Volume 4

Section 16702 Communication Cable Systems

TABOUK POWER PLANT # 2 EXTENSION PROJECT STAGE VII

VOLUME 4 DETAILED TECHNICAL SPECIFICATIONS - ELECTRICAL

SECTION

16702 COMMUNICATION CABLE SYSTEMS

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Section 16702 Communication Cable Systems

PART 1 - GENERAL 1.01 A. DESCRIPTION Definition

See Volume 1, Section 01015. B. Terminology

Technical terminology is to be defined in IEEE Standard 100 and/or ANSI Standard C42-100. 1.02 REFERENCES

The latest editions of publications listed below form part of this Specification: A. International Electro technical Commission (IEC)

60189 Low Frequency Cables & Wires with PVC Insulation and PVC Sheaths. 60304 Standard colors for insulation for low frequency cables and wires. 60540 Test Methods for Insulation and Sheaths of Electric Cables and Cords. 60708 Part 1 Low Frequency Cables with Polyolefin Insulation Moisture Barrier Polyolefin Sheaths.

B. 82

Institute of Electrical and Electronics Engineers (IEEE) Test Procedure for Impulse Voltage Tests on Insulated Conductors.

PART 2 PRODUCTS 2.01 A. GENERAL Existing Systems

The following brief summary of the existing system will be helpful in designing cable system for the extension purpose: a) b) External cable for intercom station is twisted 2 -pair of 0.8 mm size, armored. Internal cable for intercom station is twisted two pair of 0.5 mm size (min) (PVC flame retardant low smoke/PVC. For Master stations: PVC flame retardant low smoke/PVC (0.5 mm twin copper, flexible). For public address system: Polyethylene flame retardant smoke/polyethylene (cross section 0.75 mm twin copper). low

c)

d)

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Section 16702 Communication Cable Systems

B. (1)

Basic Materials and Methods Methods of Installation All cables shall be laid in ducts or on trays in tunnels or trenches. Cables shall be buried in ground only after obtaining the specific approval of the Engineer, in writing. Cables for elevator communication shall be suitably constructed, hung and clamped to withstand the duty imposed.

(2)

Cable Core The cable core shall have the following make up: 1. 2. Each conductor shall be insulated with colored solid polyethylene. Conductors shall be twisted into pairs, and the lay for individual pairs selected as may be required to meet the applicable cross-talk specification. Each cable shall contain the quantity of pairs shown on the drawings. Each pair within the cable shall be color coded for complete identification. Number of pairs to be written on cable also. The cable core shall be covered with a non-hygroscopic tape applied longitudinally with an overlap.

3.

4.

(3)

Underground Cable Jacket The underground cable jacket shall have the following make-up: 1. A polyethylene inner jacket approximately 0.8 mm thick shall be extruded over the cable core wrap. A coated flat aluminum tape shall be applied longitudinally with an integrally bonded aluminum copolymer. This tape shall be electrically continuous throughout each cable length. A layer of polyethylene shall be extruded over the coated aluminum tape. A layer of galvanized steel tape or steel wire armour shall cover the polyethylene. An outer jacket of high molecular weight polyethylene or PVC approximately 1.15 mm thick with 2% carbon black shall be extruded over the armour. The interstices of the cable core shall be filled with a suitable nonhygroscopic filling compound to prevent the ingress of water into the cable.

2.

3. 4.

5.

6.

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Section 16702 Communication Cable Systems

(4)

Splicing Boxes Splice boxes shall be used to terminate and interconnect cables along the cable route for cables on trays and underground installations. The shields of spliced cables shall be electrically interconnected inside the splice boxes. This connection shall be rated to carry all possible fault currents in the shielding. Details of the proposed method of splicing and description of all splicing materials and tools shall be provided by the Contractor. The splice boxes shall grip the cables firmly to provide a waterproof seal without putting unnecessary strain on the conductors. Splice boxes should have identification marking. Underground splice boxes shall be impact resistant and waterproof. The seals shall be particularly designed to prevent the ingress of water. These boxes shall be filled with a potting compound and the cable ends shall be sealed to prevent migration of moisture and cable filling compound.

(5)

Underground Cable Materials The sand surrounding the cable shall contain no pebbles, salt or other foreign matter. Crushed stone is not acceptable for this purpose. The layer of bricks covering the sand shall extend over the entire width of the trench. Cement or steel conduit shall be used to support the cable at road and railway crossings. The inner diameter of the conduit shall be at least 10 cm.

A shield grounding system shall be provided. The connection point to the cable shield shall be completely sealed against the ingress of moisture. Cable connectors and clamps shall be provided to connect the cable to the termination boxes.
C. (1) Design Criteria Cables on Trays Cables shall be laid on enclosed trays used exclusively for communication cables as detailed out in Volume 5, Section 16120, Wires and Cables System. Shielding and impedance imbalance reduction techniques shall be employed to minimize noise induction from nearby power sources. (2) Underground Cables Direct buried cables shall be avoided where possible however if used the underground cables shall be designed to withstand mechanical stresses both from traffic on the sidewalk above and from impacts resulting from manual excavations around the cable. Under roadways, suitable construction methods and support materials shall be provided to withstand the pressure from vehicular traffic. The cable and associated splicing materials shall completely exclude water incursions from the periodically rising water table. Cable shielding and impedance imbalance reduction techniques shall be employed to minimize noise induction from nearby power sources. (3) Electrical Design Requirements The finished cable shall have the following electrical characteristics:

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Section 16702 Communication Cable Systems

(a)

Conductor Resistance

Conductors shall be either 19 AWG or 0.9 mm diameter and shall have the following DC resistance, measured at or corrected to 20C: 19 AWG 0.9 mm (b) 57.0 Ohms per loop km (maximum) 58.6 Ohms per loop km (maximum)

Conductor Resistance Unbalance

The DC resistance unbalance between the two conductors of any pair shall not exceed 5%. The average unbalance for cables of 25 pairs or more shall not exceed 1.5%. (c) Conductor Insulation Resistance

The insulation resistance of each conductor to all other conductors connected to shield shall be not less than 1,600 Meg ohm- km at 20C measured with an applied dc voltage between 100 to 550 volts for one minute. (d) Dielectric Strength Conductor to Conductor The insulation between each conductor and all other conductors shall be capable of withstanding, for one second, a potential of 10,000 volts DC. (e) Dielectric Strength Conductor to Shield

The insulation between each conductor and shield shall be capable of withstanding, for 3 seconds, the DC potential of 20,000 volts. (f) Mutual Capacitance

The mutual capacitance of a pair is that capacitance measured between the two conductors with all other conductors in the cable and the cable shield connected to ground. The average mutual capacitance of all pairs in the cable, when measured at a frequency of 1000 Hz shall be as follows: Number of Pairs in Cable 7 to 11 12 or more (g) Cross-talk Loss Average Mutual Capacitance - nF per km____ 51 + 4 51 + 3

The far-end cross-talk loss between any two pairs, measured at a frequency of 3,000 Hz shall not be less than 73 dB for a length of 500 meters, nor less than 71 10 log L dB for a length L meters.

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Section 16702 Communication Cable Systems

(h)

Transmission Loss

The nominal attenuation for all pairs in the cable, measured at a frequency of 1,000 Hz at 20 deg.C shall be 0.78 dB/km. (i) Characteristic Impedance

The nominal characteristic impedance of each pair in the cable, measured at a frequency of 1,000 Hz, shall be 404 ohms at an angle of 42,9 Deg. C. (j) Shield Resistance

The DC resistance of the shield measured at, or corrected to 20 Deg. C shall not exceed the following values: DC Resistance Shield Diameter (ohms/500 meter) Below 2.5 cm 2.5 cm and over 2.4 1.7

PART 3 - EXECUTION 3.01 PREPARATION

Before installation, the Contractor shall check the cables for damage caused during transport. In case of damage, the Contractor shall notify the Authority immediately and obtain replacements as quickly as required. The Contractor will notify the Engineer of his installation timetable and assist the Authority in obtaining all required work permits. The Contractor will provide all information required to obtain the permits in good time to prevent delays to the installation schedule. 3.02 INSPECTION

The Contractor shall perform all inspection and routine tests stipulated in applicable standards to ensure that the material and workmanship conform to the Specification and drawings. The Contractor shall give the Engineer access to the Works to determine or assess compliance with the provisions of this Specification or to witness the Contractors inspection and tests. The Contractor shall produce copies of a certificate of compliance for type tests stipulated in the standards for the equipment. 3.03 A. CABLE INSTALLATION Cable Laying

The cable shall be buried at least 80 cm below the surface in areas of moderate surface pressure. The cable trench shall be a minimum of 90 cm deep.

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Section 16702 Communication Cable Systems

A layer of sand shall be placed along the bottom of the trench at least 5 cm thick and lightly tamped. The cable shall then be placed on top of the sand using rollers and the pulling eye in such a ma nner as to reduce the cable tension to a minimum and to prevent the cable from bending beyond its rated bending curvature. The cable shall be straight and centered in the cable trench. A second layer of sand shall be carefully placed around the cable and lightly tamped in place. The resulting layer of sand around the cable shall be at least 5 cm thick. A layer of bricks shall be placed atop the sand. The layer of bricks shall extend the full width of the trench and no spaces shall be left between adjacent bricks. The remainder of the trench shall be backfilled with the previously excavated material with all stones greater than 4 cm diameter removed. Sidewalk tiles removed for excavation shall be carefully replaced. All unused materials excavated from the trench shall be removed from the Work Site by the Contractor without delay and the Site restored to its original condition as nearly as possible. The Contractor is responsible for provision and erection of safety barricades, ropes, lights, etc. to protect his workers, pedestrians, vehicular traffic and the Work Site. Under road surfaces and railway tracks, conduit shall be installed to carry the increased surface pressure. The conduit shall be buried a minimum of 150 cm below the surface and shall extend at least one meter beyond the edges of the road and three meters beyond railway tracks. The conduit shall be laid parallel to the ground with no offset lengths. The cable shall not contact the edge of the conduit both during installation and in the final configuration. The cable curvature both for vertical and horizontal turns shall not exceed the rated curvature of the cable. In cases where water is present in the excavated trenches, the Contractor shall remove the water prior to installation of the sand and cable. The Contractor shall ground the cable shield and armour at a point approximately midway along the cable run using approved grounding methods. B. Splicing and Continuity Tests

All splicing and continuity tests shall be carried out according to methods approved by the Engineer. The Contractor shall carry out continuity checks on the twisted pairs after splicing and before the splice point has been sealed. The test results shall be approved by the Engineer prior to sealing and splice points. The Contractor shall repair all faulty splices and obtain the approval of the Engineer prior to sealing the splice point. C. Route Changes

It is expected that, during the course of installation, minor modifications to the cable route will be required. The Contractor shall not commence installation of such modifications without the prior approval of the Company Engineer.

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