CP2-0000-00-JI-SPE-0006 Rev G2 Specification for ... · PDF filePetrofac (Malaysia-PM304) Limited Cendor Phase 2 Development Project Specification for Instrument Cables CP2-0000-00-JI-SPE-0006

Petrofac (Malaysia-PM304) Limited Cendor Phase 2 Development Project Specification for Instrument Cables CP2-0000-00-JI-SPE-0006

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PETROFAC (MALAYSIA PM-304) LIMITED

CENDOR PHASE 2 DEVELOPMENT PROJECT SPECIFICATION FOR INSTRUMENT CABLES

DOCUMENT No. CP2-0000-00-JI-SPE-0006


Rev G2 Page 2 of 39

DISTRIBUTION LISTING

Copy Number Document Holder

Master (signed electronic) Document Control Centre (DCC)

Master (electronic) TeamBinder

Distribution List

001

002

003

004

005

006

007

008

009

010

REVISION CONTROL

Issue Description of Change Date

REV A1 Interdisciplinary Check 14/4/2010

REV G1 Issued For Project Implementation 27/5/2010

REV G2 Issued For Project Implementation 6/8/2010

© Petrofac (Malaysia-PM304) Limited 2009

Copyright in the whole and every part of this document belongs to Petrofac (Malaysia-PM304) Limited and the information herein contained may not be used, sold, transferred, disclosed, copied or reproduced in whole or part in any manner or form to any person without the prior consent of Petrofac (Malaysia PM-304) Limited.


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ABBREVIATIONS

AWA Aluminium Wire Armour EPC Engineering Procurement and Construction EPR Ethylene Propylene Rubber GSWA GSWB

Galvanised Steel Wire Armoured Galvanised Steel Wire Braid

ITP Inspection and Test Plan LSZH Low Smoke Zero Halogen LV Low Voltage PVC Poly Vinyl Chloride QA Quality Assurance SDRL Supplier Data Requirements List SHF2 Halogen Free Elastomeric or Thermosetting Material XLPE Cross-link Poly Ethylene


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PREFACE

Purpose

The purpose of this specification is to detail the minimum requirement of Instrument Cables for Cendor Phase 2 Field Development Project in accordance with Petrofac Group practice.

Review and Update

The Technical Authority for this document is the Project Engineering Manager who should also be consulted if further information on the subject matter is required. The Technical Authority is also responsible for the accuracy of information contained within this document.

This document will be re-issued before the award of EPC contracts.

The project management system permits continuous update to the document.

Responsibility of Copyholders

The master copy of this document is held within project records and electronic copy is accessible to all project personnel. Paper copies shall be issued to external parties in Petrofac and Contractors as registered copy holders.

It is the responsibility of the registered copyholder(s) to maintain the accuracy of this document by ensuring that all updates are promptly incorporated and acknowledged.

Furthermore, the registered copyholder must at all times maintain custody of this document unless prior approval is given by the Document Owner.


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TABLE OF CONTENTS

DISTRIBUTION LIST REVISION CONTROL ABBREVIATIONS PREFACE 1.0 INTRODUCTION.................................................................................. 6 1.1 Scope of Specification .......................................................................... 6 1.2 Scope of Supply.................................................................................. 6 1.3 Project Specifications .......................................................................... 6 1.4 Definitions ........................................................................................ 7 1.5 Order of Precedence............................................................................ 7 1.6 Supplier Exceptions ............................................................................. 8 1.7 Language.......................................................................................... 8 2.0 REGULATIONS, CODES AND STANDARDS ................................................... 9 2.1 Codes & Standards .............................................................................. 9 2.2 Regulations ......................................................................................10 3.0 GENERAL REQUIREMENTS ................................................................... 11 3.1 Operations and Design Life ...................................................................11 3.2 Environmental Conditions.....................................................................11 3.3 Materials .........................................................................................11 3.4 HSE Requirements..............................................................................11 3.5 Transportation Loads ..........................................................................12 4.0 CABLES DETAIL SPECIFICATION ............................................................ 13 4.1 Cable Type and Descriptions .................................................................13 5.0 CABLE AND DRUMS IDENTIFICATION ...................................................... 31 5.1 Marking on Cables ..............................................................................31 5.2 Marking on Drums ..............................................................................31 6.0 QUALITY ASSURANCE, INSPECTION & TESTING ......................................... 33 6.1 Quality Assurance ..............................................................................33 6.2 Inspection .......................................................................................33 6.3 Testing ...........................................................................................33 7.0 PREPARATION FOR SHIPMENTS ............................................................ 36 8.0 SUPPLIER DATA REQUIREMENTS ........................................................... 37 9.0 GUARANTEE.................................................................................... 38 10.0 DOCUMENTATION............................................................................. 39


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1.0 INTRODUCTION

1.1 Scope of Specification

This document together with the referenced document, defines the minimum requirements for the design, manufacture, construction, tests and delivery of instrument cables for Cendor Phase 2 Development Project.

The Supplier shall ensure that the cables supplied are complying with requirement stated in codes and standards stated here in; which form an integral part of this specification.

The Supplier shall ensure that all equipment and services supplied are meeting the requirements of this specification, codes and standards nominated here in whether the equipment are supplied by Supplier directly or by Supplier’s Sub-Contractor.

1.2 Scope of Supply

The supplier shall, wherever possible, draw upon his existing, pre-engineered or standard designs to satisfy the requirements of the specifications.

The scope of supply shall include but not limited to the following:

a) Performance Testing.

b) Complete documentation submitted in accordance with the specification

c) All the identified certificates including but not limited to materials and design verification.

d) Completed inspection, QA/QC and testing requirements including performance acceptance tests as defined in the specification along with all supporting documentation.

e) Suitable preparation of the units for transportation.

f) Transportation from the fabrication / assembly location to the point of delivery.

g) Provision of additional services as may be agreed at the time of order placement.

Supplier may quote alternate arrangements and specifications if they are equal to or exceed the general requirements of this specification. These alternates shall be clearly highlighted in Supplier’s bid for Purchaser evaluation and approval.

The Supplier shall submit full technical details of his equipment which meets the requirements detailed herein. Aspects of the requirements, which cannot be met, shall be identified and the variances explained.

The cables shall be DNV, ABS or LR approved for marine application.

1.3 Project Specifications

Equipment shall be designed in accordance with the latest edition of the following project specifications:

PETROFAC Project Documents CP2-0000-00-ST-SPE-0001 General Design Requirements for Fixed Offshore

Structure


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CP2-0000-00-ST-SPE-0002 CP2-0000-00-ME-DBM-0001

General Design Requirements for Floating Deck Structure Design Basis Memorandum

1.4 Definitions

The following definitions (including abbreviations) shall apply throughout this document:

COMPANY Denotes the generic Petrofac entity, which includes both Petrofac Energy Developments and Petrofac (Malaysia-PM304) Limited.

PML Petrofac (Malaysia-PM304) Limited is the legal entity that operates the Cendor field and the entity that places project related contracts and insurances. It is also the entity that will eventually operate the development.

PMT Project Management Team; specifically refers to that part of Petrofac which is directly responsible for management of the CP2 Project.

CP2 Cendor Phase 2 Development Project; also referred to as “the Project”.

Contractor Organization contracted directly by PML to complete Work

Sub-Contractor Organization contracted by a Contractor to provide defined services.

Supplier Organization responsible for providing defined goods or services associated with a Purchase Order or contract executed by Contractor or Sub-Contractor.

Shall This word, or the terms "REQUIRED" or “MUST", indicates an absolute requirement.

Should This word indicates a recommendation that whilst preferred may not be implemented provided some equivalent is proposed and agreed by Petrofac. The full implications must be understood and carefully weighed before choosing a different course.

May This word, or the adjective "OPTIONAL", indicates that an item is truly optional.

Purchaser The organization placing a purchase order for the supply of equipment or services for the CP2 Project. The Purchaser could be the COMPANY or the Contractor or some other party appointed by the COMPANY or Contractor.

1.5 Order of Precedence

In the event of any conflict arising between this Specification and other documents listed herein, refer comments to the Purchaser for clarification before design or fabrication commences. The order of precedence that applies is as follows:

1. Malaysian legislation governing the equipment and installation.

2. Purchase Order and Purchase Requisition.

3. Project Datasheets.


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4. This Specification.

5. Equipment specification

6. Project Drawings.

7. Project Specifications.

8. International Codes and Standards.

9. Petronas Technical Standards (PTS)

1.6 Supplier Exceptions

The Supplier shall be responsible to submit, together with the Tender, a list of deviations or exceptions to this Specification. In the absence of any exceptions, it will be construed that the Supplier fully complies with this Specification.

1.7 Language

All documentation and communications shall be in the English language.


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2.0 REGULATIONS, CODES AND STANDARDS

Supplier shall ensure that the supplied equipment conforms to the local and national regulations for installation and operation in Malaysia.

2.1 Codes & Standards

The Supplier shall include a detailed list of the codes and standards proposed for use to complete the scope in his proposal. These may include alternatives to those listed below, but such variances shall be highlighted in the proposal and will be subjected to the agreement of the COMPANY.

International Electrotechnical Commission (IEC) IEC 60092-350 Part 350: Shipboard power cables – General construction and test

requirements IEC 60092-351 Part 351: Insulating materials for shipboard and offshore units,

power, control, instrumentation, telecommunication and data cables

IEC 60092-352 Part 352: Choice and installation of electric cables IEC 60092-353 Part 353: Single and multicore non-radial field power cables with

extruded solid insulation for rated voltage 1kV and 3kV IEC 60092-354 Part 354: Single and three core power cables with extruded solid

insulation for rated voltages 6kV (Um = 7.2kV) up to 30kV (Um=36kV)

IEC 60092-359 Sheathing materials for shipboard power and telecommunication cables

IEC 60092-359 Part 359: Sheathing materials for shipboard power and telecommunication cables.

IEC 60092-376 Part 376: Cables for control and instrumentation circuits 150/250V (300V)

IEC 60228 Conductors of Insulated Cables IEC 60331 Test for Electric Cables under Fire Conditions – Circuit Integrity IEC 60332 Tests on Electric and Optical Fibre Cables Under Fire Conditions IEC 60446 Basic and safety principles for man-machine interface, marking

and identification - Identification of conductors by colours or numerals

IEC 60502 Power cables with Extruded Insulation and Their Accessories for Rated Voltages from 1kV (Um=1.2kV) up to 30kV (Um=36kV)

IEC 60754 Test on Gases Evolved During Combinations of Electric Cables IEC 60811 Common Test Methods for insulating and sheathing materials for

electric cables IEC 61034 Measurement of Smoke Density of Electric Cables Burning Under

Defined Conditions IEC 61892-4 Mobile and Fixed Offshore Units – electrical Installations Part 4 –

Cables IEC61158-2 Industrial communication networks - Fieldbus specifications - Part 2: Physical layer specification and service definition NEK 606 Technical specification Cables for offshore installation – halogen- free and / or mud resistant


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2.2 Regulations

All equipment shall comply with the requirements of the appointed Classification Society which is a member of IACS. The following classification societies are considered acceptable:

DNV Det Norsk Veritas

BV Bureau Veritas

ABS American Bureau of Shipping

LR Lloyd’s Register of Shipping



3.0 GENERAL REQUIREMENTS

3.1 Operations and Design Life

The cables shall be designed for minimum life duration of 10 years for FPSO and 20 years for Wellheads Platforms, in the environment and for the duty specified herein and on the Project Data Sheets.

3.2 Environmental Conditions

Cables shall be installed on FPSO and Wellheads for all environmental conditions specified in Design Basis Memorandum CP2-0000-00-ME-DBM-0001.

3.3 Materials

The cables manufactured shall also be a product regularly manufactured by the Supplier.

The cable drum radius should not be less than 125% of the minimum bending radius of the cables.

Cables shall be manufactured in one continuous length as per ordered drum length.

Cable conductors shall be made of tinned concentric stranded, continuous copper conductor made up from fully annealed round copper wires free from imperfections in accordance to IEC 60092. Non-hygroscopic fillers shall be used to maintain a circular formation.

The cable inner and outer sheath shall be extruded over the insulation and armour. They shall be resistant to scuffing, rough handling, UV radiation, heat, crude oil, diesel, and natural gas corrosive agents normally found in crude oil processing facility.

Specific for wellhead applications, cables supplied and manufactured shall be mud-resistance of SHF2-Mud type in accordance with NEK 606.

The cable outer sheath shall be coloured according to the cable type and embossed with the cable identification at one (1) meter intervals.

For non-critical equipment or circuits, cables shall as a minimum be flame retardant complying with IEC 60332 Part 2 Cat A for instrumentation and communication cables with the oxygen index of not less than 30 and acidic emission less than 0.5% in accordance with IEC 60754.

3.4 HSE Requirements

The Supplier shall be responsible for ensuring that the goods and services supplied meet all applicable regulations on health, safety and environmental issues.

Where required by the procurement documentation, the Supplier shall complete HSE questionnaires and provide information that may include:

• Safety Plan for the Scope of Supplier

• Detail of Suppliers Safety Management System



3.5 Transportation Loads

Supplier to ensure the cables are able to withstand without damage during transfer handling and the forces during transportation through proper packaging, supports, etc as defined in CP2-0000-00-ST-SPE-0001, General Design Requirements for Fixed Offshore Structure and CP2-0000-00-ST-SPE-0002, General Design Requirements for Floating Deck Structure



4.0 CABLES DETAIL SPECIFICATION

4.1 Cable Type and Descriptions

4.1.1 Instrumentation and General Process (Flame Retardant Instrument Cable) – Type I2

Multi-pair individually screened cable for use in fixed installation, indoors and outdoors.

Cable type : I2

Rated voltage : 150/250V

Construction : IEC 60092

Conductors : Tinned annealed stranded copper

Insulation : Ethylene Polypropylene Rubber (EPR)

Screen : Aluminium/PETP tape applied helically with a tinned stranded copper drain wire of 1.0mm2 in contact with PETP tape.

Bedding : SHF2

Armour : Galvanised steel wire braid

Outer sheath : Flame retardant (IEC 60332), SHF2 halogen free

Outer sheath

Colour : Light blue for I.S and Black for Non-I.S

Cable identification: As per Section 5.0

No. of pairs

Min. Conductor size Core Identification

1 1.0mm2 Black and White 2 1.0mm2 Black, White and each core printed with pair

number 5 1.0mm2 Black, White and each core printed with pair



number


Multi-pair collectively screened cable for use in fixed installation, indoors and outdoors.

Cable type : I3








Bedding : SHF2



Outer sheath



No. of pairs






number


Multi-pair individually and collectively screened cable for use in fixed installation, indoors and outdoors.

Cable type : I4






Bedding : SHF2



Outer sheath





No. of pairs






number


Individually triad screened multitriad cable for use in fixed installation, indoors and outdoors.

Cable type : I5






Bedding : SHF2



Outer sheath



No. of Triples


1 1.0mm2 Red, Black and White 5 1.0mm2 Red, Black and White and each core printed

with triad numbers 7 1.0mm2 Red, Black and White and each core printed


with triad numbers




Collectively triad screened multitriad cable for use in fixed installation, indoors and outdoors.

Cable type : I6






Bedding : SHF2



Outer sheath



No. of Triples





with triad numbers


Collectively and individually triad screened multitriad cable for use in fixed installation, indoors and outdoors.

Cable type : I7






Bedding : SHF2





Outer sheath



No. of Triples





with triad numbers

4.1.7 Fire and Gas, Vital Services and Fire Survival (Fire Resistant and Flame Retardant) – Type F2

Fire survival multi-pair individually screened cable for use in fixed installation, indoors and outdoors.

Fire resistant characteristics tested as per IEC 60331.

Flame retardant characteristics tested to IEC 60332-3 Category ‘A’

Cable type : F2




Insulation : Mica glass tape primary insulation, Ethylene Polypropylene Rubber (EPR)

Screen : Aluminium/PETP tape applied helically with a stranded copper drain wire of 1.0mm2 in contact with PETP tape.

Bedding : SHF2


Outer sheath : Fire resistant (IEC 60331), Flame retardant (IEC 60332), SHF2 halogen free

Outer sheath





No. of Pairs



numbers 5 1.5mm2 Black, White and each core printed with pair



numbers


Fire survival multi-pair collectively screened cable for use in fixed installation, indoors and outdoors.



Cable type : F3






Bedding : SHF2



Outer sheath





No. of Pairs






numbers


Fire survival multi-pair individually and collectively screened cable for use in fixed installation, indoors and outdoors.



Cable type : F4






Bedding : SHF2



Outer sheath





No. of Pairs






numbers


Fire survival individually triad screened multitriad cable for use in fixed installation, indoors and outdoors.



Cable type : F5






Bedding : SHF2



Outer sheath





No. of Triples


1 1.5mm2 Red, Black and White 5 1.5mm2 Red, Black and White and each core printed with

triad numbers 7 1.5mm2 Red, Black and White and each core printed with


triad numbers

Triplets shall be identified by having the triple number printed on the insulation in contrasting colour.


Fire survival collectively triad screened multitriad cable for use in fixed installation, indoors and outdoors.



Cable type : F6






Bedding : SHF2



Outer sheath





No. of Triples





triad numbers



Fire survival collectively and individually triad screened multitriad cable for use in fixed installation, indoors and outdoors.



Cable type : F7






Bedding : SHF2



Outer sheath





No. of Triples





triad numbers



Fire survival pair collectively screened cable for addressable fire alarm system, indoors and outdoors.



Cable type : F8






Bedding : SHF2



Outer sheath



No. of Pairs


1 2.5mm2 Black and White



4.1.14 Low Voltage Vital Power Cables (Fire Resistant Type) – Type P5

Stranded, annealed tinned copper conductors, mica glass tape – primary insulation, , galvanised steel wire armoured and extruded LSZH outer sheath or equal, 600/1000V AC grade cable.


Fire resistant characteristics tested to IEC 60331

Cable type : P5

Rated Voltage : 600/1000V

Conductors : Circular annealed tinned stranded copper wire to IEC 60228

Insulation : Mica Glass Tape-Primary Insulation, thermoset

Bedding : LSZH, Black Colour

Armour : Galvanised steel wire armoured

Outer sheath : Fire resistant, SHF-2, oil resistant as per IEC 60092-359. Black colour.

: Indelible red stripe along the length of cable

Cable identification : As per Section 5.0

No. of cores Min. Conductor size Core Identification 2 (L1,N) or (L1,L2) 2.5mm2 Black with numbering ‘1’ and ‘2’ 3 (L1,L2,L3) 2.5mm2 Brown, Black, Grey 4 (L1,L2,L3,N) 2.5mm2 Brown, Black, Grey, Blue 5 and above 2.5mm2 Black number on while sheath

4.1.15 Type TC-Thermocouple Extension Cables, Type K, Chromel-Alumel

Multipair cable, armoured, Polyethylene insulated, PVC outersheath, Steel Wire Armoured (SWA) and drain wires.

Cable type : TC

Conductors : Copper-Constantant

Insulation : Polyethylene

Drain Wire : Tinned Copper

Screen : 0.024 mm AL/PETP tape

Binding : PETP tape

Bedding : Polyethylene black


Sheath : Flame retardant reduced propagation (FRRP) PVC outer

sheath. Oxygen index greater than 30 by ASTM D2863-74 test, HCL emission when burned not greater than 17% by weight



Cable identification : The external surface of the outer sheath to be

embossed/printed every 1000mm in English with BS

number, cable size, type (FRRP) and manufacturer’s name

Core identification : To be either colour coded or number system

Outersheath colour : Black

Certification : Test certificate to be supplied per batch, identifying

applicable drums

No. of pairs

Min. Conductor size

10 0.5 mm2 20 0.5 mm2

4.1.16 Type T1-Fixed Installation for Telecom Control, Alarm & other mandatory systems.

Multipair cable, collective screened, armoured, Polyethylene insulated, PVC outersheath, Aluminium foil screen and drain wires.

Cable type : T1

Construction : Fire resistant to IEC 60331

Voltage Rating : 100 V (Min)

Conductors : High conductivity solid plain annealed copper wire

Insulation : Silicon rubber

Drain Wire : Tinned Copper


Sheath : Flame retardant, PVC outer sheath. Oxygen index greater than 30 by ASTM D2863-74 test, HCL emission when burned not greater than 17% by weight



number, cable size, type, voltage grade and manufacturer’s name



No. of pairs

Min. Conductor size

2 1/0.8 mm 5 1/0.8 mm 50 1/0.8 mm



4.1.17 Type T2-Fixed Installation for Telecom Control, Alarm & other mandatory systems.

Armoured, Individual pair, Silicon rubber insulated, Colour coded twisted pair individually screened aluminium foil screen with tinned copper drain wire EMA/EVA sheathed SWB. Cable type : T2

Construction : Colour coded twisted together. Pairs shall be laid up and individually screened. Aluminium foil screen/EMA sheath over tinned copper drain wire. Pairs shall be identified by numbers.

Voltage Rating : 100 V (Min)

Conductors : High conductivity solid plain annealed copper wire

Insulation : Silicon rubber

Drain Wire : Aluminium foil screen/EMA sheath over tinned copper

drain wire.


Sheath : Flame retardant, EMA sheathed to IEC 60 332 part 3 Cat. A. Both EMA bedding and outer sheath shall be the type with oxygen index not less than 30, temperature index not less than 260 Deg. C and HCL emission of maximum 0.5 % ( by weight ).



number, cable size, type, voltage grade and manufacturer’s name



No of Pairs Conductor Size (mm²) 1 1.5 2 1.5 5 1.5

10 1.5

1 2.5 2 2.5 5 2.5

10 2.5

4.1.18 Type CAT5e - For low speed/high speed data in fixed installations indoor for Telecom circuits

Collective screened, multipair cable, braided, Polyethylene insulated and Steel Wire Braided (SWB)

Cable type : CAT5e

Construction : Flame retardant to IEC 60332



Voltage Rating : 600V

Temperature Rating : -10 deg C to +75 deg C

Construction : TIA/EIA-568-B.2-1

Conductors : Solid insulated copper 24 AWG

Insulation : HD Polyethylene

Collective Screen : 0.024 mm AL/PETP tape

Inner Sheath (Shield) : Aluminium/polyester tape and tinned copper continuity wire

Outer Sheath : UV resistant, abrasion resistant polyethylene


Flame Test : LSZH flame retardant to IEC 60332 Part 1

Cable identification : Every 1000mm increment


Frequency : 100 Hz

Attenuation : 22 dB @100 MHz

Near End Crosstalk (NEXT): 35.3 dB (min. @ 100 MHz)

Power Sum NEXT : 32.3 dB (min. @ 100 MHz)

Equal Level Far-end

Crosstalk (ELFEXT) : 23.8 dB (min. @ 100 MHz)

Power Sum ELFEXT : 20.8 dB (min. @ 100 MHz)

Return Loss : 20.1 dB (min. @ 100 MHz)

Delay skew : 45 nsec (max. per 100m)

Nominal impedence : 100 ohms ± 15%

Wire Colour

Pair No. A-wire B-wire Pair 1 White Blue Pair 2 White Orange Pair 3 White Green Pair 4 White Brown

4.1.19 Fibre Optic Cables – O2

The optical fibres construction shall conform to the relevant standard as listed below:

• Single mode fibre ITU Recommendation G652

• Multimode fibre IEC 60793



The optical fibres shall have characteristics as defined below.

Cable type : O2

Armour : Chemical resistant nylon armour

Inner Sheath : Polyethylene

Outer sheath : Flame retardant (IEC 60332 Part 1), low smoke, zero halogen thermoset

Outersheath

colour : Black

Single Mode Fibre

• Core diameter 9 microns

• Cladding diameter 125 microns

• Coating diameter 250 microns

• Attenuation @1310nm < 0.4 dB/km, @1550nm < 0.25 dB/km

• Bandwidth ~ 100 Terahertz

• Dispersion (max) 3.8 ps/nm.km (1310nm), 19 ps/nm.km (1550nm)

Multimode Fibre

• Core Diameter 62.5 microns

• Cladding Diameter 125 microns

• Coating Diameter 250 microns

• Attenuation @850nm < 3.0 dB/km, @1300nm < 1.0 dB/km

• Bandwidth @850nm > 160MHz.km, @1300nm > 500MHz.km

Note:Supplier shall quote in the tender the termination and joints suitable for the type of the FO cable specified.

4.1.20 Composite Cables C2 – For CCTV

CCTV camera cable shall carry the following signals:

• Composite video signal

• Telemetry signals (for Pan/Tilt, Zoom, Wash/Wipe)

• Power supply for Camera Enclosure and Camera.

The cable shall comply with the following minimal specifications:

• Conductors

Video : Coaxial, 75Ω

Telemetry : Stranded copper, 0.20 mm² cross section

Power : Stranded plain copper, 2.5mm² cross section



• Composition

Video : 1 coaxial

Telemetry : 2 shielded twisted pairs

Power : 3 cores

• Colour coding : Shall be adequate to permit identification by functionality and standards

• Insulation : Cross-linked polyethylene (XLPE)

• Insulation resistance : 5000 MΩ / km minimum

• Insulation thickness : To be compatible with rail-mounted terminals

• Flame retardant : In compliance with IEC 60332-3C

• Overall outer sheath : LSZH

• Armour : steel wire braid armour

• Outer sheath colour : Black

4.1.21 FOUNDATION™ Fieldbus cable – H1

Type A, shielded, twisted pair, Individual screened, SWB,2 pairs for trunk and 1 pair for spurs

Construction Cable type : Type A, Twisted Pair With shield

Construction : IEC 61158-2, FF-844

Voltage Rating : 300V RMS

Conductors : Stranded Plain Copper

Insulation : Cellular Polyethylene With Skin layer

Screen : One side plastic coated aluminium tape, metallic surface outside in contact with a tinned copper braid

Inner Sheath (Shield) : Aluminium/polyester foil – 100% coverage

Outer Sheath : Oil resistant, UV resistant, abrasion resistant polyethylene


Core Identification : (+) core: orange, (-) core ; blue

Cable Marking : Fieldbus Cable H1, Type A, IEC 61158-2 FF-844

UL-marking, Conductor size, 300v, temperature,

Sunlight resistant marking

Cable identification : Every 500 mm increment

Outer sheath colour : Blue ; I.S / Black : Non I.S



Physical Properties and Fire Behaviour

Fire Behaviour : Flame Retardant - IEC 60332-1

Flame Propagation - IEC 60332-3, Cat. D

Oil Resistance : IEC 60092-359

UV Resistance : UL 1581, Abs.1200

Temperature Rating : -40C to +105c

Min. Bending Radius : 10 x Cable O.D.

Max. Tension : 90N

Electrical Characteristic at 20ºC

Max. DC Resistance per Conductor : 23.5Ω/km

Impedance at 31.25 kHz : 100Ω ± 10Ω

Signal Attenuation at 39 kHz : < 3 dB/km

Max . DC Resistance for drain wire : 36.6Ω/km

Wire to Shield capacitive unbalance : 4.8pF/m

Propagation Delay Change : Max. 1.7 µs/km

7.9 kHz'-39 kHz)

Operating Voltage : 300V

Test Voltage : 1500V

No. of pairs

Conductor size

1 1/1.13mm (0.88 mm2) 2 1/1.13mm (0.88 mm2) 20 1/1.13mm (0.88 mm2)



5.0 CABLE AND DRUMS IDENTIFICATION

5.1 Marking on Cables

The following information shall be indelibly printed in English (all dimension in metric), on the surface of the cable jacket at regular interval over the entire length of the cable for each of the identification.

• Voltage Grade

• Cable type

• Cable length (every 1 meter)

• Number of Conductors

• Conductor Size/Sizes

• IEC Standard

• Supplier’s name

• Year of Manufacture

Cable ends shall be properly sealed and fixed to the drum.

5.2 Marking on Drums

RED paint shall be applied on both sides of cable drums for cables intended for FPSO, while BLUE paint on both sides of cable drums for cables intended for wellhead platforms.

The non-returnable wooden drums shall be marked with the following information:

• Purchase Order Number

• Supplier’s name or Trademark

• Drum number

• Cable type

• Voltage grade

• Insulation type

• Number of Cores and core size

• Total cable length (m)

• Net and gross weight

• Manufacturer’s name or trademark

• Month and year of manufacture



The text shall be printed on stainless steel plate and stapled or fixed to both sided of the drum.

Actual cable length on the reel should be 3% more than specified on the purchase order. No negative tolerance shall be allowed



6.0 QUALITY ASSURANCE, INSPECTION & TESTING

6.1 Quality Assurance

Supplier specific project quality plan shall make reference to and reflect the requirements of Company’s Project Quality Plan CP2-0000-00-QA-QPL-0001. The Supplier, and his Sub-Suppliers, shall operate a quality system satisfying the applicable provision(s) of ISO 9000 (series), or agreed equivalent standard, commensurate with the goods and services provided.

The Supplier shall ensure that his sub-suppliers operate a quality system meeting the specified conformance criteria to ISO 9000. The Supplier’s Quality System will be subject to the Purchaser’s approval prior to issue of a Purchase Order. Major Sub-Suppliers will be subject to the same approvals. The Purchaser reserves the right to conduct a Quality Audit at the Supplier’s /Sub-Supplier’s facilities at any stage during manufacture.

The Supplier shall provide facilities for, and cooperate with, Purchaser and Inspectors during manufacturing, assembly and testing.

6.2 Inspection

Inspection and testing shall be carried out in accordance with the approved Project Quality Plan CP2-0000-00-QA-QPL-0001and shall comply with the requirements of this specification, the data sheets and other referenced documentation forming part of the Purchase Order.

The Purchaser or his nominated consultant reserves the right to carry out its own inspection at the manufacturer’s works. The Supplier shall provide free access to his works, and to that of his Sub-Suppliers, for both the Purchaser and his authorized representative(s). All necessary certification documents relating to materials, shop test data, etc., shall be made available to verify that the requirements of the purchase order are being met.

The responsibility for inspection rests with the Supplier. The approval of any work by the Purchaser, or their authorized representative, and the release of equipment for shipment shall in no way relieve the Supplier of any responsibility for carrying out the provisions of this specification.

The Supplier shall furnish a representative quality plan detailing his normal scope of inspection and testing with the bid.

6.3 Testing

All testing shall be carried out at the manufacturer’s test facility. Test equipment shall be supplied by the manufacturer and shall be calibrated within six months of the test date. The minimum scope of testing is summarised below. The Supplier shall supply an ITP with the Tender.

The Supplier shall provide the Purchaser with at least 14 calendar days advance notice to witness tests performed in either the Supplier’s shop or his sub-Suppliers shops.

Arrangement for 3rd party witness/Surveyor’s shall be by Supplier.



6.3.1 Visual Tests

Visual inspection for general workmanship, cable construction such as concentricity, dimension checks, cable marking, colour coding and so on shall be performed.

6.3.2 Type Tests

Non-electrical

• Bending test

• Flame test on sheath

• Ageing test on completed cables to test compatibility between materials

• Specific test on insulation material

• Test under fire conditions

• Test on gas evolved during combustion electric cables

Electrical

• Insulation test

• Impulse voltage withstand test

• Measurement of physical dimension of cable sheath insulation and armour

• Mechanical properties of insulation before and after ageing

• Insulation resistance measurement at ambient temperature

• Insulation resistance measurement at maximum conductor temperature.

• Immersion test.

6.3.3 Routine Tests

• Spark test on conductor insulation and oversheath

• Voltage test on completed cable

• Insulation resistance

• Conductor resistance

• Partial discharge test (on HV cables)

• DC voltage test on oversheath

6.3.4 Special Tests

• Conductor examination by inspection and measurement for compliance to IEC 60092.

• Measurement of thickness of insulation, sheath, armour/braid, etc.

• Armour resistance

• 4 hour voltage test



• Fire resistance test to IEC 60331

• Flame retardant test to IEC 60332

• Oxygen Index to ASTM D2863

• Acid gas generation as per IEC 60754-1&2

• Smoke density test to ASTM E662/IEC 61034-2

• Temperature index test.

• NEK 606 SHF-2 MUD test

Upon completion of inspection and testing, sample of cable from each reel shall be provided to Purchaser

After testing, the ends of the cables or wires shall be sealed to prevent the ingress of moisture. Three copies of certified test reports shall be submitted to Purchaser or their designated representative for each reel of cable.

Sample of typical cables shall be provided prior to purchase for Purchaser inspection. A short section of each cable type/size shall be stripped at time of inspection and gland shall be made off to demonstrate that it forms a certifiable seal. Similarly crimp/compression connectors shall be made off on the test piece.

If the test shows the cable is not acceptable then the cable shall be rejected and immediately replaced with suitable cable. If suitable cable is not available then Supplier shall be responsible for all costs in replacing the cable with suitable cable without slippage including customs duties and any resultant loss of cost recovery.

Fibre optic’s bandwidth and attenuation tests shall be performed in accordance to International standards.



7.0 PREPARATION FOR SHIPMENTS

The Supplier shall be responsible for preparation for export shipment including: packing, protection, preservation, labelling and marking of all items.

All cables shall have been fully tested and inspected prior to packaging. No packaging activities shall commence without the prior consent of the Purchaser. The purchaser shall be notified of the dates of packaging with sufficient notice to allow attendance for completion of inspection and release certificates without affecting the required delivery schedule.

A careful inspection shall be made to ensure that all operating instructions and labels plates are in place, legible and have not been obscured during painting operations.

Protection shall be provided against atmospheric corrosion while in transit and while in outdoor storage.

No equipment shall be allowed to leave the Supplier’s premises without such certificate being signed, or a written waiver issued.

Packing shall consider that the cables may be kept in storage for 12 months without damage in an outdoor tropical climate at fabrication yard and offshore salt laden environment.

Supplier shall provide full details on the preservation method and any schedule requirements during the year.

The drums and the cable details shall be recorded in detail on the packing list. The transported drums shall have necessary fastenings, protections and lifting facilities to satisfy lifting and sea fastening loads and restraints.



8.0 SUPPLIER DATA REQUIREMENTS

The Supplier shall provide the following information as appropriate for each size and type of cable. All units shall be in metric. Certified information shall be supplied a minimum of 3 weeks before cable is shipped.

• Number and size of conductors making up the cross-sectional areas of each core together with cross-sectional view.

• Insulation type and thickness

• Inner and outer sheath thickness (max. average and min.)

• Shielding (binding) tape thickness and details of shielding including overlap

• Individual conductor diameter under and over insulation

• Cable diameter, under armour, over armour as well as overall cable diameter and tolerance on overall diameter

• Maximum manufacturing and shipping length using standard cable reel

• Approximate net weight per unit length

• Reactance per unit length at 60 Hertz

• AC resistance per unit length at 60 Hertz

• Insulation resistance

• Capacitance per unit length

• Short circuit withstand capacity curve

• Current carrying capacity at ambient temperature

• Current carrying capacity derating factors due to temperature, grouping, spacing, laying.

• Maximum allowable cable pulling tension

• Minimum allowable and recommended bending radius

• Terminating and splicing instruction including list of suitable terminating fittings

• Recommended for field testing of cable after installation

• Information on the cable resistance to crude oil, natural gas, diesel, solar radiation (UV) over an extended period of time

• Zero sequence impedance of the cable

Fabrication of any equipment shall not commence until the Purchaser has reviewed and approved calculations, drawings and any other design documentation.



9.0 GUARANTEE

The Supplier shall guarantee all equipment furnished to be in compliance with this specification and drawings.

The Supplier shall guarantee all material against defect, damage or non-conformity and or workmanship.

If any defect or mal-performance occurs during the guarantee period of 12 months after commissioning, the Supplier shall make all necessary alteration, repair and replacement immediately and at no charge to Purchaser.



10.0 DOCUMENTATION

As a minimum, Supplier is responsible to provide documentation for the equipment items as defined in Supplier data requirements in Section 8.0. Supplier is responsible for all documentation in strict accordance with the requirements of the specifications.

The Supplier shall furnish soft copies of drawing/documents that are of suitable professional quality. Drawings that are, in Purchaser’s opinion not of suitable quality will be returned to the Supplier for resubmission or at Purchaser’s option may be redrafted by Purchaser or their representatives at Suppliers expense.

The electronics documents required shall be in Microsoft Office 2003 or Adobe PDF file format.