline of the cable tray. Installation and supports for cable tray system shall meet the requirements of manufacturers instructions and the NEC. Installation and supports for cable trays shall be on straight horizontal runs at a maximum span of 6100 mm and within 915 mm of fittings. Vertical cable tray runs shall be supported at 2400 mm maximum. Installation and supports for cable trays connectors shall be rigid straight, adjustable, or expansion type. Connectors shall be installed with manufacturer supplied hardware and torqued to the manufacturers specifications.

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G.

Standard accessories used to supplement straight sections and fittings shall be dropouts, conduit adaptors, dead-ends, dividers, cable clips, tray to box connectors and hold down hardware. Cable tray splices shall be made so that connectors between horizontal straight sections of cable tray runs fall between the support point and the quarter point of the span. Splice point shall not be made directly over support joints. Expansion Joints 1. Contraction and expansion shall be considered when installing cable tray systems. The length of the straight cable tray run and the temperature differential govern the number of expansion splice plates required. The temperature differential in accordance with NEMA VE-2 is indicated in Table 3A.
TABLE 3A: MAXIMUM SPACING BETWEEN PROVIDE FOR 25 mm MOVEMENT EXPANSION JOINTS THAT

H.

I.

Temperature Differential* F C 25 14 50 28 75 42 100 56 125 70 150 83 175 97

Steel feet 512 256 171 128 102 85 73 m 156 78 52 39 31 26 22

Aluminum feet 260 130 87 65 52 43 37 m 79 40 27 20 16 13 11

Fiberglass feet 667 333 222 167 133 111 95 m 203 102 68 51 41 34 29

* Temperature Differential - The difference in the temperature between the hottest and coldest days of the year. ** For designs that provide for 16 mm movement (typically non-metallic), multiply maximum spacing between expansion joints by 0.625. 2. Expansion joints shall be installed as follows: a) b) J. In each straight run outdoor cable tray: In each straight run of indoor cable tray: Every 18.2 m length Every 36.5 m length

Cable tray systems shall be electrically and mechanically continuous without breaks or gaps, except as shown on the Contract Drawing. All cable tray systems shall be connected to the plant grounding system at intervals of 150 m and at each end. Bonding jumpers, heavy duty tinned copper braid shall be installed at all expansion connectors. All cable tray systems shall be bonded together at intervals of 150 m and at each end. The minimum working space around cable trays shall be 1020 mm on at least one side of a single tray, and 1020 mm on both sides of 2 trays installed parallel to each other. The minimum vertical separation between trays shall be 510 mm.

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N.

Cable trays shall only be cut along a line of plain metal and not through any perforations. After cutting all sharp edges, it shall be smoothed and, where applicable, the finish shall be restored. All cable splicing T or Y tapping within the tray shall be protected with heat shrink jackets. Cable trays installed at outdoor or indoor locations where it may be in danger of possible mechanical damage shall be covered. Covers for power trays shall be of louver ventilated type, secured to the tray with stainless steel banding. Trays used for instrumentation or communication cables require covers with ventilation provision. Vertical runs of outdoor cable tray shall be covered on both sides. Cables installed in trays shall be approved for tray installation, approved for the area classification and suitable for the environment in which they are installed. Cables in trays shall be grouped according to voltage level, insulation class and function. Medium voltage cables shall run in separate trays, with cable of each voltage level used running in dedicated trays. Low voltage power cable and control cables may be run in the same tray provided that the cables are of the same insulation class. Instrumentation cables shall be run in separate trays. The thermocouple cables in the same tray shall be segregated by means of barriers. Critical shutdown and control system cables shall be run in separate trays or segregated from other cables by means of barriers in the trays. Cable trays shall be routed to avoid high fire risk areas, especially trays for fire alarm, communications or instrumentation systems. If cable tray has to be routed through areas of high fire risk, appropriate fire proofing and fire protection precautions shall be taken. Cable shall be secured in vertical runs of cable trays by the use of stainless steel clips. Horizontal runs of cable shall be secured through the use of black nylon, sunlight resistant cable ties. Cable ties shall be installed every 1370 mm on horizontal runs and every 450 mm on vertical runs. All work shall be done in neat and workmanlike manner to the satisfaction of the Royal Commission.

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3.06 INSTALLATION OF ELECTRICAL CONDUITS A. Below Grade Conduit 1. The installation of below grade conduit should not be avoided, except in buildings where conduit may be installed in concrete floors.

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2.

The direct buried conduits installed directly on earth shall be hot-dip galvanized rigid steel conduits. Conduits encased in the concrete shall be PVC conduits. Minimum size for below grade conduit shall be 50 mm. Below grade conduits shall be sized one size larger than required by the Code maximum wire fill. Reductions in conduit size shall be done above grade. Below grade bends shall be of the long radius type. Minimum depth for low voltage system PVC conduit installation shall be 560 mm below grade, and 610 mm below grade for medium voltage systems. For rigid steel conduit, the minimum depth for low and medium voltage system shall be 310 mm. Minimum depth for low and medium voltage system EB PVC conduits encased in concrete shall be 880 mm. There shall be no more than three 90 bends in a below or above grade conduit run. Below grade conduits shall have red tiles or concrete cover. Spare conduits shall be provided with pull, terminated with plugged couplings and installed flush with the finished floor in buildings, or 18.75 mm above the finished surface in other areas. Upon completion of a duct run, a test mandrel (6 mm less in diameter than the inside diameter of the duct) and wire brush cleaner (slightly larger than the duct) shall be pulled through each duct. The testing and cleaning of a concrete encased duct shall be done on the day after the concrete has been poured to remove any concrete splash of spalls in the ducts.

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Above Grade Conduit 1. Above grade conduit shall be rigid, hot-dip galvanized steel. In locations where conduit may be subject to mechanical damage, the conduit shall be with a 1.02 mm (40 mil) PVC coating on the exterior surface and epoxy coated on the interior surface. Rigid PVC conduit Schedule 80 shall be allowed for use, where applicable, in accordance with NEC Article 352. Minimum conduit size shall be 18.75 mm. Conduit used behind control boards or other types of panels shall be 12.5 mm. The separation of the conduit shall be horizontal, vertical, and on crossing by a minimum of 150 mm from piping or equipment with surface temperatures in excess of 45C. When conduit is terminated to equipment where vibration or movement is a concern, a flexible, liquid tight conduit shall be installed between the rigid conduit and the equipment. Conduit fitting in the above grade conduit system shall be manufactured from 24 of 32 Contract No:

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copper free aluminum. Cover screws shall be stainless steel. 6. Fittings shall be approved for the area classification and be suitable for the environment in which they are installed. When PVC coated rigid galvanized steel conduit is used, it shall consist of galvanized steel fitting with a 1.02 mm (40 mil) PVC exterior coating and epoxy interior coating. Cover screws shall be stainless steel. Fittings shall be approved for the area classification and be suitable for the environment in which they are installed. PVC coated rigid steel conduit shall be used in exposed area subject to mechanical damages and also used below grade. PVC coated clamps shall be used to fasten the aluminum conduit to ungalvanized steel or concrete surfaces. Where the aluminum conduit comes in direct contact with ungalvanized steel or concrete, the conduit shall be wrapped with insulating tape. At transition points between aluminum and steel conduit, an anti-oxidizing compound specially made for this application shall be applied to the threads. Electrical metallic tubing (EMT) shall be restricted in use to installation in offices, control rooms and other similar buildings with finished interiors. Straight runs of conduit in excess of 45 m shall be provided with an approved expansion fitting. Where conduit runs exceeds the equivalent of a 45 m run, or more than the equivalent of three 90 bends, expansion joint fittings shall be installed. One 90 bend shall be considered the equivalent of 15 m of straight run conduit. Conduit entry into enclosures or devices shall be side, bottom or top entry. For outdoor installation top entry is not allowed, without exception.

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C.

Conduit Seals, Breathers and Drains 1. Breathers and drains shall be installed at all low points in conduit systems and as required to prevent accumulation of moisture in the conduit and equipment enclosures.

D.

Conduit Elbows and Tees 1. Installation and construction of elbow and tee fittings shall be compatible with the above Specifications. For more details refer SECTION 16130.

2.

3.07 INSTALLATION OF BOXES, CUBICLES AND WIRING DEVICES A. Boxes and Cubicles 1. Boxes and cubicles shall be installed level, plumb and properly aligned to present a pleasing appearance.

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2.

Supports for boxes shall be made from auxiliary members of standard rolled structural steel. Terminal blocks of approved type shall be installed in boxes and cubicles as required. Boxes shall be spaced at least 9 mm from all vertical support framing to provide an air space. Boxes mounted outdoors shall have drain fittings. Boxes to be embedded in concrete shall be firmly attached to the forms so as not to be disturbed when the concrete is placed. The boxes shall be protected against filling up of the boxes with concrete. Cubicles shall be secured to foundations by means of expansion bolts or other approved means, or shall be tack welded to sills leveled in concrete.

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6.

B.

Wiring Devices 1. Fasten surface mounted boxes and supports to wood with wood screws or screw type nails of equal holding strength and with machine screws or welded studs on steel work. Cast flush-mounted boxes in concrete and grout into hollow masonry walls. Threaded studs driven in by powder charge and provided with either lockwashers and nuts or nail type nylon anchors are acceptable in lieu of wood screws, expansion shields or machine screws. In open overhead spaces, cast metal boxes threaded to raceways need not be separately supported, except where used for fixture support. Where bar hangers are used, attach the bar to raceways on opposite sides of the box and support with an approved type fastener not more than 500 mm from the box. Boxes installed in concealed raceway systems shall be set flush with the finished surface. The location of all boxes shall be easily accessible. Resolve interference with mechanical equipment or structural features prior to installation. Where several circuits pass through a common pull box, tag the circuits to indicate clearly the electrical characteristics, circuit number, and panel designation. Install pull boxes in all conduit runs as required and locate as approved. Not less than one pull box shall be installed every 45 m. Locate receptacles and install as shown on the drawings. The location shall be easily accessible. Resolve any interference with mechanical equipment or structural features prior to installation. Locate the center of wall mounted receptacles 300 mm above finished floor. Install switches as shown on the Contract Drawings. Where multiple switches are shown for 1 ganged box, install the switches under 1 plate. Locate the center of the wall mounted switches at 1220 mm above the finished floor. The 26 of 32 Contract No:

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voltage level and current ratings for switches shall be as indicated on the Contract Drawings. 10. Install device plates with all 4 edges in continuous contact with finished wall surfaces without the use of mats or similar devices. Install device plates vertically with an alignment tolerance of 1.5 mm. For more details, refer to SECTION 16140.

11.

3.08 INSTALLATION OF DUCT BANKS AND MANHOLES A. Duct Banks 1. Duct banks shall be constructed of PVC conduit, encased in reinforced concrete. In the assembly of a duct bank, the conduits are supported by spacers that hold the conduits in place during the backfilling of inter-conduit space with sand or cement. The spacer shall be of polypropylene plastic. Spacers for supporting conduits shall be installed at intervals not exceeding 1.5 m. Spacers shall be with interlocking lugs and matching holes for field assembly and into multiple units. Conduit runs in duct banks shall be made continuous by the use of couplings. Duct banks shall be provided with 20% spare capacity. Structural concrete shall be used in duct banks constructed with PVC conduits under areas that are subjected to vehicular traffic, for example under roadways. The concrete encasement shall extend a minimum of 75 mm from any conduit in the bank to the outside surface. The minimum distance from grade to the top of duct bank shall be 600 mm. Conduit stubs from duct bank to above grade shall be rigid steel. Where PVC conduit is used, a transition to rigid steel conduit shall be made below grade.

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3.

4. 5. 6.

7.

8. 9.

B.

Manholes 1. Manholes shall be installed in the locations as shown on the Contract Drawings and as necessary to meet cable pulling requirements. Manholes shall have a minimum inside dimensions of 2500 x 2500 mm by 2000 mm deep. Adequate space shall be allowed for: a) Making and supporting splices.

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b) c)

Supporting cables. Clearance between low voltage control, power and medium voltage cables. Bending and training cables for offsets and changes in horizontal and vertical direction. Providing adequate working clearance required as per NEC Article 314 pulling, terminating and splicing cables.

d)

e)

4.

Manholes or handholes required for the duct bank system shall be located in non-hazardous classified areas. Manholes shall be provided with cable pulling irons embedded in the concrete side walls of the duct bank. When manufactured manholes are used, the design of manholes shall be approved by Royal Commission. For more details, refer to SECTIONS 02580 and 16120.

5.

6.

3.09 INSTALLATION OF LOW VOLTAGE DIRECT BURIED CABLES A. For details, refer to SECTIONS 02315 and 16120.

3.10 INSTALLATION OF CONDUCTORS A. General 1. Low voltage power and control cables may be direct buried, installed in duct banks (concrete encased conduit) and trenches below grade, installed in conduits, trays and raised floors above grade, as specified in pars. 3.08 and 3.09. There shall be adequate access for installation of additional cables and removal of cables with ease, economy and minimum outages. Cable entrances to control buildings shall be provided with non-combustible fire barriers and protection against rodents and water seepage from outside. The cable system shall not propagate fire and shall be consistent with personnel safety and good appearance. To minimize coupling and to promote circuit integrity, separation of low voltage power, control and communication cables shall be done. Caution shall be exercised in the use of common duct or trench system which compromise circuit separation. The cable system shall be designed so that foreseeable electrical transients will not adversely affect the cable, connected apparatus or operation. Apart from design engineering and material cost, careful consideration shall be given to the installed cost for the initial as well as the ultimate installation.

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7.

Cable manufacturers recommended maximum pulling tension and sidewall pressure shall not be exceeded and the minimum bending radius shall not be reduced to avoid possible damage to the cable conductor, insulation, shield or jacket.

B.

Conductors Installation 1. The wires and conductors shall be installed only when the raceway system has been completed. The inside of all conduits shall be thoroughly clean of any dirt, moisture or other foreign materials before pulling wire and cable. Wires and cables in conduits shall be pulled after application of a suitable lubricant that shall have no injurious effects on the insulation of the conductor. No oil or grease shall be used. Each power conduit shall contain a grounding conductor. No splices or joints shall be used in low voltage feeders or branch circuits except at accessible splice or junction boxes, accessible raceway fittings or outlet boxes. Secure joints in circuit wiring mechanically and electrically as follows: a) Conductors 6 mm2 or smaller may be joined with splice caps applied with the correct indent tool which provides deformation of the cap in 2 directions at right angles to each other simultaneously. Conductors larger than 6 mm2 shall be joined by compression splicing sleeves. Split-bolt type connectors are not acceptable. Unless properly insulated by the conductor, all joints shall be insulated to a voltage level at least equal to the insulation of the conductors. Splices and joints in wet locations shall provide a moisture seal equal to the cable insulation.

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3. 4.

5.

b)

c)

d)

6.

The Contractor shall visually inspect the conductors and wires before, during and after installation in accessible positions for evidence of cracking or blistering. Should a fault be observed in the cables before, during or after installation, the Contractor shall be responsible to remove the faulted cable and replace it with a new cable. Cable attachments for pulling shall be patent cable grips or other suitable devices which are approved by the Royal Commission. In using woven basket type grips, care should be taken to avoid damage to the cable and seal, which, irrespective of the pulling method used, shall be maintained during cable installation. Special care shall be taken to avoid damage at intermediate points on cable lengths due to grip attachment, causing either excess wasted cut-off lengths or damage to insulation and jacket, which would later be concealed in conduits. Care shall be taken to avoid sharp bending or kinking the conductor, damaging insulation or jacket, or stressing cable beyond manufacturers 29 of 32 Contract No:

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recommendations in pulling. Cable shall be protected at all times from mechanical injury and from absorption of moisture at unprotected ends. No damaged or out-of-place cables shall be acceptable. 10. After pulling, but before making cable terminal connections, cable ends shall be exposed and rung out to determine if correctly installed, and the insulation tested for each power and 600 V conductor. Instrumentation cables shall be checked only for continuity and recorded into each cables record. At cable locations where the conductor and cable insulation will be terminated, terminations shall be made in a neat, workmanlike and approved manner by men specialized in this class of work. Terminations shall be made for each type and voltage class of wire or cable using approved termination materials and in accordance with the instructions or recommendations of the cable manufacturer. Wherever possible, cable entry to outdoor equipment, cubicles or terminal boxes shall be through the bottom to reduce moisture hazard. Where a cable does not enter the bottom of outdoor equipment, cubicles or terminal boxes, it shall be installed as follows: a) Unarmored cable, with side or top entrance shall be installed through conduit connected to the equipment connection box by means of a half coupling welded to the box. The cable shall leave the conduit in a weather-protected location or by means of weather protected service head with a drip loop made in the cable.

11.

12.

13.

b)

14.

Conductors shall be rung out before any cable termination according to wiring diagrams. Polarity or phasing shall be checked before connections are made. Lighting circuits will be considered as starting at lighting panels and extending to all lighting outlets, receptacle outlets and switches on the load side of the lighting panels. All portions of the system shall be tested to ensure satisfactory operation. For more details, refer to SECTION 16120.

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16.

3.11 EQUIPMENT CONNECTIONS A. General 1. Before making electrical connections to the equipment, the Contractor shall check the availability of supply voltage and the current ratings at the location and check the polarities. The supply of power shall match with the nameplate rating of the equipment. Connections shall be made as per the Contract Drawings and manufacturers instructions. The Contractor shall be responsible to make electrical connections to the mechanical, instrumentation and telecommunication equipment, in addition to electrical equipment, and coordinate with the relevant disciplines. 30 of 32 Contract No:

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3.

All the electrical connections to equipment shall be made perfect with reference to the single line diagrams, wiring diagrams, interconnection diagrams, manufacturers instructions, equipment installation layouts, cables and conduits routing drawings. In case of any misconnections to the equipment, the Contractor shall be responsible for loss of damaged or burnt out equipment and shall, as directed by the Royal Commission, replace all such equipment with new or repair properly to obtain the written approval of the Royal Commission. All the grounding connections to the electro-mechanical and other equipment, concrete and metallic structure shall be made as per the grounding layout drawings. Size of the grounding wires and cable shall be as indicated on the Contract Drawings, and in accordance with SECTION 16060. All the workmen who connect the electrical connections to the equipment shall be certified. This certification shall be valid and approved by the Royal Commission.

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3.12 PAINTING A. General 1. All shop fabricated and factory built equipment not galvanized, plated or provided with standard finish paint as per ANSI Z55-1, shall be cleaned and given 1 shop coat of lead-free primer paint before delivery to the site. All portions of the shop coating damaged during delivery or construction shall be recoated. The nameplate, label or tag of any equipment shall not be covered with the field painting. Exposed electrical work in finished areas shall be painted to match the surface to which it is attached. Exposed electrical work in unfinished areas shall not require painting, unless so noted. Outdoor electrical equipment requiring painting shall be painted using a system that will provide 10 years of service in a corrosive marine environment without cracking, peeling, fading or deterioration to a condition where repainting would be required during the 10-year period. Colors shall be manufacturers standard, unless otherwise specified. All the painting and coating for electrical equipment shall be performed in accordance with the relevant Sections as specified in par. 1.04.

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3.13 TESTING AND COMMISSIONING A. General 1. Prior to starting the electrical testing, the Contractor shall verify the correct voltage, phases and current consumption of all utilization equipment to be connected. 31 of 32 Contract No:

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SECTION 16055 GENERAL PROVISIONS OF LOW VOLTAGE ELECTRICAL WORKS

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The Contractor shall carry out all site tests in accordance with approved test procedures that conform to applicable standards referenced in the specifications. All tests are subject to witnessing by the Royal Commissions representatives. At least 4 weeks prior to starting of schedule tests, the Contractor shall submit to the Royal Commission an outline of test procedures, list of equipment required for testing, test sheets, calculations and minimum/maximum test and performance values to be used in determining the acceptability of the installation. The testing of all electrical equipment shall include the items below: a) b) c) d) General equipment check. Field wiring and grounding system verification. Conductor insulation tests. Equipment adjustment.

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All terminals, connections and attachments, covers, insulating fittings, supports, hardware and field mounted accessories shall be checked for proper tightness. Earth continuity tests shall be made from each item of equipment to the appropriate main ground system and on the main ground system to the ground rods. The testing shall be a continuous process to maintain the construction schedule to the satisfaction of the Royal Commission. The Royal Commission shall have full rights to observe all facets of the testing and commissioning. Upon completion of testing, the Contractor shall submit 5 copies of certified report attesting that each test was performed in accordance with the approved test procedures. The report for each test shall include the date of performance and the name of the person in-charge of the test. All factory and field test reports shall be included in the Operation and Maintenance Manuals.

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END OF SECTION

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