Spec for Instrument Cables

South Pars Gas Field Development Phases 13

Plant: Onshore Facilities Pars Oil and Gas Company

Doc. Number : RP-0013-999-1511-062 Rev.No.: 01 Class: 1

This document is the property of N.I.O.C.. Any unauthorized attempt to reproduce it, in any form, is strictly prohibited.

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INSTRUMENT CABLES

01 15.Nov.2010 APPROVED FOR CONSTRUCTION T.Arabi A.Mirzamohammadi S.Babaei M.Ebrahimi M.Guilandoust

Detail Engineering

0 18.Sep.2010 APPROVED FOR CONSTRUCTION B.Omidi A.Mirzamohammadi S.Babaei M.Ebrahimi M.Guilandoust

REV. DATE DESCRIPTION PREP. CHKD. P.M. P.D.

CONTRACTOR APPD.

COMPANY APPD. APPD.

South Pars Gas Field Development – Phase 13

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TABULATION OF REVISED PAGES

PAGE REV0 REV1 REV2 REV3 REV4 PAGE REV0 REV1 REV2

1 X X 2 X X 3 X 4 X 5 X 6 X X 7 X 8 X 9 X 10 X 11 X X 12 X 13 X 14 X


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1. SCOPE .......................................................................................................4 2. CODES AND STANDARDS ......................................................................4 3. DEFINITIONS AND ABBREVIATIONS .....................................................4 4. TECHNICAL REQUIREMENTS .................................................................5 4.1 SERVICE CONDITIONS .................................................................................. 5

4.2 IDENTIFICATION ............................................................................................. 5

4.3 MARKING ........................................................................................................ 5

4.3.1 CABLE MARKING ........................................................................................ 5

4.3.2 CABLE DRUM MARKING ............................................................................ 6

4.4 BASIC REQUIREMENTS ................................................................................ 6

4.4.1 GENERAL .................................................................................................... 6

4.4.2 CONDUCTORS ............................................................................................ 6

4.4.3 VOLTAGE GRADE ....................................................................................... 6

4.4.4 PARTICULAR CHARACTERISTICSFOR IS CABLES................................. 7

4.5 CABLE SPECIFICATION ................................................................................ 7

4.5.1 FLAME RETARDANT ARMORED CABLES ................................................ 7

4.5.2 FIRE RESISTANT ARMORED CABLES ..................................................... 7

4.5.3 FLAME RETARDANT UNARMORED CABLES ........................................... 8

4.5.4 FIRE RESISTANT NON ARMORED CABLES............................................. 9

4.5.5 FLAME RETARDANT EARTHING CABLES ................................................ 9

4.5.6 ARMORED OPTICAL FIBBER CABLES ..................................................... 9

4.6 CATALOGUE OF CABLES ........................................................................... 10

4.6.1 SCREEN .................................................................................................... 10

4.6.2 CONDUCTORS NUMBER ......................................................................... 11

4.7 REQUIRED INFORMATON ........................................................................... 11

4.8 PACKING ....................................................................................................... 11

5. INSPECTION AND TESTS ..................................................................... 12 5.1 INSPECTON .................................................................................................. 12

5.2 TESTS ............................................................................................................ 12

5.2.1 GENERAL TESTS ...................................................................................... 12

5.2.2 NON ELECTRICAL TESTS ........................................................................ 12 5.2.3 ELECTRICAL TESTS ................................................................................. 13 6. ATTACHMENT #1: INSTRUMENT SPECIFICATION SHEET .............. 14


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1. SCOPE

The present document defines the general philosophy to be implemented for design, manufacture and testing of instrument cables for the SOUTH PARS FIELD DEVELOPMENT PHASE 13 ONSHORE FACILITIES PROJECT. Any deviation from this specification shall be submitted to COMPANY for approval.

2. CODES AND STANDARDS

Instrument cables shall fully comply with all relevant codes and standards listed hereafter. IEC 60028 International Standard Of Resistance Copper. IEC 60092.350: L.V, Shipboard Power Cables-General IEC 60092.351: Insulating Materials for Shipboard Power Cables. IEC 60092.353: Single & Multicore Cables with Extruded Solid Insulation for Rated Voltage 0.6/1.0 KV. IEC 60092.375: General Instrumentation Control & Communication Cables IEC 60092.504: Electrical Installation in Ships-Control and Instrumentation. IEC 60228 Conductors Of Insulated Cables. IEC 60331 Tests For Electric Cables Under Fire Conditions : Circuit

Integrity. IEC 60332 Tests On Electric Cables Under Fire Conditions (With Part 1

And Part 3c). IEC 60446 Color Identification Insulated And Non-Insulated Core IEC 60811 Test Methods For Insulation And Sheats Of Electric Cables

And Cords (Elastomeric And Thermoplastic Compounds). IEC 61034 Measurement Of Smoke Density Of Electric Cables Burning

Under Defined Conditions, Test Procedure And Requirements (Part 2).

ISO 4589 Determination of burning behavior by Oxygen Index. ITU Rec. G652 Characteristics Of A Single Mode Optical Fiber Cable.

3. DEFINITIONS AND ABBREVIATIONS

The following terms and abbreviations will be used in this document : ♦ “Will” is used normally in conjunction with an action by COMPANY. ♦ “May” is used where alternatives are equally acceptable. ♦ “Should” is based where a solution is preferred. ♦ “Shall” is used where a provision in mandatory.

PCS : Process Control System ESD : Emergency Shutdown F&G : Fire And Gas IS : Intrinsically Safe ITR : Instrument Technical Room XLPE : Cross-Linked Polyethylene CCR : Central Control Room


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4. TECHNICAL REQUIREMENTS 4.1 SERVICE CONDITIONS

Instrument cables shall be suitable for onshore marine environment. See DB 0013 999 P332 204 : Basic Engineering Data for Onshore Facilities Cables will be installed indoors and outdoors. All cables shall be able to withstand prolonged exposure to direct sunlight and to service conditions described below. Cables shall be suitable for contacts with mineral oils, diesel oils, water, and glycol. Single cables shall be run preferably on cable trays and multi-pairs/cores will be run under and/or above ground.

4.2 IDENTIFICATION

Outer sheath colors: Flame retardant type (non IS): Grey Fire resistant type (non IS): Red Flame retardant (IS): Blue Fire resistant (IS): Blue with red stripes Primary earth ground: Green / Yellow Electronic ground: Green IS electronic ground: Yellow with Blue stripes Core colors: Following colors shall be used for core identification: Single pair: Black, White Multipair: Black, White (pairs shall be

identified numerically and sequentially)

Single triple: White, Red, Blue Multi triple: White, Red, Blue (triples shall be

identified numerically and sequentially)

Single quad: White, Red, Blue, Yellow Multi quad: White, Red, Blue, Yellow (quads

shall be identified numerically and sequentially)

4.3 MARKING 4.3.1 CABLE MARKING

The outer sheath of cable shall be embossed at regular intervals with marks max 400 mm along the cables entire length to distinguish the following data as a minimum: a. manufacturer’s name, year of manufacture, b. cable type,


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c. number of cores d. voltage rating e. quality of outer sheath, f. reference of fire test g. metric marking with remaining length. Max at every 1500mm of cable

length.

4.3.2 CABLE DRUM MARKING

Cable drums shall be indelibly marked as follows: a. drum number, b. requisition number and job name, c. requisition item number, d. cable type, e. length of cable on the drum (in meters), f. overall weight of cable and drum (in kg) g. rated voltage. h. number and cross section of cores.

4.4 BASIC REQUIREMENTS 4.4.1 GENERAL

All cables shall be water, oil and UV resistant, gas/vapor tight, and have an oxygen index better than 32 according to IEC 64589. All cables shall comply with the relevant applicable IEC recommendations and with the regulation of the country of installation. Cables routed outdoors in field shall be armored. Cables routed between technical room and field shall be armored. Cables installed and fully routed within CCR or ITRs shall be unarmored. All instrument cables as a minimum shall be flame retardant as per IEC 60332. Fire resistant cable shall be able to withstand the IEC 60331 fire resistant test. All inputs/ outputs to ESD and F&G systems which are energized to trip shall be fire resistant cables.

4.4.2 CONDUCTORS

Conductors shall be tinned copper, stranded class 2 (IEC 60228). Two conductor sizes shall be used:

♦ 1.5 mm2 for analog signals , contact input and interface signals to system, ♦ 2.5 mm2 minimum for on/off command (SOV) from PCS/ESD/F&G and 230

VAC power cables.

4.4.3 VOLTAGE GRADE

Analog and ON/OFF input signals: insulation grade to be 300/500 V ON/OFF commands 48VDC and 230 VAC: insulation grade to be 600/1000V.


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4.4.4 PARTICULAR CHARACTERISTICSFOR IS CABLES

Intrinsic safety cables shall have the following maximum characteristics: Capacitance between conductors: 200 pF/m Capacitance between conductor and shield: 400 pF/m Inductance to resistance ratio: 40 micro H/ohm

4.5 CABLE SPECIFICATION 4.5.1 FLAME RETARDANT ARMORED CABLES

♦ Type: Flame retardant according to IEC 60332.3. ♦ Conductor: Stranded tinned copper wire according to IEC 60228 class 2. ♦ Section: In accordance with § 4.4.2. ♦ Insulation: XLPE. ♦ Twining: The insulated conductors shall be twisted together to form a

pair/triple/quad. Lenght of lay of any pair/triple/quad shall be 70 mm ± 10 mm.

♦ Wrapping for individual screen (as specified) : Each pair/triad/quad shall be wrapped with polyester tape 0.023 mm thick applied with 25% overlap.

♦ Individual screen (as specified) : Each pair/triple/quad shall be screened with aluminium backed Mylar tape helically applied with 25% overlap. Aluminium on the inside to be in continuos contact with a tinned stranded copper drain wire of the same diameter as the conductor. Each screen shall be insulated from the remaining cable components by the application of suitable tapes numbered in accordance with the pair numbering system.

♦ Over the foil a protective wrapping of a non-hygroscopic tape shall be applied. All foil shall have a minimum overlap of 20%. Each screen shall be insulated from the remaining cable components by the application of suitable tapes numbered in accordance with the pair numbering system.

♦ Overall screen (as specified) : Each pair/triple/quad shall be screened with aluminium backed Mylar tape helically applied with 25% overlap. Aluminium on the inside to be in continuos contact with a tinned stranded copper drain wire of the same diameter as the conductor.

♦ Inner sheath: PVC. ♦ Wrapping below inner sheath: The screened cable shall be wrapped with

polyester tape helically wound. ♦ Armor: Galvanized steel wire braid coverage, density and thickness in

accordance with IEC 60092.3. ♦ Overall outer sheath: PVC low smoke emission, flame retardant type in

accordance with IEC 60332.3.The outer sheath shall be resistant to water, UV, and aliphatic hydrocarbons or aromatic hydrocarbons (when required).

♦ Outer sheath color: In accordance with § 4.2.

4.5.2 FIRE RESISTANT ARMORED CABLES

♦ Type: Fire resistant according to IEC 60331. ♦ Conductor: Stranded tinned copper wire according to IEC 60228 class 2. ♦ Section: In accordance with § 4.4.2.


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♦ Insulation: Silicone rubber or Mica-XLPE. Thickness in accordance with IEC 60092-3.

♦ Twining: The insulated conductors shall be twisted together to form a pair/triple/quad. Lenght of lay of any pair/triple/quad shall be 70 mm ± 10 mm.

♦ Wrapping for individual screen (as specified): Each pair/triad/quad shall be wrapped with polyester tape 0.023 mm thick and mica glass silk tape applied with 25% overlap.

♦ Individual screen (as specified): Each pair/triple/quad shall be screened with copper tape helically applied with 25% overlap. Copper to be in continuos contact with a tinned stranded copper drain wire of the same diameter as the conductor. Each screen shall be insulated from the remaining cable components by the application of suitable tapes numbered in accordance with the pair numbering system.

♦ Overall screen (as specified): The pairs/triples/quads shall be screened with copper tape helically applied with 25% overlap. Copper to be in continuos contact with a tinned stranded copper drain wire of the same diameter as the conductor.

♦ Wrapping below inner sheath: The screened cable shall be wrapped with polyester tape helically wound.

♦ Inner sheath: LSZH. ♦ Armor: Galvanized steel wire braid coverage, density and thickness in

accordance with IEC 60092-3. ♦ Overall outer sheath: PVC low smoke emission fire resistant type, in

accordance with IEC60331.The outer sheath shall be resistant to water, UV, and aliphatic hydrocarbons or aromatic hydrocarbons (when required).


4.5.3 FLAME RETARDANT UNARMORED CABLES

♦ Type: Flame retardant according to IEC 60332.3. ♦ Conductor: Stranded tinned copper wire according to IEC 60228 class 2. ♦ Section: In accordance with § 4.4.2. ♦ Insulation: XLPE. ♦ Twining: The insulated conductors shall be twisted together to form a


♦ Wrapping for individual screen (as specified): Each pair/triad/quad shall be wrapped with polyester tape 0.023 mm thick applied with 25% overlap.

♦ Individual screen (as specified): Each pair/triple/quad shall be screened with aluminium backed Mylar tape helically applied with 25% overlap. Aluminium on the inside to be in continuos contact with a tinned stranded copper drain wire of the same diameter as the conductor. Each screen shall be insulated from the remaining cable components by the application of suitable tapes numbered in accordance with the pair numbering system.

♦ Overall screen (as specified): Each pair/triple/quad shall be screened with aluminium backed Mylar tape helically applied with 25% overlap. Aluminium on the inside to be in continuos contact with a tinned stranded copper drain wire of the same diameter as the conductor.

♦ Wrapping below outer sheath: The screened cable shall be wrapped with polyester tape helically wound.


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♦ Overall outer sheath : PVC low smoke emission, flame retardant type in accordance with IEC 60332.3.The outer sheath shall be resistant to water, UV, and aliphatic hydrocarbons or aromatic hydrocarbons (when required).


4.5.4 FIRE RESISTANT NON ARMORED CABLES

♦ Type: Fire resistant according to IEC 60331. ♦ Conductor: Stranded tinned copper wire according to IEC 60228 class 2. ♦ Section: In accordance with § 4.4.2. ♦ Insulation: Silicone rubber or Mica-XLPE. Thickness in accordance with

IEC 60092-3. ♦ Twining: The insulated conductors shall be twisted together to form a


♦ Wrapping for individual screen (as specified): Each pair/triad/quad shall be wrapped with polyester and mica glass silk tape 0.015 mm thick applied with 25% overlap.

♦ Individual screen (as specified): Each pair/triple/quad shall be screened with copper tape helically applied with 25% overlap. Copper to be in continuos contact with a tinned stranded copper drain wire of the same diameter as the conductor. Each screen shall be isolated from the remaining cable components by the application of suitable tapes numbered in accordance with the pair numbering system.

♦ Overall screen (as specified): The pairs/triples/quads shall be screened with copper tape helically applied with 25% overlap. Copper on the inside to be in continuos contact with a tinned stranded copper drain wire of the same diameter as the conductor.

♦ Wrapping below inner sheath: The screened cable shall be wrapped with polyester tape helically wound.

♦ Overall outer sheath: PVC low smoke emission fire resistant type,in accordance with IEC60331.The outer sheath shall be resistant to water, UV, and aliphatic hydrocarbons or aromatic hydrocarbons (when required).

♦ Outer sheath color: In accordance with § 4.2. 4.5.5 FLAME RETARDANT EARTHING CABLES

♦ Conductors: Tinned copper, stranded. ♦ Outer sheath: PVC low smoke emission, flame retardant type in

accordance with IEC60332-3.The outer sheath shall be resistant to water, UV, aliphatic hydrocarbons and aromatic hydrocarbons (when required).


4.5.6 ARMORED OPTICAL FIBBER CABLES

♦ One type of optical fibber cables shall be used: Single mode optical fibber cables. These cables shall be used at 1300 nm wavelenght (to be confirmed during detailed design engineering). The fibbers contained in these cables shall fully comply with ITU Rec. G 652 requirements.

♦ Structure: Each optical fibber shall be protected by an individual color-coded polycarbonate tube filled with a petroleum gel or equivalent.


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♦ Inner sheath: Polyethylene. ♦ Armor: Galvanized steel wire braid coverage, density and thickness in

accordance with IEC 60092-3. ♦ Outer sheath: PVC low smoke emission, flame retardant type in

accordance with IEC60332-3.The outer sheath shall be resistant to water, UV, aliphatic hydrocarbons and aromatic hydrocarbons (when required).

♦ Color: Black. ♦ Maximum pulling force: 600 daN (temporary, during installation). ♦ Minimum bending radius: 200 mm max (temporary)

300 mm max (permanent). ♦ Compression: More than 50 daN/cm.

4.6 CATALOGUE OF CABLES

The PETROSINA ARIA shall define during the detail engineering the catalogue of cables with related codification, to be used for the Plant, in accordance with the general principles listed hereafter.

4.6.1 SCREEN

♦ Type 1:

• Single cables for on/off commands & 230 V – flame retardant – without screen.

• Multi cables for on/off & 230 V – flame retardant – without screen.

♦ Type 2:

• Single cables for analogue– flame retardant – individual screen. • Multi cables for analogue– flame retardant – individual & overall screen.

♦ Type 2-1:

• Single cables for on/off contacts-flame retardant – overall screen. • Multi cables for on/off contacts-flame retardant-overall screen.

♦ Type 3:

• Single cables for on/off commands & 230 V – fire resistant – without screen.

• Multi cables for on/off commands & 230 V – fire resistant – without screen.

♦ Type 4:

• Single cables for analogue– fire resistant– individual screen. • Multi cables for analogue – fire resistant – individual & overall screen.

♦ Type 4-1:

• Single cables for on/off contacts-fire resistant-individual screen.


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• Multi cables for on/off contacts-fire resistant-overall screen.

♦ Type 5:

• System cable – flame retardant – overall screen (to be confirmed with System Vendor/Supplier).

4.6.2 CONDUCTORS NUMBER

The number of pairs/cores in signal cables shall be as follows:

♦ number of pairs, triples or quads :

• 1 pair/triple/quad, • 2 pair/triple/quad, • 7 pairs/triples/quads, • 12 pairs/triples/quads, • 19 pairs/triples/quads, • 27 pairs/triples/quads,

♦ number of cores:

• 2 cores • 8 cores • 12 cores • 19 cores • 27 cores

4.7 REQUIRED INFORMATON

The Vendor shall provide the following information for each cable type :

♦ Resistance at 35°C in Ohms/1000 m, ♦ Inductance at 50 Hz in mH/1000 m, ♦ Capacitance at 50 Hz in micro F/1000 m, ♦ Weight in kg/1000 m, ♦ Overall cable diameter and tolerances, ♦ Diameter of cable under braiding and tolerance, ♦ Thickness of braiding and tolerance, ♦ Bending radius at minimum installation temperature, ♦ Minimum installation temperature, ♦ Maximum pulling tension of cable, ♦ Cable drums capacity and weight of drums, ♦ Oxygen index. ♦ Datasheet in attachment #1 should be filled by Vendor.

4.8 PACKING

Cable shall be delivered in maximum manufacturing drum length, except if a specific length is required. Drum lengths shall be continuous. Cable or conductor jointing, in any form, is unacceptable.


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Cable ends shall be fitted with a heat-shrink cap to prevent entry of moisture inside the cable and shall be fixed to the drum. Cable shall be shipped on non-returnable drums. The drums shall be lagged or covered with suitable material, to provide physical protection during transit, ordinary storage and handling operations.

5. INSPECTION AND TESTS 5.1 INSPECTON

Cables shall be subject to inspection during manufacturing and testing. The Vendor shall provide access for inspection / surveillance when required by the company/PETROSINA ARIA. These tests shall be performed either on all finished cable lengths or on samples of completed cables. 1-All cables shall have certificate(s) in accordance with relevant standards. The certificates shall be submitted to company review. 2-The vendor shall propose test time and procedure for company and contractor review and approval at least two month before testing. 3-after finalization of the test, the test report with all necessary information and result of the measurements shall be prepare and submitted to company.

5.2 TESTS

Copies of test certificate shall be provided as per project and requisition requirements. These tests shall be performed by the Vendor and in accordance with the IEC standards. The Vendor shall supply with his bid a complete description of his proposed test procedures. These tests shall include but shall not be limited to the following .

5.2.1 GENERAL TESTS ♦ Qualitative and quantitative control of technical documentation given with

cables and its compliance with the particular specifications. ♦ Control of drums: quality of flanges, marking and labeling, cable

designation, lenght, section, sizes and weight, observance of minimum curve radius, capping of terminations, packaging and protection against shocks.

♦ Control of conformity with the technical documentation.

5.2.2 NON ELECTRICAL TESTS

♦ Control of the nature and composition of conductors. ♦ Control of mechanical properties of insulating covering. ♦ Measurement of the thickness of the insulating covering. ♦ Inspection of bedding and assembly. ♦ Control of the mechanical properties of the external protective sheaths. ♦ Measurement of the thickness of the external sheaths. ♦ Verification of the nature, composition and thickness of the metallic armor. ♦ Measurement of the external dimensions of the complete cable.


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♦ Test for flame retardant according to IEC 60332-3 (Test C) for bunched cables.

♦ Test for fire resistance according to IEC 60331. ♦ Conformity of fibber optic cables with required specification and code. ♦ Reflectometry test of fibber optic cables during factory acceptance tests ♦ Reflectometry test of fibber optic cables at site, before pulling.

5.2.3 ELECTRICAL TESTS ♦ Measurement of electrical resistance of conductors. ♦ Electric strength tests. ♦ Insulation resistance tests.


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6. Attachment #1: INSTRUMENT SPECIFICATION SHEET

Spec for Instrument Cables

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