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1.0 Introduction
• Segregation
• Standard recommended practices
• Cabling – design aspects
• Cable carriers/trays
• Fire protection with regard to cables
• Hermetic cable penetration
The requirements for the electrical segregation of the cable systems for Class 1E
circuits, according to voltage levels, signal levels and vulnerability to electrical
noise are as follows.
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1.1.3 Control cables
Used for transmitting variable current or voltage signals (analog) or those used
for transmitting coded information (digital). Instrumentation cables shall be
installed to minimize unacceptable noise pickup from adjacent circuits and
equipments.
• Isolation devices
• Separation distances
• Shielding and wiring techniques
• Combination of any
• Non-hazard areas
• No high energy equipment
• Limited to C&I functions, power circuits for which are in enclosed trays
• Control & limiting of introduction of potential hazards the area-possible
• Limited hazard areas
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2.1 Hazard areas
2.2 Shielding and Shield grounding (for MV and instrumentation cables for
1E)
2.2.1 Cable shield: A non-magnetic material applied over the insulation of the
conductor or conductors to confine the electrical field of the cable to the
insulation of the conductor or conductors. It is required that cables rated above 5
kV shall be shielded, except for special applications or cable designs as per IEEE
690.Shielding can also be used in cables rated less than 5kV to monitor or test
cable installation for additional assurance of insulation integrity.
Cables are normally carried on cable trays and through conduits at a few
locations. Cable trays are fixed on the existing walls/ceiling/floors of the
buildings. Exclusive walk through tunnels are used where there will be a large
number of cables from one building to another and trenches are provided when
there are less number of cables. Cable tunnels are advantageous from the point
of view of minimum interference to traffic and drainage, good physical protection,
ease of addition of cables, shielding effect of the ground mat.
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However the disadvantage lies in the high initial cost and the danger that a fire
could propagate between cable trays and along the length of the tunnel. The fire
hazard is minimized by provision of fire barriers of suitable rating at specified
intervals.
Cable trays are basically cable carriers supported on cable tray supports. Cable
trays may be of ladder type, perforated type, solid type in line with the type of
cable to be carried and the importance.
Generally hot dip galvanized cable trays are used in our plants. Wherever the
galvanized surface on the steel tray is broken the area is coated to protect
against corrosion. However, within the process rooms and corridors the cables
are laid in ducts or in pipes.
3.1.4 Grounding
Cable trays are made electrically continuous and solidly grounded and normally a
GI ground conductor is run all along the stack of trays and is connected to the
grounding grid.
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3.1.5 Identification
Cable tray sections are permanently identified with the tray section number as
required by drawings/specifications giving reference to the category, group and
the area of use.
Natural rubber, which was later vulcanized by adding sulphur and heating and
maintaining the temperature to specified levels for cross linking to improve its
qualities like moisture ingression, higher tensile strength and to prevent flow
under high pressure.
Butyl rubber which is better resistant to strong acids but is sensitive to alkalis.
Silicone rubber which is used for low temperature applications because of its
flexibility and for very high temperature applications upto 250 deg Celsius.
Low price
Process ability
Resistance to chemicals and moisture
Flexibility at low temperature
Excellent electrical properties
High density Polyethylene has enhanced properties of surface hardness, yield
strength, heat and chemical resistance.
Cables are installed in trays with supports that are qualified for the design basis
event. During storage the ends of the cables are sealed against moisture and
contamination. Other than the generally known guidelines it is also kept in mind
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that cable trays filled to the predetermined quantity (design) should not be used
for more cables till a proper inspection/analysis is made to ensure that the
(1) Ampacities (due to de-rating) does not change from the designed values
(2) The actual loadings (physical) do not exceed the design values from the point
of view of the seismic requirement.
It is also important to ensure that the vertical runs of the cables are secured
properly to avoid subjecting the terminals to any excessive tensions.
To verify that the installed cables are free from any major cable insulation
damage during installation I) MV cables are subjected to high potential tests prior
to connection to the equipment ii) LV cables are checked for insulation resistance
and continuity prior to connection to the equipment and the records maintained.
The main cable routes between buildings (with large number of cables) in PLANT
are provided through underground cable tunnels and cable routes with small
number of cables are through trenches. The cable routes for safety related
systems are through underground tunnels only. The cable structures of normal
operation are designed to withstand OBE and safety systems for SSE.
The following types of cables have been designed for PLANT.
Basic characteristics of Cables for Safety System and Normal Operation systems
are given in table -1 &2.
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Conductor
XLPE XLPE XLPE PVC XLPE
insulation
Cable inner Containing Containing
LS PVC FRLS PVC FRLS PVC
sheath no halogen no halogen
Cable outer Containing Containing
LS-PVC FRLS PVC FRLS PVC
sheath no halogen no halogen
Armour for Un- Un- Un- Un- Un-
the cable armoured armoured armoured armoured armoured
Oxygen
index for 35 % 35 % 35 % 35 % 35 %
the sheath
The
contents of
chlorides 0.05% 0.05% 5% 5% 5%
(halogens)
for sheath
Fire rating, Fire
90 90 90 90
min retardant
Smoke
10-12 % 10-12 % <60% <60% <60%
density
HF – Halogen Free;
Routing of the cables from the basic route to the load is made through rigid/
flexible metal pipes.The cables for loads within the reactor containment are
routed through sealed penetrations designed for emergency environmental
parameters, inside the containment.
The cables cross the internal walls and floors through pipe penetrations and the
opening is to be sealed by a fire resistant sealant.
Provision of space for accommodating additional cabling, in future, to the extent
of 15 % is available. Mutually redundant cables are installed in different routes to
prevent simultaneous failure due to a common cause.
Having decided the type of the cable the following consideration are made while
selecting the cable size.
For Breaker protected feeder with relays, the minimum cable size depends on
the short circuit current of the system as well as on the duration of the short
circuit. Due consideration is given while selecting the minimum size of the cable
so that it can withstand the specified system fault current for the specified fault
duration. At times, the minimum size of the conductor is decided by the short
circuit withstanding capacity, especially when feeders are protected with
switchgear and relay (as the actuation time of the relay - instantaneous (0.2s) or
IDMT (1s) + breaker operating time + a safe margin is taken into account).
The minimum size of the cable should be such that while carrying the normal
running or starting load, the voltage drop at the equipment terminal should not
cross the specified limits.
Designed
Designed
ambient
ambient
temperature
Power Cabling -areas/locations temperature
under
during normal
emergency
operation
condition *
DG room 43 deg. C 50 deg. C
6kV & 0.38 kV switchgear / MCC room 35 deg. C 43 deg. C
Battery room 20-25 deg. C 35 deg. C
Rectifier and inverter room 35 deg. C 40 deg. C
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Cable inside containment 40 deg. C 43 deg. C
Ageing simulation is designed, to put a test specimen, in the end –of- life or the
plant design life service condition, whichever is earlier and this includes thermal
and radiation ageing.
The concept of defense in depth against fire and its consequences includes the
use of non-combustible materials. When the use of non-combustible materials is
not practical such as in the case of cables, lubricants, etc. their flame retarding
properties is considered.
In tunnels,
Distance
galleries,
cable floors In trenches and double floors
and on
trestles
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Height in air 1800 Not limited, but not more than
1200 mm
Horizontally in air between structures 900 300 with depth down to 0.6 m
when positioned single-side (passage 450 with depth more than 0.6
width) down to 0.9 m
600 with depth more than 0.9 m
Vertically between horizontal structures
for power cables having voltage 200 150
under 10 kV*
Vertically between horizontal structures 100 100
for control cables and communication
cables, power cables with section up to
3 x 25 mm2 and voltage up to 1 kV*
Between support structures (cantilevers) 800 -1000 800 -1000
along the length of cable structures*
In air between single power cables with Not less Not less than a cable’s
voltage up to 35 kV** than a diameter
cable’s
diameter
Horizontally between control cables and No standard No standard
communication cables**
* Usable length of cantilever must be not more than 500 mm on the straight parts of the
route.
** The same applies to cables, laid in cable wells.
Fire barriers or fire stops are passive fire protection systems which
prevent/resist/attenuate propagation of fire from one fire zone to the other,
maintaining the required fire rating.
I) the openings in walls and floors where the cables cross from one building
to another, one redundant area to another, one floor to another and from
one room to another
II) at the entry and exit of cable trenches and along cable tunnels at regular
intervals (one in every 30M horizontal – 0.75 hour rating and 20M
vertical). Doors at the ends of the cable tunnels are also of 0.75 hour
rating.
III) Between groups when the required segregation cannot be adhered to.
The cables in each of the four safety channels of emergency power supply
system are installed in separate routes with building/structures having fire
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resistance of not less than three hours.In case of crossing of cable ducts of
different channels of safety systems crossing of cables of normal operation over
safety systems cables with a separation distance less than two meters, a coat of
a fire resistant compound with a fire resistance of 1.5 hours is provided on the
outer surface of the duct . Cables feeding power to the mutually redundant loads
of the same channel are also routed separately, with a partition between them
having a fire rating of not less than 0.75 hours.
Material of the fire barrier is selected with the objective of meeting the following
requirements:
Testing of the barrier is done by preparing a sample of the barrier with specified
number of cables and subjecting it to various tests like impact test, water
absorption test, ageing test, vibration conditioning test, fire rating test and hose
stream test.
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• Elements ensuring leak-tightness, gas tightness, thermal stability and
elements of fixation with the containment wall.
• Manometer for recording of gas leakage.
6.1General Requirements
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• The electrical penetrations are adopted to the required properties of the
measuring circuits so that the cable penetrations do not deteriorate the
measuring circuits
• Cable connections and splices of medium & low voltage conductors are
capable of carrying rated continuous current before and after continuous
rated short circuit currents without causing the connections and splices to
exceed the temperature design limit.
• The penetrations are designed to withstand stresses resulting from the
short circuits without changing leakage characteristics
• The electrical integrity of conductors, connections and electrical insulation
systems are designed to withstand all electrical environmental loading
without failure or loss of function.
• Fire resistance of penetrations is similar to that of the containment.
• Cables penetrations are capable of maintaining the containment integrity
even in case of a cable fire.
• Penetrations are delivered under dry nitrogen pressure that provides
visual inspection / control of leak-proofness of each penetration after its
installation.
• Penetrations have a lifetime of not less than 50 years.
6.5 Construction
7.0 Figures
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3. Connection of two cables to penetration
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