Draft.docx

NUCLEAR POWER CORPORATION OF INDIA LTD (A Government of India Enterprise) KUDANKULAM NUCLEAR POWER PROJECT3&4

PROJECT

:

KKS CODE NO.

:

EPC CONTRACTOR’S REF. NO.

:

GID/379/EL/YYY/BS/3006

:

CMM/MEQ/25-00-2-1116/e-PO/22513 CMM/MEQ/25-00-2-1116/e-PO/22516 400kV & 230kV SWITCHYARDS AND BoP ELECTRICAL AREAS OF KKNPP 3&4 - EPC PACKAGE

EPC PACKAGE NO. & DESC.

REVISION NO

:

P0

DATE OF ISSUE (MONTH/YEAR)

:

24.09.2018

TOTAL NO OF PAGES (Including Cover : Sheet)

33

DESIGN BASIS REPORT FOR CABLING SYSTEM FOR 400kV & 230kV SWITCHYARDS AND BoP ELECTRICALAREAS OF KKNPP 3&4 - EPC PACKAGE Name

M/s BGR ESL Signature & Date

PREPARED & CHECKED BY

Vijayakumar K

24.09.2018

REVIEWED BY

Madhanagopal. K

24.09.2018

REVIEWED & CONCURRED BY

Madhanagopal. K

24.09.2018

APPROVED BY

Uma.R

24.09.2018

NPCIL Name CHECKED BY REVIEWED BY REVIEWED & CONCURRED BY APPROVED BY

ISSUED BY: M/s BGRESL, Chennai

File Name: GID/379/EL/YYY/BS/3006

Signature & Date

NUCLEAR POWER CORPORATION OF INDIA LTD. PAGE NO. : Page 2 of 35 KUDANKULAM NUCLEAR POWER PROJECT-3&4 REV. NO : P0 DESIGN BASIS REPORT FOR CABLING SYSTEM REV. DATE : 24.09.2018

REVISION CONTROL SHEET DOCUMENT TYPE: BS TITLE:DESIGN BASIS REPORT FOR CABLING SYSTEM

File Name: GID/379/EL/YYY/BS/3006

SEPTEMBER2018

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APPROVED BY

REVIEWED & CONCURRED BY

REVIEWED BY

CHECKED BY

NPCILCHECKED BY

APPROVED BY

DESCRIPTI ON OF REVISION

CHECKED BY

REV No. DATE

REVISED BY

M/S BGR ESL

NUCLEAR POWER CORPORATION OF INDIA LTD. PAGE NO. : Page 3 of 35 KUDANKULAM NUCLEAR POWER PROJECT-3&4 REV. NO : P0 DESIGN BASIS REPORT FOR CABLING SYSTEM REV. DATE : 24.09.2018

TABLE OF CONTENTS 1.0

SCOPE ............................................................................................................................... 4

2.0

PURPOSE .......................................................................................................................... 4

3.0

SYSTEM DESCRIPTION............................................................................................... 4

4.0

CABLE SIZING & SELECTION .................................................................................. 5

5.0

6kV (UE) MV POWER CABLES ................................................................................ 10

6.0

LV POWER CABLES ............................................................................................... 1514

7.0

CONTROL CABLES ..................................................................................................... 18

8.0

245kV EHV POWER CABLE .................................................................................. 2120

9.0

FIBRE OPTIC U/G CABLE ......................................................................................... 23

10.0 CABLE CARRIER SYSTEM ................................................................................... 2423 11.0 CABLING INSTALLATION WORK ..................................................................... 2827 12.0 REFERENCES ........................................................................................................... 3433

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1. SCOPE This design basis report is intended to cover the design of cabling including supply, storage,laying / installation, testing and commissioning of MV & LV powercables, control cablesincluding termination kits, glands, lugs, cable termination kits, hardwareaccessories, fire barriers/stops, fire belts, fire resistant coating for cables, etc.required for completion of cabling system works for KKNPP-3&4 Switchyard packages. Also, this design includes supply, installation, testing and commissioning of cable carrier system with all accessories, hardware, etc., required for safe installation. It’s also includes selection of fire barriers/stops, fire belts, fire resistance coating on cables.

2. PURPOSE This design basis is created to define the minimum requirements for the design, selection, laying and termination of cables (MV & LV Power cables and Control cables) along with cable carriers and its accessories and are read in conjunction with all other Project specifications and the requirements of applicable codes, standards and regulations. The main objectives are:    

Proper sizing and selection of cables, cable tray supports & cable trays Explain the philosophy adopted for selection of supports and trays Explain the philosophy adopted for selection of cables Explain the philosophy adopted for fire barrier and fire resistant coating

3. SYSTEM DESCRIPTION The system consists of sizing and design for selection of MV & LV power cables, control cables and all special cables like OFC cables, LAN cables, cable supports etc.The cables shall be laid in above-ground cable trays as well as on supports in the underground trenches / tunnels or on overhead trestles as per the requirement. Cables shall not be directly buried in the ground. Wherever small lengths of cables exist which cannot be run on trestles, tunnels, etc. the same shall be routed in RCC trenches. The main cable routes between buildings (with large number of cables) in KKNPP-3&4shall be provided through underground cable tunnels and cable routes with smaller number of cables can be routed through covered trenches. MV & LV Power cables shall be laid on top tier and control cables shall be laid below power cable tray and instrumentation, OFC cables shall be laid on bottom most cables trays. However for 230kV tie feeder from Unit – 1 & 2 to Unit - 3 & 4, 245kV EHV cable from existing Unit – 1 & 2 shall be buried in ground initially to cross 400kV Substation of Unit – 1 & 2 till the 1st Transmission Line tower.

File Name: GID/379/EL/YYY/BS/3006

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4. CABLE SIZING & SELECTION 4.1. Cable sizing: The following design parameters of the systems are considered for arriving at appropriate type and size of cables, Formatted: Font color: Red

4.1.1 6kV &415V Systems cables      

Short circuit level of the system, RMS - 50kA Design Ambient Air Temperature (0C) - 450C Conductor temperature assumed as per IS: 1554 for - PVC / XLPE Maximum normal operating temperature - 700C / 900C For short circuit duty - 1600C / 2500C Duration of short circuit The duration of short circuit for which cables shall be designed are based on the normal clearing time of the protective devices to clear the faults.

4.1.2

Power cable selection will be as mentioned below, 4.1.2

Design criteria Loads located beyond 1 kM Loads located 200 – 1000 M Load located up to 200M No. of cores for power supply panel incomer cables No. of cores for motor cables Loads beyond 1000A rating and located near the transformer Recommended limiting size of multi-core cable (mm2) Recommended limiting size of multi-core cable (mm2)

Short circuit withstand time (seconds)

Insulation voltage grade Type of cable insulation Conductor materials File Name: GID/379/EL/YYY/BS/3006

Formatted: Indent: Left: 1", No bullets or numbering

MV Single core cable Single core / 3 Core cable Single core / 3 Core cable

1 Core / 4 Core cable

-

5 (3Ph+1N+1PE)

-

4 (3Ph+1N)

Bus duct

Bus duct

630

300 (for 4/5 core cable) 630 (for 1 core cable)

300 (for 3 core cable)

300 (for 4/5 core cable)

- Incomerfrom transformer: 1 - Incomer from other switchboard: 0.6 - Plant feeder: 0.6 - Motor/Transformer feeder: 0.2/higher as decided during detailing Unearthed XLPE Cu

LV -

1 Core / 4 Core cable

Not Applicable

Unearthed PVC Cu SEPTEMBER2018

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4.1.3             

Type of Power cables used for various purpose:

For feeding Motors (LV) Switchgear to Power Distribution Centre MCC to MCC MCC to Power Panels DC Supply Distribution Switchgear to 3 Phase Power Sockets Looping between 3 Phase Power Sockets Power Distribution Centre to 1 Phase Power Sockets Looping between 1 Phase Power Sockets Working (normal & emergency) Lighting Distribution Centre to Lighting Board Evacuation Lighting Distribution Centre to Lighting Board Switchgear to Transformer/OLTC Cabinet

4.1.4

: 4 Cores : 5 Cores : 5 Cores : 5 Cores : 2 Cores : 5 Cores : 5 Cores : 3 Cores : 3 Cores : 5 Cores : 3 Cores : 5 Cores

Voltage drop calculation

Voltage drop can be computed using the following formula =

IRCos Ѳ + IXsin Ѳ

Vd Cos Ѳ I R

= = = =

X

=

Voltage drop (line to neutral) per metre Power Factor Full load current in Amps AC Resistance in ohm per metre at 70⁰C for PVC and at 90⁰C for XLPE insulated cables. Reactance in ohms per metre at 50 Hz.

Vd Where

The maximum voltage drops in various section of the electrical system under steady state conditions at full load shall be within the limits and typical requirements are as per the following table:

Sl No

System Description

a)

Cables between transformer secondary and switchboards LV Cables between PCC/PMCC and MCC or Auxiliary switchboard MCC/ASB located near PCC/PMC MCC/ASB located remote from PCC/PMCC MV Cable between MV switchboard and MV motor LV Cables between PCC/PMCC and motor LV cables between MCC (situated near

b)

c) d) e)

File Name: GID/379/EL/YYY/BS/3006

Maximum permissible voltage drop 0.5 %

0.5 % 2 to 2.5 % 3% 5% 5% SEPTEMBER2018

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f) g) h) i) j) k) l) m) n)

o)

PCC/MCC) and motor LV cables between MCC (situated remote from PCC/MCC) and motor LV cables between auxiliary switchboard / LDB and lighting panel Circuit between lighting panel and lighting points DC supply circuits (Electrical control) DCDB to control room UPS outgoing circuits 220V DC Power cable 48V DC Power cable Control Cable: Metering purpose Protection purpose At motor load end during motor starting

3% 1 to 1.5 % 4% 5% 2% 5% 2.5 % 2.5 % 0.2 % 1% 15 %

4.1.5 Effective current carrying capacity: The current carrying capacity of a cable corresponds to the maximum current that it can carry under specified conditions without the conductors exceeding the permissible limit of steady state temperature for the type of insulation concerned. The current carrying capacity of the above Ground Installation and in RCC Trench / Tunnel can be calculated as below: C Where C Ca Cg Cd

=

Ca X Cg X Cd

= = = =

De-rating factor Rating factor for variation in Ambient air temperature Rating factor for Grouping of cables Rating factor for variation in depth of cables

De-rating factor as obtained above multiplied by the cable current gives the effectivecurrent carrying capacity of a cable. Appropriate de-rating factors shall be used in sizing of the power cables depending on thetype of laying of cables, either in ladder tray or cable ducts in concrete trenches, etc. If theroute consists of different methods of laying the worst de-rating factor shall be used forconsidering the design ambient temperature. Typical data given below for choice of deratingfactors. a)

For cables in ladder type trays and one diameter spacing. Without cover 0.9 With cover 0.85

b)

For cables in ladder type trays touching formation Without cover 0.682 With cover 0.65

c)

For cables in ladder type trays in concrete trenches without covers with 1 diameter spacing 0.800

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d)

For cables in ladder type trays in concrete trenches with covers with 1 diameter spacing 0.62

e)

For cables laid in ground

0.78

f)

For cables laid in cable ducts in trestle

0.6

The above values are for reference only. For the sizing calculations however the data from prospective vendor catalogue will be considered.

4.1.6 Short circuit withstand capability for 6kV (UE) cable The cross sectional area calculated shall not be less than the value determined by the following formula

𝑆=

𝐼 √𝑡 K

Where S = I = t =

K

Nominal cross sectional area of the conductor in mm2. Value of fault current for a fault of negligible impedance in Amperes. Operating time of the disconnecting device in seconds for fault current – I as given below: - (1.0 sec.) Incomer from Transformer - (0.6 sec.) Interconnecting cables between two MV Switchboards - (0.2 sec.) Motor/transformer breaker feeder = Protective factor for conductor taking account of the resistivity, temperature Co-efficient, heatcapacity of the conductor material, initial and finalTemperature. - 115 and 143 for PVC and XLPE insulated Copper Cables respectively.

Where the application of the formula results in a non-standard size, a conductor of the next higher standard cross-section area shall be used.

a) For Incomer Feeders: Value of fault current I

= 50 kA

Fault clearing time t

= 1.0 sec for Incomer feeder

Protective factor for Conductor k

= 143 for XLPE insulated Cu. Cables.

Nominal cross sectional area of conductor in mm2𝑆

=

𝐼 √𝑡 K

𝑆 = 50000 x √1 / 143 𝑆 = 350 Sqmm Next higher standard cross section of conductor is 400 mm2. Minimum cable size used for 6kV incomer is 9 Runs of 1C x 400 mm2, XLPE, Cu. Cable.

b) For Interconnecting cable b/w two MV Switchboards: Value of fault current I File Name: GID/379/EL/YYY/BS/3006

= 50 kA SEPTEMBER2018

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Fault clearing time t

= 0.6 sec for Switchboard feeder

Protective factor for Conductor k

= 143 for XLPE insulated Cu. Cables.

Nominal cross sectional area of conductor in mm2𝑆

=

𝐼 √𝑡 K

𝑆 = 50000 x √0.6 / 143 𝑆 = 271 Sqmm Next higher standard cross section of conductor is 300 mm2. Minimum cable size used for 6kV tie feeders is 9 Runs of 1C x 400 mm2, XLPE, Cu. Cable runs between two MV Switchboards. c) For Motor / Transformer feeders: Value of fault current I

= 50 kA

Fault clearing time t

= 0.2 sec for Motor / Transformer feeder

Protective factor for Conductor k

= 143 for XLPE insulated Cu. Cables.

Nominal cross sectional area of conductor in mm2𝑆

=

𝐼 √𝑡 K

𝑆 = 50000 x √0.2 / 143 𝑆 = 156 Sqmm Next higher standard cross section of conductor is 185 mm2. Proposed minimum cable size for 6kV Motors and Transformers is 3C x 185 mm2, XLPE, Cu. Cable.

4.2 Cable Selection: 

The cables shall be sized based on the type of usage, type of load, maximum continuous load current, voltage drop, system voltage, system earthing and short circuit withstand criteria as applicable. The de-rating, due to ambient air temperature (40 degree centigrade as standard), ground temperature, grouping and proximity of cables with each other, thermal resistivity of soil (if applicable), depth of laying, etc. will be taken into account while sizing of the cable.



All incoming cables to switchgear/UPS/DC system/DBs and other equipment shall be sized for maximum anticipated load including 10-15% additional margin.



Cables connected in parallel shall be of the same type, cross-section and terminations.



All power and control cables shall be in continuous lengths without any splices or intermediate joints along the entire length.

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

All cables shall be flame retardant low smoke with low hydrogen chloride emission (Maximum halogen content by weight will be referred from respective technical specification).



Fire resistant cables with three hour rating are used for the selected critical systems/equipments.



LAN and Optical fibre cables shall be used as per requirements.



Fire proof coating over a bunch of cables installed on trays where volume of combustible material in tray exceeds 7 liters per running meter of tray as per IEC60332.

Formatted: Indent: Left: 0.5", No bullets or

Formatted: Font: Underline Formatted: Indent: Left: 0.5", No bullets or

Formatted: Underline Formatted: Indent: Left: 0.75", Bulleted + Level: 3 + Aligned at: 1.5" + Indent at: 1.75"



 

Screened cables shall be used for the following systems / circuits: o Overall screening for VT Circuit o Overall screening for electrical protection circuit o Overall screening for communication system o Overall screening for control cables when the system voltage is less than 220V. o Additionally, individual core / pair shielding shall be provided for control cable circuits with millivolt / mill ampere signals. o In addition to the above requirements, shielding will be provided to suit the selected equipment as per the system developer’s recommendations, to ensure minimum permissible voltage drop or signal loss, as applicable / as the case may be. All control cables shall have at least 10% spare cores. The conductor shall be solid for nominal area up to and including 6mm2 and stranded beyond 6mm2. Conductors of nominal area less than 16mm2 shall be circular. Conductors of nominal area 16mm2 and above may be circular or shaped. Conductors in fire resistance (fire survival) cables shall also be circular.

5. 6kV (UE) MV POWER CABLES MV Power Cables shall be steam cured / gas cured / electron beam cured cross-linked polyethylene (XLPE) insulated, extruded of polyvinyl-chloride thermoplastic compound (ST2 type) (inner and outer) sheathed with low hydrogen chloride emission, unarmored type with copper. MV Power cable voltage rating U0/U (Um) 6/6 (7.2) kV, frequency 50 Hz and above shall be provided with both conductor screening and insulation screening.

5.1 MV Power cable details: Cable Type designation Conductor Screening Insulation Tape Screen Binding Tape Inner sheath Thermal Barrier File Name: GID/379/EL/YYY/BS/3006

PvVng(A) – LS Stranded Copper Semiconductor cross-linked compound XLPE Semiconducting Copper Wire Copper FRLS PVC Two layers of glass mica tape with SEPTEMBER2018

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Formatted: Normal, Indent: Left: 0"

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minimum 30% overlap alternative. FRLS PVC

Outer sheath

or a better

5.2 Data Sheet       

Nominal Power system voltage (kV) Maximum system voltage for continuous operation (kV) System Neutral Earthing (UE/E) Design Ambient Air Temperature (0C) Frequency Maximum conductor temperature Short Circuit temperature



The inner and outer sheaths will have properties as mentioned below: - Minimum critical oxygen index value at room temperature When tested as per ASTM-D-2863-77 - Minimum temperature index - Maximum halogen content (by weight) in sheaths material When tested as per IEC-60754-1 - Minimum light transmittance during smoke density test as per IEC-61034-2



: 6 kV : 7.2 kV : UE : 450C : 50 Hz : 900C : 2500C

: 35 : 3000C : 14 % : 60 %

Finished cables shall pass the flammability test as per IEC: 60332 Part-1 and PartIII

5.3 Construction and Technical Requirements   

Suitable for all climatic for macroclimatic regions on land and sea, except macroclimatic regions with a very cold climate for indoor operation (inside enclosed spaces) with elevated humidity Cable voltage rating (U0/U) 6/6 kV frequency 50 Hz. Peak AC voltage of the power cable is intended for – 7.2 kV. Cable shall be single conductor or three conductor depending upon the application. cable design is in compliance with the requirements of IEC 60502-2 Maximum outside diameter, maximum permissible specific combustion heat, combustion mass of polymer materials and design mass of PvVng(A)-LS type cables shall be as per below table

Core number and cross section, nx Sq mm 50 (16) 70 (16) 95 (16) 120 (16) 150 (25) 185 (25) 240 (25) File Name: GID/379/EL/YYY/BS/3006

Maximum outside diameter, Mm 30.1 31.9 33.8 36.3 38.1 40.1 43.1

Combustion mass l/m 0.528 0.583 0.636 0.727 0.773 0.844 0.982

Specific combustion heat, MJ/m 25.328 27.999 30.533 34.879 37.101 40.533 47.117

Design mass of 1kM cable, kg 1291 1525 1808 2126 2532 2909 3523 SEPTEMBER2018

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300 (25) 400 (35) 500 (35)

46.1 50.7 53.8

1.066 1.248 1.361

51.184 59.894 65.344

4152 5278 6286

1. Electric conductor 2. Semiconducting cross-linked compound screen 3. Insulation 4. Semiconducting cross-linked compound screen 5. Semiconducting tape 6. Copper wire screen 7. Copper binding tape 8. Inner sheath File Name: GID/379/EL/YYY/BS/3006

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9. Thermal barrier 10. Outer sheath.    



The cables shall be manufactured with copper conductors. Conductor shall be round, compacted and comply with class2 as per IEC 60228 Cable insulation shall be made of cross-linked polyethylene (XLPE) as per IEC 60502-2 The “ng – LS” cable inner and outer sheaths shall be extruded of polyvinyl-chloride thermoplastic compound (ST2 Type) as per IEC 60502-2 with low release of hydrogen chloride. Maximum hydrogen chloride release shall not be more than 14% The conductor screen, XLPE insulation and insulation screen shall be extruded in one operation by “Triple Extrusion” process to ensure perfect bonding between the layers. Curing shall be through continuous vulcanization (CV). Core identification shall be by colored strips or printed numerals.

The physical-mechanical and chemical characteristics of PvVng(A)-LS as per below table

Characteristics Before Aging - Tensile strength, N/mm2, not less than - Break relative elongation, % not less than After Aging in thermostat - Temperature, 0C - Duration - Tensile strength, N/mm2, not < max. deviation, % - Break relative elongation, %, not < max. deviation, % Heat Deformation - Relative elongation after ageing for 15 min at (200+3) 0C and tensile load of 0.2 N/mm2, %, Not more than - Relative elongation after the load removal and cooling, %, not more than Water absorption after 336h aging in water at (85+3) 0C Mass change mg/cm2 not more than Shrinkage after ageing in thermostat at (130+3) 0C for 1 hr, %, not more than

File Name: GID/379/EL/YYY/BS/3006

Value 1

Value 2

12.5 200

11.0 200

135+3 168 h

100+2 7d

+25

+20

+25

+20

175

-

15

-

1 4

-

Formatted: Font: 10 pt

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Heat Shock Test - Temperature, 0C - Duration, h Deformation Resistance at high temperature - Temperature, 0C - Duration, h - Indention depth, %, Not greater than Combustibility determined by oxygen index method, % not less than Mass portion of hydrogen chloride, release duration combustion, % not more than   



150 + 3 1

-

80 + 2 4 50

-

40

-

14

All electrical parameters of the cable shall be as per IEC 60502-2and fungi fouling level shall not be more than two points during the test as per IEC 60068-2-10. Inner and outer sheath – Oxygen index shall be 35% minimum and temperature index 300 0C minimum Cable service life shall be not less than 40 years

The allowable current load of cables shall correspond to the value provided in below table

Nominal conductor section, mm2



-

Permissible load for open-air copper conductor cables, A At 250C ambient temperature for cable laid in Triangle Flat

50

240

290

70

300

360

95

387

448

120

445

515

150

503

574

185

577

654

240

677

762

300

776

865

400

891

959

500

1025

1080

Correctional factor for current loads of PvVng (A)-LS Cables shall be as per below table

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5.4 Special Requirements: 

The 6kV (UE) MV Power cables shall meet the Special requirements mentioned in NPCIL Technical specification for MV Power cables (Cable type – PvVng(A)-LS), Clause no. 6.2



Implementation and operation condition requirements shall meet the NPCIL Technical specification for MV Power cables (Cable type – PvVng(A)-LS), Clause no. 6.4 Formatted: Indent: Left: 0.5"

6. LV POWER CABLES LV Power Cablesshall be extruded of PVC compound (PVС/А type) with low hydrogen chlorideemission, extruded of polyvinyl-chloride thermoplastic compound (ST1 type) (inner andouter) sheathed with low hydrogen chloride emission, unarmored type with copperconductors. LV power cable voltage rating U0/U (Um) 0.6/1 (1.2) kV frequency 50 Hzand above.

6.1. LV Power cable details: Cable Type designation Conductor Screening Insulation Tape Screen Binding Tape Inner sheath Thermal Barrier Outer sheath

VVGng-FRLS, VVGEng-FRLS, VVGng-LS &VVGEng-LS Stranded Copper PVC Polymer compound PVC Semiconducting Copper Wire Copper FRLS PVC Two layers of glass mica tape with minimum 30% overlap or a better alternative. FRLS PVC

6.2. Data Sheet     

Nominal Power System Voltage 220V DC Maximum System Voltage for continuous operation kV System Neutral Earthing UE/E Design Ambient Air Temperature Frequency

File Name: GID/379/EL/YYY/BS/3006

: 415V AC/ : 1.2 kV AC/300V DC : UE : 450C : 50 Hz SEPTEMBER2018

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   



Normal operating conductor temperature Short circuit temperature Maximum Halogen content (by weight) in insulation - material when tested as per IEC-60754-1 The inner and outer sheaths will have properties of - Minimum critical oxygen index value at room temperaturewhen tested as per ASTM-D-2863-77 - Minimum temperature index - Maximum Halogen content (by weight) in sheaths materialwhen tested as per IEC-60754-1 - Minimum light transmittance during smoke density testas per IEC-61034-2

: 700C : 1600C : 15%

: 35 : 300oC : 14% : 60%

Finished cables shall pass the flammability test as per IEC: 60332 Part-1 and Part-III and fire-resistant (fire survival) test as per IEC 60331-23

6.3. Construction & Technical requirements          

  

 

Suitable for all climatic for macroclimatic regions on land and sea, except macroclimatic regions with a very cold climate for indoor operation (inside enclosed spaces) with elevated humidity Cables are to be manufactured for rated AC voltage (U0/U) 0.6/1 kV, 50 Hz frequency or 2.4 kV DC voltage. The design of screened and non-screened cables shall meet the requirements of IEC 60502-1, 2004. The cables shall be manufactured with copper conductors. Conductors shall comply with Class 1 or 2 as per IEC 60228. The fire resistant (fire survival) cables ("ng - FRLS") shall be with circular conductor. The fire resistant (fire survival) cables ("ng - FRLS") shall be provided with minimum two layers of Glass Mica tapes, over conductors, with a minimum 30% overlapping of individual tapes. Cable insulation shall be of extruded PVC compound (PVС-А type) as per IEC 60502-1 with low hydrogen chloride emission. Maximum hydrogen chloride emission during cable testing as per IEC 60754-1 shall not exceed 15 %. Nominal cable insulation thickness shall comply with the requirements of IEC 60502-1. For all twisted insulated conductors of multi-conductor screened cables and insulated conductor of single-conductor screened cable it is necessary to provide an inner extruded sheath of polyvinylchloride polymer compound with low hydrogen chloride emission, which shall fill the space between conductors of multi-conductor cable. Maximum hydrogen chloride emission during PVC compound testing as per IEC 60754-1 shall not exceed 14 %. The inner sheath shall not weld with conductor insulation and during cable termination shall freely separate from the conductor insulation without insulation damage. The inner sheath thickness shall be not less than 1.0 mm. A screen in the form of wrapped copper foil or copper strip with a rated thickness of not less than 0.1 mm, with overlapping of at least 30 % shall be provided on top of the inner sheath of the screened cable, which ensures the continuity of the screen at permissible cable bending radius. A bare copper wire of 0.4 mm diameter shall be provided longitudinally under the screen as drain wire. The elongation of Copper foil/ tape for screened cables shall not be less than 15%.

File Name: GID/379/EL/YYY/BS/3006

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    

The cable outer sheath shall be extruded from PVC compound (ST1 type) as per IEC 60502-1 with low hydrogen chloride emission. Maximum hydrogen chloride emission during PVC compound testing as per IEC 607541 shall not exceed 14 %. Nominal cable outer sheath thickness shall comply with the requirements of IEC 605021. Outside diameters, maximum permissible specific combustion heat and combustible mass of cable polymer materials shall comply with the values provided in NPCIL Technical specification for LV Power Cables, table 6.1.14.1& 6.1.14.2 ## The physical-mechanical and chemical characteristics of LV Power cables as per below table Characteristics

Before Aging - Tensile strength, N/mm2, not less than - Break relative elongation, % not less than After Aging in thermostat - Temperature, 0C - Duration, days - Tensile strength, N/mm2, not < max. deviation, % - Break relative elongation, %, not < max. deviation, % Combustibility determined by oxygen index method, % not less than Minimum temperature index Maximum Halogen content (by weight) when tested as per IEC-60754-1     

Value 1

Value 2

12.5 150

12.5 150

100 +2 7

100 +2 7

12.5 +20

12.5 +20

150 +20 35%

150 +20 35%

300oC

300oC

15%

14%

All electrical parameters of the cable shall be as per IEC 60502-1. The fire-resistant (fire survival) cables ("ng - FRLS") shall comply with IEC 60331-21 requirements for 180 minutes (three hours) rating at a temperature of 750 00 C. Inner and outer sheath – Oxygen index shall be 35% minimum and temperature index 300 0C minimum. Cable service life shall be not less than 40 years. The allowable current load of cables shall correspond to the value provided in below table Nominal conductor section, mm2 2.5 4 6 10 16 25 35 50

Permissible load for open-air copper conductor cables, A Single Two Three- four and Conductor Conductor five- conductor* 40 33 28 53 44 37 67 56 49 91 76 66 121 101 87 160 134 115 197 166 141 247 208 177

File Name: GID/379/EL/YYY/BS/3006

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70 95 120 150 185 240 

318 386 450 521 594 704

c i 25 a l Requirements

 

226 274 321 370 421 499

Correctional factor for current loads of LV Power Cables shall be as per below table

Design Standardized 6.4. S ambient conductor ptemperature, temperature, e о о С С



282 321 378 438 499 591

70

Ambient temperature, оС 5

10

15

20

25

30

35

40

45

50

Correctional factor 1.2 1.15 1.11 1.05

1

0.94 0.88 0.81 0.74 0.67

LV Power cables for a voltage below 0.6/1kV shall meet the Special requirements mentioned in NPCIL Technical specification for LV Power cables (Cable type VVGng-FRLS &VVGEng-FRLS) and (Cable type – VVGng-LS &VVGEng-LS), Clause no. 6.2 . Implementation and operation condition requirements shall meet the NPCIL Technical specification for LV Power cables (Cable type - VVGng-FRLS &VVGEng-FRLS) and (Cable type – VVGng-LS &VVGEng-LS), Clause no. 6.4 .

7. CONTROL CABLES Control Cable shall be extruded of PVC compound (PVС/А type) with low hydrogen chloride emission, extruded of polyvinyl-chloride thermoplastic compound (ST1 type) (inner and outer) sheathed sheath with low hydrogen chloride emission, unarmoured type with copper conductors. Nominal alternating voltage of the control cables is not higher than 660 V of frequency not higher than 100 Hz or direct voltage is not higher than 1000 V.

7.1. Control cable details: Cable Type designation Conductor Screening Insulation Tape Screen Binding Tape Inner sheath Thermal Barrier File Name: GID/379/EL/YYY/BS/3006

KVVGng-FRLS, KVVGEng-FRLS, KVVGngLS &KVVGEng-LS Stranded Copper PVC Polymer compound Extruded PVC Semiconducting Copper Wire Copper FRLS PVC Two layers of glass mica tape with minimum 30% overlap or a better SEPTEMBER2018

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alternative. Extruded PVC

Outer sheath

7.2. Data Sheet         



Nominal Power System Voltage : 220V DC/240V AC Maximum System Voltage for continuous operation kV : 300V DC/264V AC System Neutral Earthing UE/E o 220V DC : Unearthed o 240V AC : Solidly earthed Design Ambient Air Temperature : 450C Normal operating conductor temperature : 700C Short circuit temperature : 1600C Voltage grade :660V AC/1000V DC Maximum Halogen content (by weight) in insulation material when tested as per IEC-60754-1 : 15% The inner and outer sheaths will have properties of - Minimum critical oxygen index value at room Temperature when tested as per ASTM-D-2863-77 : 35% - Minimum temperature index : 300oC - Maximum Halogen content (by weight) in sheaths material when tested as per IEC-60754-1 : 14% - Minimum light transmittance during smoke density test as per IEC-61034-2 : 60% Finished cables shall pass the flammability test as per IEC: 60332 Part-1 and Part-III and fire-resistant (fire survival) test as per IEC 60331-23

7.3. Construction & Technical requirements         

Suitable for all climatic for macroclimatic regions on land and sea, except macroclimatic regions with a very cold climate for indoor operation (inside enclosed spaces) with elevated humidity. Nominal alternating voltage of the cables is not higher than 660 V of frequency not higher than 100 Hz or direct voltage is not higher than 1000 V. The design of screened and non-screened cables shall meet the requirements of IEC 60502-1, 2004. The cables shall be manufactured with copper conductors. Conductors shall comply with Class 1 or 2 as per IEC 60228. The fire resistant (fire survival) cables ("ng - FRLS") shall be with circular conductor. The fire resistant (fire survival) cables ("ng - FRLS") shall be provided with minimum two layers of Glass Mica tapes, over conductors, with a minimum 30% overlapping of individual tapes. Cable insulation shall be of extruded PVC compound (PVС-А type) as per IEC 60502-1 with low hydrogen chloride emission. Maximum hydrogen chloride emission during cable testing as per IEC 60754-1 shall not exceed 15 %. Nominal cable insulation thickness must correspond to the table given below Conducting core section, mm2 0.75 – 2.5 4.0 – 6.0

File Name: GID/379/EL/YYY/BS/3006

Nominal thickness for insulation, mm 0.6 0.7 SEPTEMBER2018

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10.0 

  

    

For all twisted insulated conductors of multi-conductor screened cables and insulated conductor of single-conductor screened cable it is necessary to provide an inner extruded sheath of polyvinylchloride polymer compound with low hydrogen chloride emission, which shall fill the space between conductors of multi-conductor cable. Maximum hydrogen chloride emission during PVC compound testing as per IEC 60754-1 shall not exceed 14 %. The inner sheath shall not weld with conductor insulation and during cable termination shall freely separate from the conductor insulation without insulation damage. The inner sheath thickness shall be not less than 1.0 mm. A screen in the form of wrapped copper foil or copper strip with a rated thickness of not less than 0.06 mm, with overlapping of at least 30 % shall be provided on top of the inner sheath of the screened cable, which ensures the continuity of the screen at permissible cable bending radius. A bare copper wire of 0.4 mm diameter shall be provided longitudinally under the screen as drain wire. The elongation of Copper foil/ tape for screened cables shall not be less than 15%. The cable outer sheath shall be extruded from PVC compound (ST1 type) as per IEC 60502-1 with low hydrogen chloride emission. Maximum hydrogen chloride emission during PVC compound testing as per IEC 60754-1 shall not exceed 14 %. Nominal cable outer sheath thickness must correspond to the table given below. Cable diameter under outer sheath, mm Up to 6 From 6 up to 15 From 15 up to 20 From 20 up to 30 From 30 up to 40 Above 40

    

0.9

Nominal thickness for outer sheath, mm 1.2 1.5 1.7 1.9 2.1 2.4

Outside diameters, maximum permissible specific combustion heat and combustible mass of cable polymer materials shall comply with the values provided in NPCIL Technical specification for Control Cables, table 6.1.14.1 & 6.1.14.2 ## All electrical parameters of the cable shall be as per IEC 60502-1. The fire-resistant (fire survival) cables ("ng - FRLS") shall comply with IEC 6033121 requirements for 180 minutes (three hours) rating at a temperature of 750 0C. Inner and outer sheath – Oxygen index shall be 35% minimum and temperature index 300 0C minimum. Cable service life shall be not less than 40 years.

7.4. Special Requirements 



The control cables, fire resistant at alternating voltage up to 660 V by frequency not higher than 100 Hz or at direct voltage up to 1000 V shall meet the Special requirements mentioned in NPCIL Technical specification for Control cables (Cable type - KVVGng-FRLS &KVVGEng-FRLS) and (Cable type – KVVGng-LS &KVVGEng-LS), Clause no. 6.2 . Implementation and operation condition requirements shall meet the NPCIL Technical specification for control cables ((Cable type - KVVGng-FRLS

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Formatted: Bulleted + Level: 1 + Aligned at: 0.75" + Indent at: 1"

NUCLEAR POWER CORPORATION OF INDIA LTD. PAGE NO. : Page 21 of 35 KUDANKULAM NUCLEAR POWER PROJECT-3&4 REV. NO : P0 DESIGN BASIS REPORT FOR CABLING SYSTEM REV. DATE : 24.09.2018



&KVVGEng-FRLS) and (Cable type – KVVGng-LS &KVVGEng-LS), Clause no. 6.4.

8. 245kV EHV POWER CABLE EHV Power Cableshall be 245kV, single core 1200 mm2Aluminium conductor, XLPEinsulated, aluminum sheathed and FR PVC outer sheathed cable.

8.1. Scope details: 





2454kV EHV cable have been proposed for the tie line connectivity between KKNPP-1&2 and KKNPP-3&4, which are crossing the 400kV outdoor switchyard. On one side of the cable, the respective phases of the cable shall be connected to lattice columns (one for every phase) and on the other side the cable shall be connected to a tower (for overhead line). Cable will be directly buried below the ground at a level of 800mm from ground. Trench will be made at a depth of 1000mm and width of 600mm. Fine sand to be filled, after laying the cable in trefoil formation and top layer of trench will be made by red colored reinforced concrete slab at a size of 400x300x100mm. (Reference NPCIL Drawing No. I05.KK34.0.0.ET.OKS.WD006 – Appendix-10 for Details of 230kV Cable and FOP cable laying arrangement). EHV cables size as per tender specification has been followed. Description 245kV, single core 1200 mm2 Aluminium conductor XLPE insulated, Aluminium sheathed and FR PVC outer sheathed cable Outdoor air termination suitable for 245kV, single core 1200 mm2 Aluminium conductor XLPE insulated cable

Approx length (m) 270 ( R &Y Phase), 265 ( B Phase) -

Qty 3

6

8.2. EHV Cable Technical particulars             



Rated voltage (U) Highest voltage (Um) Basic impulse level Conductor material Minimum Conductor size Stranded/Solid Number of core Insulation material Metallic sheath External overall sheath properties Maximum conductor temperature Maximum short-circuit temperature Properties of outer sheath - Oxygen index value at room temperature - Minimum temperature index Type of Laying

File Name: GID/379/EL/YYY/BS/3006

:230kV :245kV :050kV(UG)/900kV(G) :Aluminium :1200 mm2 :Stranded :one :XLPE : Aluminium : PVC type ST-2 with

FR

:90°C :250°C : 29 : 250°C : Underground in trefoil formation SEPTEMBER2018

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

Type of bonding

:Single point bonding

8.3. Construction & Technical requirements                  

     



The XLPE cable and the associated accessories shall conform to the followingIndian and International standards as amended /revised till date, as applicable: IEC 62067 Power cables with extruded insulation and their accessories forrated voltages above 150 kV (Um = 170 kV) up to 500 kV (Um = 550 kV)– Test methods and requirements IEC 60228 Conductor for insulated cables. IEC 60229 Tests on cable over sheaths. IEC 60230 Impulse tests on cables and their accessories. IEC 60270 Partial discharge measurements. IEC 60287 Calculation of continuous current carrying capacity and losses. IEC 60502 All cables with extruded insulation and their accessories. IEC 60840 Test for power cables with extruded insulation. IEEE 48 Test procedure and requirement for high voltage cabletermination. IEEE 404 Joint for use with solid dielectric cables. IEEE 635 Guide for selection and design of aluminum sheaths. IS 7098 (Part 3) Cross linked polyethylene insulated thermoplastic sheathed cables – specification for working voltage from 66 kV up to and including220kV IS 5216 Guide for safety procedure and practices in electrical works IS 1893 Criteria for earthquake resistant design of structure Indian Electricity Rules. Indian Electricity Act The continuous vulcanizing, dry cured cross linked polyethylene insulated (XLPE) cable shall be manufactured in accordance with the internationally accepted standard and also conform to the requirements of IEC 62067 / IS 7098. The cable shall be suitable for laying in an area likely to be flooded by water and shall be designed to be protected against rodent and termite attack. The conductor screen, insulation and insulation screen shall all be extruded through common head triple extrusion in a single onetime process to ensure homogeneity and absence of voids 245 kV cable shall be supplied in single length without any joint. The conductor shall consist of Aluminium stranded wires of nominal cross section of minimum 1200 sq. mm. The shape of the conductor shall be compact circular stranded. The conductor screen shall consist of extruded semi conducting compound. Semi conducting separator tapes shall be applied between conductor and the extruded insulation The extruded XLPE insulation shall be of very high degree of purity and dry cured. The insulation shield shall consist of extruded semi-conducting XLPE. Suitable bedding tapes shall be applied over the extruded semi-conducting XLPE. Water swellable absorbent shall be applied over the insulation screen. The metallic sheaths shall consist of corrugated Aluminum. It shall be able to withstand earth fault current of 40 kA for 3 second. Bidder shall furnish prequalification tests on complete cable system and meet other qualifying requirements of specification. The minimum thickness at any point shall not fall below the nominal value by more than 10%. Anti-corrosive compound shall be applied over the aluminum sheath. The outer jacket shall consist of extruded PVC type ST-2 with fire resistance (FR) properties. The minimum thickness at any point shall not fall below 90% of the

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nominal. For facilitating testing of non-metallic outer sheath, a conductive outer layer shall be provided over the nonmetallic outer sheath

8.4. Cable End Termination & Other accessories      

Rated voltage Highest voltage Basic insulation level (1.2/50 μ sec) Short circuit current Phase clearance Installation

: 230kV : 245kV : 1050kV(UG)/900kV(G) : 40 kA, 3 second : 6000mm : Outdoor

8.5. Construction & Technical requirements 





 



The cable end termination and other accessories shall include out-door end cable termination, cable fixing clamps, surge voltage limiter, link boxes, bonding cable of required length and also any special tools and tackles required for making these terminations. All accessories shall be suitable for tropical climatic conditions specified in the specification and are likely to be subjected to submergence in water. The cable end termination shall be of outdoor anti-fog type complete with porcelain insulators. The outdoor terminal should be suitable for heavily polluted atmosphere conditions with creepage distance of 44mm/kV for highest phase to earth system voltage. The housing shall be made of homogeneous, vitreous porcelain of highmechanical and dielectric strength. Glazing of porcelain shall be of uniformbrown or dark brown colour with a smooth surface arranged to shed awayrain water or condensed water parties. The internal electric stress of the cable termination shall be controlled by premoulded silicon cone arrangement The largest load out of the following combination of loads shall be taken as the maximum working load of insulator and to be considered for the Mechanical design of the cable end termination insulator. - Electromagnetic force due to short circuit current + wind load +Normal operating load. - Electromagnetic force due to short circuit current + Earthquake force+ Normal operating load. Outdoor type sealing end: The cable sealing end with Composite/Porcelain type insulator, link box with sheath voltage limiter conforming to IEC- 62067 of termination for maximum continuous voltage of 245 kV cables. The silicone rubber /composite bushing termination of rated capacity, suitable for outdoor installation in moderately polluted atmosphere shall be used. It should resistant to UV exposure. The termination stress control shall be means of stress cone. The stress cone made of silicone rubber shall inhibit possible mechanical stress and deformation of the cable insulation surface during operation and also shall be capable of accommodating minor radial and longitudinal movement without determent to the dielectric stress in the insulation shield.

9. FIBRE OPTIC U/G CABLE Fibre Optic Cable shall be provided on Transmission Tower end. The other end of 245 kV cable will be connected to LA with suitable outdoor termination kit. File Name: GID/379/EL/YYY/BS/3006

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 

   





The Armoured underground fibre optic cable required to connect Overhead Fibre Optic Cable (OPGW) between the two overhead transmission wherever 220kV line is crossing 400kV outdoor switchyard. Fiber optic cable will be laid through protective duct (HDPE Pipe) on the same trench, where EHV cables are laid to cross the 400kV Outdoor switchyard of KKNPP-1 & 2. FO cable will be laid above the EHV cable by maintaining minimum clearance of 200mm throughout the trench. (Reference NPCIL Drawing No. I05.KK34.0.0.ET.OKS.WD006 – Appendix-10 for Details of 230kV Cable and FOP cable laying arrangement) Approach cable shall contain fibres with identical optical/ physical characteristics asthose in the OPGW cables. Cable and fibre service loops are provided for facilitating the installation, maintenance andrepair of the optical fibre cable plant. Indoor Cable Service Loops: FODPs shall provide at least three (3) meters of cable service loop. Service loops shall be neatly secured and stored, coiled such that the minimum recommended bend radius' are maintained. Fibre Units Service Loops: For all fibre optic cable splicing, the cable shall be stripped back a sufficient length such that the fan-out of fibre units shall provide for at least one (1) meter of fibre unit service loop between the stripped cable and the bare fibre fan-out. Pigtail Service Loops: Connectorised pigtails spliced to bare fibres shall provide at least 1 meter of service loop installed in the FODP fibre organizer and at least one (1) meter of service loop to the couplings neatly stored behind the FODP coupling panels. Fibre Service Loops: At least 0.5 meter of bare fibre service loop shall be provided on each side of all fibre splices

10. CABLE CARRIER SYSTEM 10.1.

Technical requirements:   

10.2.

Cable carrier system elementsshall be hot dip galvanized and fabricated from carbon steel with a thickness of zinc coating not less than 80 microns. The quality category shall be commensurate with safety class 2S. For BOP areas the safety class shall be 3N or 4 as applicable. The elements/components of cable metal structures shall include: - Racks (ceiling, wall, floor, spacer-types); - Cantilevers; - Trays for laying power and control cables; - Flat Cable ducts for laying power and control cables; - Modular Cable ducts for laying power and control cables; - Separating partitions for installation in ducts; - Duct - bend sections. - Accessories for the elements/components - Fasteners for the assembly - Cable fastening clamps – of all types

Racks 

Vertical support elements for cable trays/ducts are called as racks.

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

  

  

The lengths of racks shall be in standard sizes ranging from 300 to 3000 mm with a 50-mm pitch for the (circular) slotted holes on all the faces. The thickness of the racks (sheet steel) shall be 3-4mm approximately and.actual

dimensions shall be as in the drawings to be provided by NPCIL to the successful bidder

Formatted: Left, Right: 0", Don't adjust space between Latin and Asian text, Don't adjust space between Asian text and numbers

In cases where the requirement at site is in between two standard lengths, it is permitted tocut and weld standard elements to suit actual site conditions. Care needs to be taken toproperly coat the affected surfaces with cold galvanizing paint. Rack fastening elements shall permit attachment to the previously installed embedded parts by welding. The designs of racks shall have provisions (through appropriate fittings/accessories) for attachment to the building floor, wall and ceiling by anchor bolts wherever EPs are not available.

Formatted: Font: (Default) Times, 12 pt

The design/fabrication/assembly/installation elements shall be permit easy disassembly when called for

Formatted: Font: (Default) Times, 12 pt

It shall be possible to secure horizontal supports to vertical supports anywhere along thelength of the rack, at multiples of not more than 50 mm. Typical sections of the racks are shown below.

Typical sketch of the racks (S, S1, S2) File Name: GID/379/EL/YYY/BS/3006

Typical sketch of the racks (SS3) SEPTEMBER2018

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10.3.

Brackets   

Horizontal support elements for cable trays/ducts are called as brackets/cantilevers. Brackets shall be attached to the rack fasteners and trays/ducts are fastened to it. Standard sizes of brackets facilitate installation of standard trays and ducts of widths of 100, 200, 300, 400, 500, and 600 mm. The thickness of the brackets (sheet steel) shall be 2-3mm. Typical sections and details of the brackets are given below

Typical sketch of brackets (P) The type of a brackets P-100 P-200 P-300 P-400 P-500 P-600

10.4.

H (mm) 130 230 330 430 530 630

D (mm) 55 55 55 80 80 80

B (mm) 28 28 28 50 50 50

Cable trays   

The trays are intended for installation of cables and wires. Cable trays shall be in standard widths of – 100, 200, 300, 400, 500, 600mm. The thickness of the sheet steel for forming of cable trays shall be about 2mm. The cable tray rungs shall be welded to the collar through a full weld on the meshing area. The various types of cable tray element include the following: - Straight trays; - Tray corner section with a 90º turn in a horizontal plane; - Tray branching section for 3 directions with a 90º turn; - Tray branching section for 4 directions with a 90º turn; - Separating partition; - Section with an upward turn (rotary connection elements can be used); - Section with a downward turn (rotary connection elements can be used).

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  

10.5.

Typical sections of cable trays are shown in NPCIL Technical specification for Cable carrier systems, Clause no.5.3.7 Wire mesh cable trays are to be used in Indoor for running the cables for lighting and receptacles, fire alarm and protection, welding/multipurpose receptacles and maintenance lighting. Wire mesh cable tray installed in indoor common access area shall be made of hot dip galvanized carbon steel with the thickness of zinc coating no less than 85 m. For outdoor applications and a corrosive atmosphere, the material shall be SS 316.

Flat Cable Ducts  



     

10.6.

Flat cable ducts shall be fabricated as a finished factory-made product. Flat cable ducts (FCDs) are intended for installation of wires, control and power cablesinside and outside the various buildings. FCD sections are made as metal structuresfabricated of sheet metal bent in the form of ducts of different configuration with coversinstalled onto them. The various types of cable duct include the following: - Straight section; - Duct corner section with a turn through 90º in a horizontal plane; - Duct branching section for 3 directions with a 90º turn; - Duct branching section for 4 directions with a 90º turn; - Section with an upward turn; - Section with a downward turn; - Separating partition; - Covers for all types of duct sections. The duct fabrication/design shall have brackets attached to the duct through fasteners. Thedesign/fabrication also have provision to connect trays with a turn in a horizontal planethrough 135° and 90º. Width of the duct shall be of 100, 200, 300, 400, and 500 mm. and Height of the duct shall be 100 and 150 mm. The thickness of the sheet steel of the ducts shall be about 2mm. There are no sharp edges at connections attachments of ducts. The duct covers shall be fastened to ducts both in horizontal and vertical sections so as toexclude possible damage to cables during an earthquake. If required, the ducts shall permit installation of a separating partition inside them with apitch of 50 mm. The distance between supports, for cable ducts, in general shall be 2m. Typical sections of cable duct are shown in NPCIL Technical specification for Cable carrier systems, Clause no.5.4.15

Modular Cable Ducts   

Modular cable ducts (MCDs) are supplied as a finished factory product. MCD ducts are intended for installation of wires, control and power cables of up to 10 kVvoltage rating for both indoors and outdoors. The MCD design shall comprise a welded frame with a top cover, bottom, front and rear walls attached to it. The covers and bottom shall be attached to the frame with self-threading screws. The removable front and rear walls are installed and fixed on the duct. Louvers are to be made in the duct bottom, which serve to ventilate the duct and remove moisture resulting from condensation of vapors contained in the air. The top cover design allows water to be removed from the vertical walls.

File Name: GID/379/EL/YYY/BS/3006

SEPTEMBER2018

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NUCLEAR POWER CORPORATION OF INDIA LTD. PAGE NO. : Page 28 of 35 KUDANKULAM NUCLEAR POWER PROJECT-3&4 REV. NO : P0 DESIGN BASIS REPORT FOR CABLING SYSTEM REV. DATE : 24.09.2018

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Control and power cables shall be taken out from the duct through an outlet wall, installed in place of the duct rear wall. The interval of support shall not be more than 6 m in a straight cable route. The support interval is based on the self-bearing capacity of a 6-m block assembled out of three numbers of 2-m-long sections. MCD sections shall be connected to each other using bolted or welded joints. Elements for fastening of modular cable duct to the civil structures of buildings The typical details/ sketch of MCDs are shown in NPCIL Technical specification for Cable carrier systems, Clause no.5.5.8, Figures 5.5.1 - 5.5.6.

Typical sketch of straight section of modular cable duct

11. CABLING INSTALLATION WORK 11.1.

Cabling philosophy  

   

Cabling inside buildings shall be through a combination of cable spreader room, cable trench and cable shaft and external cabling shall be through a combination of underground cable tunnels and cable trenches. All the cables in main routes shall be installed in cable trays / or on supports in the formof ladder type trays /cable duct with consoles. Laying orDistribution of cables for individual loads, lighting and receptacles, fire alarm, otherservices shall be through wire mesh type trays/troughs. Branching out of single cables toelectrical loads, lighting boards/fixtures, receptacles, fire alarm and other services can berun in small pipes for limited distances or to be clamped directly on the wall/ceiling forvery short distances. Separate cables shall be used for AC and DC System. Power and control cables shall belaid in separate trays, identified as power and control cable trays. Medium and low voltage power and control cables shall be separated from each other by minimum spacing of 250mm or by running through independent pipes, trenches or cables trays. Remote controls (tripping /closing) from control panels shall be with 48 V DC.Controlcables and terminal blocks for this shall be segregated from 220 V DC cables. Provision of space for accommodating additional cabling, in future, to an extent of at least10-15% shall be kept in all cable trays/ cable ducts, racks, trenches and

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11.2.

tunnels. Mutuallyredundant cables shall be installed in different routes to prevent simultaneous failure dueto a common cause. Cable installations shall meet the minimum cable bending radius recommended by the cable manufacturer. Separate trays shall be provided for MV cables,LV power and control cables and plant communication cables. Cables of different service class like safety-related and non-safety related cables shallhave separate routes. Cables connected in parallel shall be run together so that their length remains the same. Cable tray loading shall generally be limited to 70% fill. In any case, no cable shall beinstalled above the top of the side rails of the cable tray, except as necessary atintersections and where cables enter or exit the cable tray systems. The cable layout design pre-supposes that main cable runs are laid on cable trays and in metal ducts. Fibre-optic cable is laid in multiple layers or in bundles in metal ducts or pipes to prevent mechanical damage. Cables of mutually redundant services are located in different runs or on different horizontal levels (brackets) of one run. Cables diverted from the main cable run to individual loads shall be located in GI pipes or flexible conduits. Where possible mechanical damage is anticipated, cables shall be protected up to a height of 2 m from floor/ground or 0.3 m deep in earth with the help of cable ducts, pipes, flexible conduit, etc. Where power cables are in parallel or are crossing various pipes as close as less than 0.5m, or near gas pipelines and pipelines with combustible fluids at less than 1 m, cables shall be protected against mechanical damage by metal pipes, enclosures, etc. along the entire distance near the pipe. The RCC cable trenches shall be sized depending upon the number and voltage grade of cables. The trenches in hazardous areas shall be filled up with sand. The width of cable trench shall be sufficient enough to facilitate 600mm width cable tray, fixed to the supporting member on one side of the trench, along with suitable gap for personnel to stand inside the trench for safe pulling of the cables. Signal cables shall preferably not be laid in the same trench/ tray along with electrical cables. In case these are laid in the same trench/ tray, a clearance of Min.300 mm from electrical cables shall be provided. The overall cable layouts shall be designed for minimum interference between signal and power cables

Cable Grouping 

  

Group 1 Cables above 1000 V; they are located on separate brackets apart from allother Cable Groups in bundles, consisting of three separate cores / phases and spaced atintervals / distance at least the diameter of one phase between them. Group 2 Cables up to 1000 V with conductor cross section greater than 16 mm2 insection.They shall be installed in one layer on separate trays. Group 3 Cables up to 1000 V with conductors 16 mm2 in section and lower. They maybe installed in one/ multiple layer(s) on separate tray with due de-rating factors. Group 4 Cables greater than 42V, free of any specific requirements for their locations,cables feeding valves and controllers and cables towards end switches of valves. Theyshall be installed on separate trays apart from all other Cable Groups in one/multiplelayers within cable trays/ducts or in bundles over supporting structures

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NUCLEAR POWER CORPORATION OF INDIA LTD. PAGE NO. : Page 30 of 35 KUDANKULAM NUCLEAR POWER PROJECT-3&4 REV. NO : P0 DESIGN BASIS REPORT FOR CABLING SYSTEM REV. DATE : 24.09.2018

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11.3.

and in trays; CableGroups 3 and 4 can be located together, if they belong to same process unit. Group 5 Cables of 42V and lower, with no specific system requirement andcommunication cables. They shall be installed in one/ multiple layers within cabletrays/ducts or in bundles over supporting structures and in trays or separate brackets apartfrom all other Cable Groups. Group 6 Control cables of special systems, which require special protection, LAN andall fibre-optic communication. They are located in multiple layers or in bundles withinclosed metal ducts or pipes. It is allowed not to have shields where cable runs are turning,but unshielded sections be no longer than 0.5 m. All sections of pipes and ducts along thecable run shall have reliable electric contact between themselves by connecting individualpipes or ducts with copper wire soldered or bolted to pipes or ducts. Ends of pipes andducts shall be free of sharp edges, to prevent damage to cables. Ends of pipes and ductsare to be closed with sleeves. Distance between pipes or ducts with control cables ofspecial systems and power cables greater than 0.5 A to be at least 0.5 m, and distance topower cables greater than 20 A to be at least 1 m. Group 8 Power cables 24 V free of any specific requirements for their locations, whichare jumpers between power supply cabinets and basic cabinets. They are located in oneline in trays on separate brackets apart from other Cable Groups without gaps, belowCable Group 2 or 3 and above Cable Groups 4 or 5.

Cable laying  

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The cable layout design pre-supposes that main cable runs are laid on cable trays and in metal ducts. Fibre-optic cable is laid in multiple layers or in bundles in metal ducts or pipes to prevent mechanical damage. Cables diverted from the main cable run to individual loads shall be located in suitable size of GI pipes orflexible conduits RCC cable trenches shall be sealed against ingress of liquid and gases wherever the trenches leave or enter a control room or power supply building. Pipes laid for mechanical protection shall be sealed at both ends. All cable openings shall be

sealed with suitable sealing compound to prevent ingress of water from outside All cables shall carry cable tag numbers for easy identification Signal cables shall preferably not be laid in the same trench/ tray along with electrical cables. In case these are laid in the same trench/ tray, a clearance of minimum 300 mm from electrical cables shall be provided All MV &LV power cables in racks/trays/ cable ducts shall be laid in single layer only. However LV cables below 16 sq. mm (Group-3) may be laid in multiple layers as well, as per technical specification for cable system & cabling guidelines. No cable joint shall be acceptable except in cases where a single length cannot be manufactured/ transported and in case of any such constraint, the same shall be brought to the notice of Purchaser before finalization of design & engineering. No joints shall be permissible in hazardous areas. Single core 6kV cables shall be laid in trefoil configuration with 1D gap. The clamping and banding of the 6kV cables in trefoil format shall be carried out as per the technical requirement for cable system & cabling guidelines (I02.KK34.0.0.ET.TT.PR001) 15% spare space shall be provided in cable trays/ trenches.

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NUCLEAR POWER CORPORATION OF INDIA LTD. PAGE NO. : Page 31 of 35 KUDANKULAM NUCLEAR POWER PROJECT-3&4 REV. NO : P0 DESIGN BASIS REPORT FOR CABLING SYSTEM REV. DATE : 24.09.2018

11.4.

Cable tray earthing 

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11.5.

All cable trays and cable ducts and its supporting structures in main routes shall be connected to the nearest earthing grid through 40 x 4 mm galvanized steel strips, at intervals not exceeding 25m and at both the ends. Smaller sections/field routing of the cable tray shall be earthed with appropriate sizes of earthing conductor Earthing continuity in cable trays shall be ensured as per IEC 61537 Grounding shall be ensured all along cable trays/cable trench. Where lined cable trenches are available, the ground conductor shall be laid in the trenches and shall be firmly cleated to the sidewall of concrete trenches using GI clamps at interval of 400 mm to 500 mm and near to the termination ends. The grounding conductor shall run along one of the cable trays along a cable route. The grounding conductor shall be suitably cleated and electrically bonded to all the other cable trays on the same cable route at a regular interval of 25 to 30

meters. The grounding for equipment shall be tapped from the mainground conductor and not from cable tray support structure Fire barrier and Fire resistant coating

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Cable fire barriers are passive fire protection systems which prevent propagation of fire from one fire compartment to the other through floor and wall penetrations for power and control cables. The construction consists of mineral wool board through which cables are laid and the gaps sealed with a fire resistance sealant. Fire resistant coating for passive fire protection are intended for coating power and control cables in order to ensure non-propagation of fire in cables in switchyard areas. A fire resistant coating is applied on the surfaces of the partitions and cables coming out of the seal. The fire barrier and fire resistant cable coating material shall be suitable for cables installed in above ground trays, underground tunnels- trays, direct in underground RCC trenches, ductsFire resistant (fire survival) cables with three hour rating shall be used for the selected criticalsystems/equipment. The applicable standards, guide and codes of practice and reports are listed in NPCIL Technical Specification for Fire barrier and Fire resistant coating (I02/KK34/0/0/ET/TS/PR/015) Clause No.3.0 Fire Barriers for passive fire protection - Fire rating required (hr.) : 3, 2& 1 Hrs. - Details of structures through which cables / Cabletrays /Pipe sleeves penetrate. o Wall thickness (mm) : To be arrived at during Detailed engineering o Floor thickness (mm) : To be arrived at during Detailed engineering - Material of frame / conduits / pipes / pipe : MS / GI SleevesCable trays provided by Purchaser Fire resistancecoating (FRC): Types of cables specified by the purchaser : XLPE/LDPE/PVC/EPR/EVA insulated and flame retardant

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Formatted: Font: 12 pt Formatted: Left, Right: 0", Bulleted + Level: 1 + Aligned at: 0.75" + Indent at: 1", Don't adjust space between Latin and Asian text, Don't adjust space between Asian text and numbers Formatted: Indent: Left: 0.75", First line: 0.5" Formatted: Indent: Left: 4"

NUCLEAR POWER CORPORATION OF INDIA LTD. PAGE NO. : Page 32 of 35 KUDANKULAM NUCLEAR POWER PROJECT-3&4 REV. NO : P0 DESIGN BASIS REPORT FOR CABLING SYSTEM REV. DATE : 24.09.2018

low smoke PVC/EVA sheathed power and control cables & fire survival cables with above insulation/sheath or any other type of cables 

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11.6.

The design of fire-resistant coating for passive fire protection shall correspond to environmental climatic factors; - Environmental temperature in a range between +15 and + 45 ºС; - Maximum average monthly humidity is 87 % (December), minimum average monthly humidity is 26 % (July-August); - Height of location above sea level – not more than 1000 m; - Type of atmosphere – seaside, tropical. A fireproof coating over the bunch of cables installed on trays shall be provided in caseswhere: - Volume of combustible material in the tray exceeds 7 litres per running metre of tray(for cables of category "A" as per IEC 60332). - Thickness and material of coating shall be kept uniform and shall be commensuratewith the flame spread category, actual quantity of cables and the IEC requirement. Fire-resistant coating for passive fire protection shall not reduce the allowable currentloads on cables by more than 2 %. Fire-resistant coating for passive fire protection shall have electric strength during operation ≥ 12 kV/mm Fire-proof sealing shall be done for Conduits/pipe inserted in the floor slabs. All cable entries through walls and floors shall be sealed with fire-resistant materials of 3 hours fire rating. Fire resistance shall be 3 hours rated for cable ways entering buildings and structures Fire-proof belts (barriers) in metal ducts with a minimum fire resistance rating of 1 hour, at intervals of 20 m in vertical sections and 30 m in horizontal sections shall be provided. When cables are installed, the ducts shall be closed with covers. Welding of covers withduct is not allowed Pipe sleeves and floor/wall openings for cables shall be provided with fire barrier using the requisite mineral wool, sealant and coating to achieve the required fire rating. Openings of the size more than 200mm (higher dimension) shall be provided with grills (of 8/12mm dia MS rods) fixed to the wall/EP through welding/approved anchor fasteners, prior to laying of the cables, to support the fire barrier material Fire ratings indicated are tentative only, the same will be concluded during details engineering and validated through fire hazardous analysis. Material Requirements:

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All material shall be new, freshly manufactured and of first class quality. The materials used in the passive fire protection systems shall not contain flammable materials or solvents which are toxic or release toxic gases during exposure to fire.

File Name: GID/379/EL/YYY/BS/3006

SEPTEMBER2018

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NUCLEAR POWER CORPORATION OF INDIA LTD. PAGE NO. : Page 33 of 35 KUDANKULAM NUCLEAR POWER PROJECT-3&4 REV. NO : P0 DESIGN BASIS REPORT FOR CABLING SYSTEM REV. DATE : 24.09.2018

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The materials used in the passive fire protection systems shall have no shrinkage or cracking after prolonged use. The materials used in the passive fire protection systems shall be nonhygroscopic. The materials used in the passive fire protection systems shall retain its integrity andperform satisfactorily even after remaining in water for long periods. The materials used in the passive fire protection systems shall be anti-rodent. The materials used in the passive fire protection systems should be nonhazardous andshould not emit any excess smoke under fire exposure. The materials used in the passive fire protection systems shall have compatibility withFRLS PVC, PVC, neoprene, silicone rubber, EVA sheathing materials of cable The materials used in the passive fire protection systems shall be resistant to chemicals. The material used in the passive fire protection systems (excluding mineral wool board)shall have oxygen index greater than 60%. The shelf life of all materials which form a part of supply of the fire barrier shall beindicated. Mineral wool board shall be ROCKWOOL, of density not less than 150 kg/m3. Theboard shall be at least 50 mm thick of minimum size 1m x 0.5m. FRC shall comply with the requirement of allowable long-term load current, if after tests(as per IEC 60332-3-10, IEC 60332-3-22) the value of allowed long-term load currentreduction factor for cable with FRC is no less than 0.98. FRC shall comply with fire-non-propagation requirements, if as a result of test (as perIEC 60332-3-10) the length of cable with FRC damaged by flame or carbonized does notexceed 1.5 m, measured according to IEC 60332-3-22. Material used for passive fire protection systems shall not have any corrosive effect onmetal structures and cables. Materials used for passive fire protection systems shall not contain organic (withexplosive-fire-hazard vapors) solvents as their base. Materials used for passive fire protection systems shall be non-toxic. Materials used for passive fire protection systems shall comply with sanitaryepidemic regulations in force at the NPP and in case of possible radiation and heat flows shall notgenerate harmful or toxic gases. Fire resistant coating shall be capable to be applied on cable surface, on mineral woolboard and on the surface of cable metal structures, both painted and non-painted. Fire resistant coating shall be capable to be applied on cable surface both in horizontal and vertical position. Materials used for passive fire protection systems shall not peel from the surface in anyNPP operation mode. The following indicate fire safety class: HF - Halogen-free; FR - Fire-resistant; LS - With low smoke and gas emissions; FRHF - Fire-resistant, halogen-free;

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FRLS - Fire-resistant with low smoke and gas emissions. 11.7.

Cable Interface For cable interface, refer Cabling Interface diagram (BGR Doc. No. GID/379/EL/YYY/GN/3011) for scope of cables and cable carrier system in switchyard & E-BoP package.

12. REFERENCES The subject DBR has been prepared based on the following:                  

Technical requirement for Cable System and Cabling Guidelines for KKNPP - 3&4 (Doc.No.I02.KK34.0.0.ET.TT.PR.001) Technical specification for MV Power cables for KKNPP – 3&4 (Doc. No. I02.KK34.0.0.ET.TS.PR.010) Technical specification for LV Power cables for KKNPP – 3&4 (Doc. No. I02.KK34.0.0.ET.TS.PR.011 and 012) Technical specification for Control cables for KKNPP – 3&4 (Doc. No. I02.KK34.0.0.ET.TS.PR.013 and 014) Technical specification for 245kV Cables for KKNPP – 3&4 (Doc. No. I05.KK34.0.0.ET.TS.PR002) Technical specification for Optical Ground Wire(OPGW)/Fiber Optic Cable(FOC) (Doc. No.I05.KK34.0.0.ET.TS.PR003) Technical Specification for Cable Carrier System Elements for KKNPP – 3&4 (Doc. No. I02.KK34.0.0.ET.TS.PR.009) Concept note on electrical power supply system (GID/379/EL/YYY/BS/3002) Key single line diagram (GID/379/EL/ADA/XJ/3035) DBR for General Electrical Systems and Equipment (GID/379/EL/YYY/BS/3004) DBR for SCADA and Protection System (GID/379/EL/YYY/BS/3083) DBR for Fire Fighting System (GID/379/ME/SGA/BS/1002) DBR for Ventilation System (GID/379/ME/SA/BS/1125) 400kV switchyard layout plan (I02.KK34.0.UAB.ET.0KS.WD001) 230kV switchyard layout plan (I02.KK34.0.UAD.ET.0KS.WD002) Refer “Annexure-1” for the proposed tentative sketch of 230kV tie line interconnection between KKNPP-1&2 and KKNPP-3&4. Refer “Overall Electrical Bus duct& Cable layout – Balance of plant for KKNPP-3&4 (EIL Drg. No.A209-000-16-50-0015 Refer “Annexure-2” for the proposed tentative sketch of 400kV layout plan-option 1

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Refer “Annexure-3” for the proposed tentative sketch of 400kV layout plan-option 2 Refer “Annexure-4” for the proposed tentative sketch of 230kV layout plan-option 1 Refer “Annexure-5” for the proposed tentative sketch of 230kV layout plan-option 2

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