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Specification for Instrument Cable
FINAL
02 FA AN MM 89.12.23
APPROVED
01 IFC FA BM AB 89.10.14 Generally Revised
00 IFC MK BM BM 89.07 -
PURPOSE OF
REV. PREPARED CHECKED APPROVED DATE REMARKS
ISSUE
REVISED □
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«» ﺧﻂ ﻟﻮﻟﻪ ﺷﺸﻢ ﺳﺮاﺳﺮي ﮔﺎزاﻳﺮان
Contents
1 INTRODUCTION ............................................................................................................... 4
2 DEFINITIONS .................................................................................................................... 4
3 PURPOSE ......................................................................................................................... 5
4 SCOPE .............................................................................................................................. 5
5 CODES AND STANDARDS ................................................................................................ 5
6 PRECEDENCE ................................................................................................................... 7
7 AMBIENT CONDITIONS ................................................................................................... 7
8 TECHNICAL REQUIREMENTS ........................................................................................... 7
9 GENERAL INFORMATION FOR SELLERS ........................................................................ 13
10 PREPARATION FOR SHIPMENT .................................................................................... 17
ﻃﺮاﺣﻲ و ﻣﻬﻨﺪﺳﻲ ﺗﻔﺼﻴﻠﻲ
«» ﺧﻂ ﻟﻮﻟﻪ ﺷﺸﻢ ﺳﺮاﺳﺮي ﮔﺎزاﻳﺮان
1 INTRODUCTION
Iranian Gas Engineering & Development Company (I.G.E.D.C) has intended to perform gas
transmission pipeline and gas compressor stations for transferring of 110 MMSCMD of
natural gas to be fed from South Pars phases 22 ~ 24 from Assalouyeh to Bazargan.
Design of a new 56" gas transmission pipeline from Assalouyeh to Bazargan has been
described under this EPC Contract.
The purpose of this document together with the referred standards, specifications and
project documents is to define the general requirements for Instrument Cables.
2 DEFINITIONS
PROJECT 56" gas transmission pipeline from Assalouyeh to Bazargan
CLIENT Iranian Gas Engineering & Development Company (IGEDC)
MANAGING CONSULTANT Ghods Niroo Consulting Engineers
CONSULTANT Haraz Rah Consulting Engineers
EPC CONTRACTOR Gharargah Khatam‐AL‐Anbia. Niroo Goostar Institute
MANUFACTURER/
SUPPLIER/VENDOR The manufacturer and/or vendor of a commodity, system,
or piece of equipment to perform the specified duty. This
may be the MANUFACTURER or his agent, an integrator or
factory. Several manufacturers may supply equipment to
the same SUPPLIER
2.1 SHALL & SHOULD
When used in this or referenced documents the following words are used in the manner
described below:
The words shall and must is to be understood as mandatory
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The word should as strongly recommended to comply with the requirements of this
document.
The word ‘Will’ is used in the preferred sense.
The word ‘Includes’ means ‘includes but not limited.
3 PURPOSE
The purpose of this document together with the referred standards, specifications and
project documents is to provide a basis for the identification and standardisation of
information to be used in the Project.
02
4 SCOPE
This document together with the referred standards, specifications and project documents
covers the minimum requirements for instrument cables to be used in the project. This
specification shall be used as a basis of design for preparation of detail engineering and
purchase of instrument cables.
5 CODES AND STANDARDS
All work specified shall be in accordance with all applicable sections of the latest editions of
the Codes and Standards (and their current amendments), listed as below:
IPS‐C‐IN‐190 Construction and installation for Transmission
systems
IPS‐E‐IN‐190 Engineering and design for Transmission systems
IPS‐M‐EL‐271 Material and equipment for Low voltage cables and
wires
IEC 60028 International Standard of Resistance for Copper.
IEC 60092‐3 Cables (construction, testing and installations)
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IEC 60189‐1 to 7. L.F. Cables and Wires‐General
IEC 60228 Class 2. Conductors of Insulated Cables.
IEC 60230 Impulse Tests on Cables and their Accessories.
IEC 60245‐1 to 4 Rubber Insulated Conductors & Cables, Nominal Voltage
450/750 Volts
IEC 60331 Characteristics of Fire Resisting Electric Cables.
IEC 60332‐1 to 3 Tests on Electric Cables Under Fire Conditions.
IEC 60344 Guide to the calculation of resistance of plain and
coated copper conductors of low‐frequency cables
and wires
IEC 60446 Identification of Colours or Numerals of Conductors
Electric Cables.
API‐552 Transmission Systems
ISO‐4589 Determination of Burning Behaviour by Oxygen Index.
6 PRECEDENCE
In the event of conflict between the various documents, their order of preference will be as
follows:
- Purchase Order
- Material Requisition
- This Specification
- Other referenced Specifications
- Codes and Standards
7 AMBIENT CONDITIONS
The instrument cables shall be suitable for permanent operation with environmental
conditions as described in “SITE CONDITION”.
8 TECHNICAL REQUIREMENTS
8.1 Basic Requirements
8.1.1 General
All cable shall be water, oil, UV resistant, gas/vapor tight, burn with a low release of
halogens.
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«» ﺧﻂ ﻟﻮﻟﻪ ﺷﺸﻢ ﺳﺮاﺳﺮي ﮔﺎزاﻳﺮان
All cables shall comply with the relevant applicable IEC recommendations and with the
regulation of the country of installation.
Cables used for external installation shall be armoured.
In extreme instances, where areas are susceptible to oil or condensate spillage or
contamination, cables with laminated outer sheaths to be considered as an alternative
to conventional lead covered cable.
Cables installed within Local Equipment/Control Rooms shall be unarmoured.
Flame retardant cables according to IEC 60332.3 shall be used for instrument cables as a
minimum requirement.
8.1.2 Particular requirements
Cables shall be of the low smoke and low halogen type and shall be water, oil & sunlight
resistant and gas & vapor tight.
Cables shall be low fume emission for:
- Sulphur
- Nitrogen
- Carbon Monoxide
the sequence running 1 to N.
Cables for ‘Intrinsic Safety (IS)’ signals shall be with the following characteristics:
- Mutual capacitance between cores 0.13 µF/km (maximum)
- Capacitance between any core and screen 0.13 µF/km (maximum)
- Inductance/resistance ratio 30 µH/Ohm (maximum)
8.1.3 Installation conditions
Instrument cables may be installed on open racks and shall withstand intense sunlight,
seawater spray, H2S + CO2 sour gas. Covers shall be provided where oil spillage can
occur to protect cables.
Cables shall be secured to racks by cleats and shall be sealed into Local
Equipment/Control Rooms by multi cable transit frames.
Instrument cables may also be direct buried within trenches or ducts.
8.2 Cable Specification
8.2.1 Flame retardant cables
Voltage grade:
500 volts
Type:
Flame retardant according to IEC 60332.3.
Conductor:
Stranded tinned copper wire according to IEC 60228 class 2.
Temperature class:
90°C
8.2.1.1 Instrument Analogue Signals:
Cross section:
For 24v D.C. Analogue Signals: Single Pairs – 1.5 mm2, 7 strands
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Multi Pairs – 1.5 mm2, 7 strands
Insulation:
PVC, low smoke, low halogen, thickness in accordance with IEC 60092‐376
Twinning:
The insulated conductors shall be twisted together to form a pair/triad/quad.
Lay of twist per pair/triad/quad shall be approximately 13 to 20 times per meter.
Wrapping for individual screen (as specified):
Each pair/triad/quad shall be wrapped with Polyester tape 0.023 mm thick, helically
wound with 25 % overlap.
Lay‐up:
The pairs shall be laid up to form a cable with a minimum of cross talk.
Bonding wire:
Stranded tinned copper drain wire as per IEC 60228.
Overall screen (as specified):
The pairs/triads/quads shall be screened with aluminium backed Mylar tape helically
wrapped with a 25 % overlap. Aluminium on the inside to be in continuous contact with
a tinned stranded copper drain wire of the same diameter as the conductor. Thickness
of screen to be 0.012 mm aluminium on 0.023 mm Mylar tape.
Individual screen (as specified):
Each pair/triad/quad shall be screened with aluminium backed Mylar tape helically
applied with 25 % overlap. Aluminium on the inside to be in continuous contact with a
tinned stranded copper drain wire of the same diameter as the conductor. Thickness of
screen to be 0.012 mm aluminium on 0.023 mm Mylar tape.
Each screen shall be insulated from the remaining cable components by the application
of suitable tapes and numbered in accordance with the pair numbering system.
Wrapping below inner sheath:
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The screened cable shall be wrapped with Polyester tape helically wound.
Inner sheath (except for unarmoured cables):
PVC, low smoke, low halogen, thickness in accordance with IEC 60092‐375
Armour (except for unarmoured cables):
Galvanised mild steel wire braid armour. Density and thickness in accordance with IEC
60092‐376 Paragraph 9.
Overall outersheath:
PVC, low smoke, low halogen, flame retardant type in accordance with IEC 60332‐3.
Outersheath colour:
LT. Blue for I.S. signals and Grey for Non‐I.S. signals
Notes: All cables specified as individual screen shall also have an overall screen.
8.2.1.2 Instrument Alarm, SOV & Power Supplies
Cross Section:
For 24v D.C. Alarm Signals: Single and Multicores ‐ 1.5 mm2 min.
For 110v A.C. (UPS) 2.5 mm2 min. to IEC 60092–353
For 230v A.C. Power Supplies: 2.5 mm2 min. to IEC 60092‐353
Insulation:
PVC, low smoke, low halogen, thickness in accordance with IEC 60092‐375
Wrapping below inner sheath:
The cable shall be wrapped with Polyester tape helically wound.
Inner sheath (except for unarmoured cables):
PVC, low smoke, low halogen, thickness in accordance with IEC 60092‐375.
Armour (except for unarmoured cables):
Galvanised mild steel wire braid armour, density and thickness in accordance with IEC
60092‐376.
ﻃﺮاﺣﻲ و ﻣﻬﻨﺪﺳﻲ ﺗﻔﺼﻴﻠﻲ
«» ﺧﻂ ﻟﻮﻟﻪ ﺷﺸﻢ ﺳﺮاﺳﺮي ﮔﺎزاﻳﺮان
Overall outer sheath:
PVC, low smoke, low halogen, flame retardant type in accordance with IEC 60332‐3.
Outer sheath color:
LT. Blue for I.S. signals and Grey for Non‐I.S. signals
8.2.2 Earthing cables
Conductors : Stranded tinned copper
Number of Cores : One
Outer sheath : PVC, low smoke, low halogen, flame retardant type in
accordance with IEC 60332‐3
Outer sheath color : In accordance with service (Yellow/Green, Green)
8.3 Core colors:
Single pair : Black, White
Multi‐pair : Black, White
The pairs shall be identified numerically and sequentially
Single Triad : : White, Red, Blue
Multi Triad : : White, Red, Blue
The triads shall be identified numerically and sequentially.
Single quad : : Black, White, Black with White strips, White with Black
strips
Multi quad : : Black, White, Black with White strips, White with Black
strips
The quads shall be identified numerically and sequentially.
8.4 Marking
8.4.1 Cables
The outersheath of cable shall be embossed at every 3 meter intervals with marks to
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distinguish the following data as a minimum:
a) Manufacturer's name and year of manufacture
b) Voltage grade (specified voltage)
c) Number of core and core sizes
d) Cable type
e) Quality of outer sheath
Single core cables shall be marked with painting and multi core cable shall be embossed
marking type.
8.4.2 Cables drums
Cable drums shall be indelibly marked by weatherproof stenciling at last one on each
flange as follows:
a) Manufacturer's name and year of manufacture
b) Drum number
c) Requisition number
d) Requisition item number
e) Rated voltage
f) Cable type by abbreviation letter and outersheath diameter
g) Number and cross section of cores
h) Length of cable on the drum (in meters)
i) Overall weight of cable and drum (in kg)
9 GENERAL INFORMATION FOR SELLERS
The requisition to which this specification is attached covers the manufacture and supply of
Instrument Cables in accordance with this specification.
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9.1 Codes and Standards
Cable shall comply with the standards listed in this specification. (Refer to Section 2.)
9.2 Cable Construction (General)
Identifications printed onto individual core insulation shall be permanent and resist
removal when abraded.
The final cable make‐up shall be homogenous and circular in cross section.
No splices are permitted in any cable conductors. Continuous conductors shall be used.
9.3 Electrical Specifications
Nominal Conductor Resistance in Ohms per 1000 meters at 20°C shall be in accordance
with IEC 60028:
- Insulation Integrity Verified by Spark Test 6000 VAC
- Finished product given dielectric test 1500VAC
- Conductor to conductor and conductor to shield for one minute
- Insulation Resistance Constant at 15.6°C 3000
(Natural Material)
9.4 Testing
Factory tests on completed wire and cable shall be in accordance with IEC 60811 and
other relevant standards listed for each cable type.
However, the following tests shall be performed on each drum of completed cable in
addition to those listed in Electrical Specification clause:
a) Continuity of conductors and shields
b) Shield isolation jackets shall withstand a dry test of 2000VAC between shields for
c) one minute
d) The insulation resistance between shields shall be a minimum of 10 mega ohms
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«» ﺧﻂ ﻟﻮﻟﻪ ﺷﺸﻢ ﺳﺮاﺳﺮي ﮔﺎزاﻳﺮان
e) per 300m of cable corrected to 15.6°C
f) Test of gases evolved during combustion of cables (IEC 60754).
Three copies of cable test certificate for each manufactured cable shall be provided by the
Seller. The following additional information shall be included in the certificate:
a) Resistance of each copper conductor in ohms/1000 metre at 20 0C
b) Maximum mutual capacitance values in pf/metre
c) Maximum L/R Ratio for adjacent cores in uH/ohm
9.5 End Sealing
After testing, the ends of the cable shall be sealed by an approved method to prevent the
ingress of moisture. Supplier shall state proposed method in his quotation.
9.6 Drum Label
Each drum shall be identified by an indestructible label securely attached, containing the
following information:
a) Requisition/Item No.
b) Drum Number (where applicable)
c) Cable Type Number
d) Conductor Size
e) Length (metres)
f) Rated Voltage
g) Weight of Cable and Drum (Kg)
This information is in addition to any other marking required by Purchaser’s Materials
Management and/or shipping Departments.
9.7 Drum Lengths
Cable drum length shall have a positive tolerance only. Purchaser reserves the right to
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«» ﺧﻂ ﻟﻮﻟﻪ ﺷﺸﻢ ﺳﺮاﺳﺮي ﮔﺎزاﻳﺮان
reject drums with a negative tolerance.
Maximum Length for single pair cable shall be 500 meters.
9.8 Cable Sample
When specified in the requisition, Seller shall provide Purchaser with a 300mm length of
each type of cable, clearly marked with its Type No, to enable glands to be checked.
9.9 Cable Data
Vendor shall submit complete data sheet to the purchaser with his quotation. The
following data are required for each cable type. Seller shall complete
Table 1 and return to Purchaser. Preliminary data shall be supplied at enquiry stage. Final
data shall be supplied prior to commencement of production.
a) Cable weight (kg/km)
b) Maximum allowable pulling tensions (kN)
c) Minimum pulling temperature (0C)
d) Minimum bending radius (mm)
e) Inductance/Resistance (L/R) ratio between the insulated conductors of any one pair.
(uH/ohm)
f) Maximum mutual capacitance per metre (pF/m)
g) Resistance of each copper conductor in ohms/1000 metre at 200C (ohm/km)
h) Cable dimensions relevant to sizing cable glands. In millimetres with
maximum/minimum tolerances allowable:
- Overall diameter
- Under armour diameter
- Over armour diameter
- Armour wire diameter
Items e, f, g are required only when specified in requisition.
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10 PREPARATION FOR SHIPMENT
Splices in individual conductors of single and multi‐pair cables, drain wire or shielding are
not acceptable.
Watertight seals shall be applied to the ends of the cable to prevent entrance of moisture
during shipment or out‐of‐doors storage at the job site.
The manufacturer shall be solely responsible for the adequacy of the preparation for
shipment provisions employed with respect to materials and their application to insure
that the cable reaches its destination in excellent working condition when handled by
commercial carrier systems.
All drums shall have lagging to prevent damage to the finished cable.
The manufacturer shall submit with his quotation, his standard “packaging” of drums.
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TABLE 1
CABLE DATA
SELLER’S NAME
CABLE TYPE NUMBER
CABLE WEIGHT (KG/KM)
MAX. ALLOWABLE PULLING TENSION (KN)
MIN. PULLING TEMPERATURE (0C)
MIN. BENDING RADIUS (MM)
L/R RATIO (Uh/ohm)
MAX. MUTUAL CAPACITANCE (pF/METRE)
CONDUCTOR RESISTANCE (OHM/KM)
OVERALL DIAMETER (Max/Min)
UNDER ARMOUR DIAMETER(Max/Min)
OVER ARMOUR DIAMETER (Max/Min)
ARMOUR WIRE DIAMETER