Conductors and Cables

8/19/2019 Conductors and Cables

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KING ABDULLAH BIN ABDULAZIZ PROJECT –

THIRD SAUDI EXPANSION OF HOLY HARAM MAKKAH & SURROUNDING AREASMASAA AC PLANT AT AJYAD

CONDUCTORS AND CABLES 16120 - Page 1 of 9S11013-0100D-TD-SPC-11B-EL-01 REV 0

SECTION 16120 - CONDUCTORS AND CABLES

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including Conditions of Contract and

Division 1 Specification Sections, apply to this Section.

1.2 SUMMARY

A.

This Section includes low voltage (LV) feeder cables, branch circuit wiring, control and

signal cables, termination, jointing and splicing.

B.

Related Sections include the following:

1. Division 7 Section “Fire stopping for fire stopping materials and installation

equipment

2. Division 16 Section "Basic Electrical Materials and Methods".

3.

Division 16 Section "Cable Trays" with its related section.

4.

Division 16 Section "Raceways and boxes" with its related section.

5.

Division 16 Section "Under floor raceways" with its related section.

6.

Division 16 Section "Electrical Identification" with its related section.

1.3

SUBMITTALS

A. Technical Data: Submit data for approval including, but not limited to, the following:

1.

Constructional details, standards to which cables comply, current carrying capacities,

de-rating factors for grouping and temperature.

2.

Manufacturer's catalogue cuts.

3.

Dimensional and electrical characteristics.

B.

Samples of each cable and wire and, if requested by Engineer, other accessories.

C. Shop and Construction Drawings: Submit drawings for approval including, but not limited

to, the following:

1. Exact routing layouts, sections and profiles of trays, feeder, sub-feeder cables and

branch circuits, with indication of any equipment to show and verify coordination

between various trades.

2.

Details of supports and fixings for buses, trays and cables.

3.

Details of connections to transformers, switchboards, panelboards etc.

4.

Details of terminations, splices and tapings where permitted, glands and bushings at

enclosures.

5. Number and size of conductors in conduit for all branch circuits in accordance with

final conduit routing.


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D. Certificate of Origin: For each lot of cable supplied, provide a certificate of origin issued by

manufacturer stating origin, date of manufacture, composition, standards to which it

complies and test certificates. All test certificates are to comply with the test requirements of

the relevant standard to which the cable is manufactured.

E.

Cable Jointing Qualifications: Submit details of the proposed cable jointers qualifications

prior to work commencing on site.

F.

Field Test Reports: Indicate and interpret test results for compliance with performance

requirements.

1.4

QUALITY ASSURANCE

A.

Installer Qualifications: Engage an experienced and certified cable splicer to install, splice

and terminate low-voltage cables.

B.

Standards: Wires and cables are to comply with IEC or other equally approved standards

and are to bear the mark of identification of the Standards to which they are manufactured.

Wires and cables not having this identification will be rejected.

C.

Current carrying capacities of conductors have been determined in accordance with the

Regulations for specified type of insulation and expected conditions of installation. No

change will be accepted in specified type of insulation unless warranted by special

conditions and approved by Engineer. Check various loads and current carrying capacities

and report any discrepancies or insufficiency of sizes indicated to Engineer.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Deliver wires and cables properly packaged in factory packed or fabricated containers,

wound on factory reels.

B. Store wires and cables in dry areas, and protect from weather, fumes, water, debris, etc.

C. Handle wire and cable carefully to avoid abrasing, puncturing and tearing wire and cable

insulation and sheathing. Ensure that dielectric resistance integrity of wires/cables is

maintained.

1.6 COORDINATION

A. Coordinate layout and installation of cables with other installations.

B.

Revise locations and elevations from those indicated, as required to suit field conditions and

as approved by Engineer.

C.

Set sleeves in cast-in-place concrete, masonry walls and other structural components as they

are constructed.


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PART 2 - PRODUCTS

2.1

MANUFACTURERS

A.

Approved Manufacturers: Subject to compliance with requirements, provide products byone of the following or approved equal:

1. B.I.C.C. (England)

2. Nexans (France)

3.

Prysmian (Italy)

4.

Lapp Kabel (Germany)

5.

Belden (U.S.A.)

6.

The Okonite Co. (U.S.A.)

7.

General Cables (U.S.A.)

8.

Draka (Holland)

9. Saudi Cables (Saudi Arabia)

10.

Jeddah Cable Company (Saudi Arabia)

11. Riyadh Cables (Saudi Arabia)

12. Bahra Cables (Saudi Arabia)

13.

El-Sewedy – Egytech (Egypt)

14.

Mesc – Fujikura (Jordan)

2.2 GENERALLY

A. Conductors: Unless otherwise specified or shown on the Drawings, cables and other feeders

are to have copper conductors. Cable conductors are to be stranded for sections 4 mm2 and

above, based on IEC 60228 Class 2. Signal and control cables are to have solid conductors

unless otherwise specified. Flexible cords are to have finely stranded conductors.

Conductors of single-core cables 25- mm2 and above are to be compacted. Multi-core

cables 35- mm2 and above are to be sectoral shape.

B.

Conductor sizes are to be metric and as shown on the Drawings. Conductors with cross-

sectional area smaller than specified will not be accepted.

C. Building wiring insulation is to be color coded or otherwise identified as required by the

Regulations and as follows:

1.

Neutral is to be blue.

2.

Protective earth is to be green-and-yellow striped.3.

Phase colors are to be brown, black and grey, or use color coding in accordance with

state enforced local regulations and standards

D.

Maintain color coding throughout installation. Phase-conductors for which outer jacket is

not color-coded are to have engraved alphanumeric mark (L1, L2, L3) or color coded heat-

shrinkable sleeves.

E. Buried Cables: Cables buried directly in the ground are to be armored type, unless otherwise

indicated in particular Sections of the Specification or on the Drawings.

F.

Water tight cables are to be used for buried cables in high water content soil are to be

watertight type, provided with water blocking swellable tape above insulation aslongitudinal water barrier, PE laminated aluminum foil longitudinally applied with suitable


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overlap as radial water barrier and an external outer sheat made of extruded black

polyethylene compound.

G.

Outdoor cables exposed to sunlight are to be provided with ultraviolet resistant PVC sheath

having 2.5% black Carbon content.

2.3 LV WIRES AND CABLES

A. Single Core PVC Insulated (85 deg. C.) Non-Sheathed Cables (Building Wires): Unless

otherwise specified, single conductor cables for wiring in conduit are to have annealed

copper conductors, compacted, generally with concentric strands and insulated with flame

retardant, moisture and heat resistant PVC/E to IEC 60227-1and -3 and SASO 1319 and

1320, suitable for wet locations and for conductor temperature of 85/90 deg. C. and flame

retardant insulation to IEC 60332-1. Wires and cables are to be 450/750 V grade.

B.

Multi-Core PVC Insulated (85 deg. C.) Cables (0.6/1 kV): To have annealed, copper

conductors, compacted, insulated with PVC/E to IEC 60502-1, flame retardant, moisture

and heat resistant, suitable for wet locations and conductor temperatures of 85 deg. C, laid

up, bedded with suitable filler and sheathed with flame retardant PVC/ST2. Armoured

cables are to have single layer of galvanized steel wire armor with flame retardant PVC/ST2

over-sheath. Cables are to comply with IEC 60502-1 and IEC60332-1.

C. Single Core XLPE Insulated Feeder Cables (0.6/1 kV): Single-core circular stranded,

annealed copper conductors, compacted, insulated with cross-linked polyethylene (XLPE),

suitable for and conductor temperatures of 90 deg. C. and flame retardant PVC/ST2 over-

sheath. Armored cables are to have taped bedding, single wire aluminum armor and flame

retardant PVC/ST2 over-sheath to IEC60502-1and IEC60332-1.

D.

Multi-Core XLPE Insulated Feeder Cables (0.6/1 kV): Single core annealed copper

conductors, compacted, XLPE insulated, for conductor temperature of 90 deg. C, laid up

and bedded with suitable non-hygroscopic material compatible with the insulation and flame

retardant PVC/ST2over-sheathed, colour black. Armored cables are to have single layer of

galvanized steel wire applied helically over extruded flame retardant PVC/ST2 bedding

(which may be an integral part of filling) and over-sheathed with PVC/ST2, colour black to

IEC60502 and IEC60332-1.

E.

Multi-Core Duel Shielded XLPE Insulated Feeder Cables (0.6/1 kV): stranded copper

conductors, compacted, XLPE insulated, for conductor temperature of 90 deg. C. An overall

tinned copper braided Shield in conjunction with an aluminium/polymer tape shield is

provided, with flame retardant PVC/ST2 over-sheathed, colour black to IEC 60502 and IEC60332-1. Each feeder is to be provided with 3 nos. symmetrically arranged grounding

conductors except for feeders less than 16 mm2 which is to be four core having the fourth

core acting as a ground conductor. Cables are to be used with variable frequency drive

applications. Cable length is not to exceed 50 m unless proper filters are specified in the

VFD.

F. Low Smoke Zero Halogen (LS0H) Cables: 600/1000 V grade, copper conductor,

compacted, insulated and sheathed with extruded material to IEC 61034-1 and 2 for low

smoke emission, IEC 60754-1 for halogen acid gas content and IEC 60754-2 for degree of

acidity of evolved gas. Cores and cross sectional area are to be as shown on the Drawings.

Phases are to be color coded in conformity with the Standards, and overall cable sheath is to

be extruded black LS0H material.


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G. Flexible cable for connection to appliances, window fans, pendants etc. is to be 300/500 V

grade to BS 6500, three or four core, with tinned finely stranded copper wires, EPR

insulated, twisted and Sheathed With Chlorosulphonated Polyethylene (CSP) Compound

And With Strengthening Cord.

H.

Fire resistant LS0H Cable (similar to Prysmian - Type FP 100 , or approved equal):

Stranded plain annealed copper conductors to IEC 60228, fire resistant insulation to BS

7655 and Low Smoke Zero Halogen (LS0H) composite sheath to IEC 61034-1 & 2 and IEC

60754-1 & 2. Cable is to be rated 600/1000 V, capable of accepting voltage surges up to 5

kV, operating conductor temperature of 90 deg. C. Cables are to be certified to have passed

IEC 60331 and IEC 60332-1 and IEC 60332-3 flame resistance fire retardant and reduced

flame propagation. Cables are to be used for central battery system, smoke curtains and

other similar loads where shown on the drawings.

I. Fire resistant LS0H Cable (similar to Prysmian - Type FP 200 Gold, or approved equal):

Solid or stranded plain annealed copper conductors to IEC 60228 (in sizes up to 4 mm²), fire

resistant insulation to BS 6899 (0.6 mm radial thickness), laminate aluminum/screen and

Low Smoke Zero Halogen (LS0H) composite sheath with tinned earth continuity

conductor/drain wire to IEC 61034-1 & 2 and IEC 60754-1 & 2. Cable is to be rated

300/500 V, capable of accepting voltage surges up to 5 kV, operating conductor temperature

of 70 deg. C. Cables are to be certified to have passed IEC 60331 and IEC 60332-1 and IEC

60332-3 flame resistance fire retardant and reduced flame propagation tests and to comply

with category CWZ of BS6387. Cables are to be used for fire alarm installations unless

otherwise specified under fire alarm section.

J. Fire resistant LS0H Cable 600/1000 V, (similar to Prysmian - Type FP-400, or approved

equal): plain copper stranded circular conductor (sizes up to 400mm²) complying with IEC

60228 with fire resistant insulation complying with BS 7655 operating conductor

temperature 90ºC, single galvanized steel wire armour and extruded low smoke zerohalogen (LS0H) over sheath . Cable is to be rated 600/1000 V. It is to be certified to have

passed IEC 60331, IEC60332-1, and IEC 60332-3 fire retardant and reduced flame

propagation tests and to comply with category CWZ of BS 6387. Cables are to be used for

feeders of the fire pumps, smoke and pressurizing fans, fire fighting elevators and other

loads where shown on the drawings.

2.4

CONTROL AND SIGNAL CABLES

A.

Multi-Core PVC Insulated Control Cables: 0.6/1 kV rating, solid 1.5 mm2, 2.5 mm2 or

stranded 4 mm2 plain circular copper conductors, with heat resistive PVC/A to IEC 60502 -

1 rated for 70 deg. C, of 7, 12, 19, 24, 30 or 37 cores. Cores are to be laid up together andfilled with non-hygroscopic material and covered with copper wire or tape screen, over

sheathed, and with flame retardant PVC/ST1, to form compact and circular cable for use in

switchgear, control gear and generally for control of power and lighting systems. Armored

cable is to have extruded PVC bedding which may be an integral part of the filling,

galvanized steel wire armoring, and over-sheath of flame retardant PVC/ST1 to IEC 60502

and IEC 60332-1, colour black. Core identification is to be white printed numbers 1, 2, 3

etc. over black insulation.

B.

Cables are to be certified to have passed IEC 60331 fire resistant and IEC 60332-1 & 3

flame retardance and reduced flame propagation to category CWZ of BS 6387.


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C. PE insulated control and signal cables, for use on data systems, are to be generally 300 V

rating, polyethylene insulated, color-coded, tinned copper conductors (0.6-mm diameter),

twisted together into pairs. Multi-pair core assembly is to be covered with binder tape,

spirally wound 0.075-mm bare copper shielding tape and provided with drain wire and

overall PVC sheath.

D. Control and signal cables, enclosed in conduit and raceways with power cables, are to be

insulated for same voltage grade.

E.

Multi core PVC insulated cables (300/500 V) annealed copper conductors, solid conductors,

up to 4 mm2 unless otherwise indicated, insulated with moisture and heat resistant PVC/C

to IEC 60227 and with over sheath of flame redundant PVC type ST1 to IEC 60227 and IEC

60332-1.

2.5

CONNECTORS (LV POWER)

A.

Connector - Type A-1: Pressure indent type, for terminating or making T-taps and splices on

conductors 10 mm2 and smaller. Connector is to be non-ferrous copper alloy applied to

conductor by mechanical crimping pressure, with vinyl insulating sleeves or phenolic

insulating covers.

B.

Connector - Type A-2: Bolted pressure split type for terminating or making T-taps and

splices on conductors 16 mm2 and larger. Connector is to be cast non-ferrous copper alloy

applied to conductor by clamping with minimum of two screws and provided with phenolic

insulating cover.

C. Connector - Type B-1: Pre-insulated, spring type, for branch circuit and fixture wiring.

Connector is to be steel encased spring with shell, insulated with vinyl cap and skirt, type

Scotchlok brand, as manufactured by Minnesota Mining & Mfg. Co. or 3M or other equal

and approved.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine raceways and building finishes to receive wires and cables for compliance with

requirements for installation tolerances and other conditions affecting performance of wires

and cables. Do not proceed with installation until unsatisfactory conditions have been

corrected.

B.

Before pulling wires in conduit check that inside of conduit (and raceway in general) is free

of burrs and is dry and clean.

3.2

INSTALLATION

A. General: Building wires and cables are to be installed in conduit, trunking or ducts indoors

and in conduit outdoors, unless otherwise shown the Drawings.


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3.3 FEEDER AND SUB-FEEDER INSTALLATION (0.6/1 KV)

A.

Cables generally are to be run through duct-banks, shafts or special recesses, clamped to

steel racks or cable trays. Cables run through ventilation shafts are to be installed in steel

conduits.

B. Fixing: Single cables above suspended ceilings or in concealed spaces are to be fixed

directly to walls or ceilings but must be accessible. Where two or more cables are run in

parallel, they are to be fixed on galvanized steel perforated trays or on other approved

special cable supporting and protecting arrangement.

C.

Clamps: Where cables are fixed to steel trays or supporting structures, approved galvanized

cast steel clamps, cleats (or molded aluminum clamps for single core cables) are to be used

at distances not exceeding 20 diameters.

D.

Joints or splices will not be accepted on main and sub-feeders. Cables are to be supplied in

lengths sufficient for straight-through un-jointed termination to termination pull.

E. Directly buried cables crossing under roads, pipe banks or other services, are to be laid in

heavy duty PVC duct banks. In no case are cables to be directly buried in concrete, in

masonry or in floor finishing.

F.

Buried cables liable to mechanical damage are to be drawn through PVC conduit or asbestos

cement pipe. If steel conduit is used, all three-phase conductors, neutral and protective earth

circuits are to be in the same conduit.

G. Exposure to Heat: Route wires and cables to prevent exposure to excessive heat or to

corrosive agents. If such condition is unavoidable, cables are to be type designed for

particular condition.

H. Insulating covers are to be applied to prevent exposure of bare cable connections. Insulating

cover is to be purpose made and is to provide minimum insulation level equal to that of

conductor insulation.

I.

Glands for various single-core and multi-core cables are to be purpose made and suitable for

rigid mounting to equipment enclosure.

J. Seal around cables penetrating fire-rated elements using approved fire-stopping material

according to Division 7 Section “fire stopping”

3.4

CABLES CONNECTIONS, JOINTING AND TERMINATIONS

A.

Through joints will not be allowed in feeder cables where adequate manufacturer's lengths

are available. Where a joint is necessary, it has to be made inside boxes, handholes or

manholes.

B.

Recommendations: Through joints and terminations are to be carried out strictly in

accordance with cable manufacturer's recommendations, and made with correct specified

materials, boxes, tapes, compounds or mixtures, stress cones, glands and bonds as

applicable.


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C. Jointing: Joints are to be filled with epoxy resin after taping unless contrary to cable

manufacturer's recommendations. Sample site constructed cable terminations and through-

joints are to be submitted prior to commencing work on site. Samples are to be constructed

in the presence of the Engineer and are to be available for test and inspection in accordance

with manufacturer's recommendations.

D. Cutting tools for jointing and terminating cables are to be purpose made, to prevent damage

to insulation in general.

E.

Cleaning of lacquer on conductors is to be by use of 'Scotch Brite' sponge and white spirit or

equal approved.

F.

Tighten electrical connectors and terminals including screws and bolts, in accordance with

manufacturers published torque-tightening values. Where manufacturer’s torquing

requirements are not indicated, tighten connectors and terminals to comply with

international standards.

3.5 FIELD QUALITY CONTROL

A.

Cable tests are to be carried out in accordance with the requirements of the Regulations and

Standards.

B.

Test Equipment: Provide megger testers of various ranges as applicable. Use 500 V megger

on installations with nominal voltage up to 500 V, and 1000 V megger on installations with

nominal voltage over 500 V up to 1000 V.

C. Insulation resistance for LV power and lighting installations is to be carried out in

accordance with BS7671 (The IEE wiring Regulations”)..

D. Insulation resistance for control and signal cables is to be minimum 10000 Megohm-km for

PE insulated cables and 100 Megohm-km for PVC insulated cables, all measured core-core

and core-earth, in accordance with the Regulations.

E.

Prior to energization of circuitry, check installed wires and cables with megohm meter to

determine insulation resistance levels to ensure requirements are fulfilled.

F. Prior to energization, test wires and cables for electrical continuity and for short-circuits.

G. Subsequent to wire and cable hook-ups, energize circuitry and demonstrate functioning in

accordance with requirements. Where necessary, correct malfunctioning units, and then

retest to demonstrate compliance.

END OF SECTION 16120

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Conductors and Cables