Auxiliary Cables and Wiring System

Document Reference: XDS-GFS-11-001-R2

Functional Specification
Auxiliary Cables and Wiring System
Revision History
Revision Date Description Originator Approver
First Issue – This document supersedes
R0 31/08/2011 XDS-WTS-11-001-R1. Section 2 Paul Moran Christy Kelleher
updated.
Minor revision to sections 5 and 14,
R1 29/05/2014 Sandra Howard Paul Moran
colour coded table added
Minor updates to sections 13 and 14
R2 30/04/2019 Philip Kennedy Conor Farrell
regarding wiring colour

COPYRIGHT © EirGrid
All rights reserved. No part of this work may be modified or
reproduced or copied in any form or by means - graphic,
electronic or mechanical, including photocopying,
recording, taping or information and retrieval system, or
used for any purpose other than its designated purpose,
without the written permission of EirGrid

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 Auxiliary Cables and Wiring System

1 SCOPE 3
2 STANDARDS 3
3 ENVIRONMENTAL CONDITIONS 4
4 SAMPLES 4
5 GENERAL 4
6 MATERIALS 5
7 ROUTING AND ARRANGEMENT 5
8 LAYING OF CABLES 6
9 CORROSION ACTION 6
10 SUPPORTS 7
11 JOINTING 7
12 SIZES 7
13 PVC COLOUR 7
14 CORE IDENTIFICATION 8
15 CABLE MARKING 8
16 LAYING UP AND COMMON CORE COVERING 8
17 SCREENING (APPLICABLE TO SCREENED CABLES) 9
18 FIRE RETARDATION 9
19 TESTS AND INSPECTION 9
20 PACKING AND LABELLING 9
21 GUARANTEES 10
22 INFORMATION TO BE INCLUDED WITH INITIAL SUBMISSION 10
22.1 THE FOLLOWING SHALL BE SUBMITTED AS PART OF THE TENDER: 10
22.2 DRAWINGS TO BE SUBMITTED WITH INITIAL SUBMISSION 10
22.3 TO BE SUBMITTED BEFORE STATION HANDOVER 10

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 Auxiliary Cables and Wiring System

1 SCOPE
This Specification covers the supply, testing and delivery of L.V. multicore control
cables with copper conductors, PVC insulation, copper screen (where applicable)
and PVC sheathing.

2 STANDARDS
The cable supplied under this specification shall conform to and be tested in
accordance with this specification and with the latest editions of the following
standards:

IS 201:2001 Polyvinyl Chloride (PVC) insulated cable and flexible

cords of rated voltage up to and including 450/750V.

IEC 60189 Low frequency cables and wires with p.v.c. insulation
and p.v.c. sheath.

IEC 60227 Polyvinyl chloride insulated cables of rated voltages

up to and including 450/750V.

IEC 60502 Extruded solid dielectric insulated power cables for

rated voltages from 1kV up to 30kV.

IEC 60811 Common test methods for insulating and sheathing

materials of electric cables.

IEC 60228 Nominal cross-sectional areas and composition of

conductors of insulated cables.

IEC 60331 Fire-resisting characteristics of electric cables.

IEC 60332 Tests on electric cables under fire conditions.

IEC 60885 Electrical test methods for electrical cables.

BS 6234 Specification for polyethylene insulation and sheath

of electrical cables.

Where a particular subject is not covered by one of the above standards then a
recognised national standard shall apply.

In case of conflict between this specification and any of the listed standards, this
specification shall take precedence.

In addition, there shall be compliance with the provisions of all relevant Directives of
the European Union relating to work equipment, i.e. in regard to safety of personnel
who operate and maintain equipment. In order to prove compliance, the equipment
shall carry the CE Mark in accordance with Direction 93/465/EEC.

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3 ENVIRONMENTAL CONDITIONS
1 The cables shall be suitable for indoor and outdoor use, and may be buried in
the ground, laid in ducts and/or submerged in water.

2 The cable shall be suitable for indoor and outdoor operation at a height of 0-
1000 metres above sea level in salt-laden, damp, polluted atmosphere with
heavy rain. The cable shall be capable of operating normally within the following
temperature range:

Maximum Air Temperature: +40 °C (Degrees Celsius).

Minimum Air Temperature: -25 °C (Degrees Celsius).

3 The cable shall be capable of operating in electrically exposed locations also

where high humidity (65% to 100% relative humidity) and dew point are
commonplace.

4 SAMPLES
The Customer may be asked to supply a short (five metre) sample of any of the
cables offered.

Where a new supplier is involved, this is an essential requirement.

5 GENERAL
The cables supplied under this Specification are intended for connection to
Instrument Transformers, Measuring Instruments, Control and Relaying Equipment.

Working Voltage A.C. 110V, 230V, 400V.

Working Voltage D.C. 24V, 48V, 110V, 220V.

Voltage Class Uo/U 0.6/1kV.

Cable types include screened mulitcore and screened/unscreened multiple twisted

pair cables.

Screened multicore cables shall be used for all outdoor circuits and for all circuits
involving voltages greater than 50V. Multiple twisted pair cables must be used for all
control, status and alarm connections to EirGrid SCADA equipment within the
control building. It may also be used for 24V or 48V applications totally within the
control room. The use of unscreened cable for any particular application is subject
to EirGrid approval.

Conductor cross-section shall be rated for the relevant current-carrying capacity

duty. The Customer shall ensure that the cross-section of the wiring is adequate for
the operating current and voltage conditions.

The screens of screened cables shall be connected to the earth grid at both ends of
the cable by the shortest practical connection.

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Each multi-core/multi-pair cable shall be used for one type of duty for example, a
cable used for connections to instrument transformers shall not include connections
to switchgear operation.

Instrument transformer secondaries shall be segregated i.e. shall use dedicated

cables.

Each multi-core/multi-pair cable shall be used for one battery voltage only, batt1 and
batt2 cables shall be segregated.

Cable use shall also be on a switchgear bay basis where possible. This requirement
shall be reflected right through the station including control rooms.

Cables and wires for any particular circuit shall have a dielectric test level at least
matching the minimum level of the equipment to which it is connected and rated
duty at least equal to that of the equipment to which it is connected.

Wires and cable cores of circuits with different voltage ratings shall be segregated
unless they are rated for the higher voltage rating.

AC and DC circuits shall not be carried on the same cable. Cables shall be fitted
with numbered permanent identification tags at termination points. Suitable glands
shall be used to connect cables to mechanism boxes, cabinets etc.

Typically, 25mm2 or 35mm2 PVC double insulated single core cables are used for
the connection from battery to battery charger. As above, conductor cross-section
shall be rated for the relevant current-carrying capacity duty.

6 MATERIALS
The conductor shall be un-tinned copper complying with IEC 60228. The insulation
and sheath shall consist of a thermoplastic material based on PVC complying with
the requirements of IEC 60502, IEC 60811 and IEC 60885.

7 ROUTING AND ARRANGEMENT

Cable routes shall be chosen so as to minimise the pick-up of induced voltages
liable to cause damage or interference.

Routing and arrangement of cables shall be approved by EirGrid and shall be

planned to provide an orderly formation, free from unnecessary bends and
crossings, which will permit the removal of any one cable without undue disturbance
to adjacent cables.

Cables shall be installed so that no temporary or permanent bends are made which
are sharper than those recommended by the manufacture and confirmed as
acceptable by tests. There shall be no joints in cables laid entirely within the
substation.

Where cables entering the control building or pass from room to room within a
building, fire retardant barriers shall be provided.

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8 LAYING OF CABLES
Cables shall not be laid directly in the ground but, in the main, shall be laid in
reinforced concrete troughs with removable covers, this type of trough shall be used
for cables exiting the building and running between it and each bay.

The type and method of removing the covers shall be agreed with EirGrid.

In addition to the main artery troughs, pipe ducting shall be used from the cable
trough to each item of plant within each bay.

Cable ducts to HV plant shall be directly encased in the concrete Plinth for each
item of Plant. On exiting, the duct shall be suitably located within the concrete Plinth
so as to minimise the length of exposed cable to the equipment. The Customer shall
ensure that the cable is appropriately supported by means of metal cable tray along
its exposed length to ensure secure support and to prevent damage.

The pipe ducts shall be buried at a minimum depth of 600mm.

Where cables are run across roads or enter buildings the cables shall be run in
concrete encased pipes.

All pipe ducts shall be brushed clean immediately prior to installation of cables. The
Customer shall deal with and dispose of water and other extraneous materials so as
to avoid risk of damage to cables.

The pulling arrangements for cable installation shall be subject to EirGrid approval.

The cable shall where necessary, be lubricated to facilitate drawing in. The lubricant
used shall have no deleterious effect on the cables or other surrounds. At the point
of cable entry into the pipe or duct, a bell mouth of suitable soft material shall be
provided to prevent damage to the cable during installation.

Suitable barriers shall be provided where control cables enter the control building to
prevent ingress of vermin and water. The type of barrier shall be approved in
advance by EirGrid. Indoor cables shall be run under false floors or in ducts in the
floors, the ducts shall have removable covers.

Indoor cables, which are run above floor, shall be supported by suitable metal trays
or racks. Protective covers shall be placed over trays etc. where the cables may be
exposed to damage from falling material or moving equipment.

Where cables enter a building, or pass from room to room within a building fire
retardant barriers shall be provided.

9 CORROSION ACTION
Every precaution shall be taken to ensure that cables and accessories are not
installed in a manner or under conditions likely to cause electrolytic or other
corrosive action or damage to, or be detrimental to the performance of the cables
during operation.

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10 SUPPORTS
The Customer shall supply and install all the supports, racks, trays, cleats, saddles,
clips and other parts required to carry and secure the cleats without risk of damage,
in a neat and orderly manner. The spacing of all supports, racks, cleats, saddles
and clips shall be subject to EirGrid approval.

Support structures for cables shall be free from rough edges and sharp corners. If
such support structures are of mild steel they shall be Hot-dip galvanised.

Cable connections to kiosks, boxes, cabinets etc. shall be at least 300mm over
ground. Vertical portions of cable runs shall be supported by clamps, saddles on
ladder racking or in conduit or trunking. All cables shall be securely supported at a
point not more than 1.0m from their terminations.

11 JOINTING
Jointing of the conductors shall only be acceptable where the electrical and
mechanical characteristic of the joint matches those of the conductors (e.g. fusion
process). Spliced soldered joints are not acceptable.

12 SIZES
The cable sizes shall be as follows

 4 x 1.5mm²

 7 x 1.5 mm²

 12 x 1.5 mm²

 19 x 1.5mm²

 4 x 2.5mm²

 4 x 10mm²

 4 x 6mm²

 4 x 4mm².

Any cables with core size of 1.5mm² shall be single stranded; those cables with core
size greater than 1.5mm², i.e. 10mm², 6mm² and 4mm² shall have between 4 and 7
strands.

13 PVC COLOUR
The core insulation for multi-core cable shall be black. The sheath colour shall be
black.

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14 CORE IDENTIFICATION
Core identification shall be by numbers. The numbering, which shall be both in
figures and words, shall be printed clearly and permanently on the insulation of each
core at intervals of not more than 50mm. The figures and lettering shall not rub off
under conditions of normal handling.

The preference is to use the bay number in the cable identifier.

Figures should be a minimum of 3mm high and the colour preference is white on
black insulation. Cores shall be numbered as follows:

 4 Core cable - Nos. 1, 2, 3 and 4.

 7 Core cable - Centre core, No. 1. 6 cores around centre, Nos. 2 to 7.

 12 Core cable - Centre 3 cores, Nos. 1, 2 and 3. 9 cores around centre, Nos. 4
to 12.

 19 Core cable - Centre core, No. 1.6 cores around centre, Nos. 2 to 7. 12 outer
cores, No. 8 to 19

Core Identification for multiple twisted pair cable may be carried out by means of a
recognised colour coding system as referenced in EN 60446.

15 CABLE MARKING
The cable sheath shall be clearly embossed with raised lettering of height not less
than 20% of the overall diameter of the cable. Embossing shall be at intervals of not
more than one metre with the following data:

Electric Cable, 600/1000 Volts, ESB Specification No. 16118 Rev3 size designation
e.g. NYCY (NYCWY) 4 x 6mm², manufacturers name (or trade mark), year of
manufacture.

In addition, the cable outer sheath shall be sequentially marked in metres so that
when a length of cable is removed from the drum/coil, the remaining length can be
easily determined.

Each cable shall be marked from zero up to the specified drum/coil length

16 LAYING UP AND COMMON CORE COVERING

A layer of thermoplastic material shall be extruded over the laid up cores and under
the sheath. The filler shall be resilient, homogeneous, preferably of a different colour
to sheath and core insulation, and must not adhere to the core. Alternatively, a
rubber-based material or a wrapping of fabric or plastic tapes may be substituted for
the extruded common covering.

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17 SCREENING (APPLICABLE TO SCREENED CABLES)

The cables shall have a copper screen over the common core covering. The cable
screen in all cases shall consist of two layers, an inner layer of plain annealed
copper wires and an outer layer of copper tape laid on helically with an overlap of
20%. The cross-sectional area of the inner layer of the screen (plain annealed
copper wires) shall be as follows:
No. of Cores Screen Cross-Sectional Area
Under 12 equivalent to core cross-section
12 and under 19 not less than 2.5mm²
19 and over not less than 4mm²

18 FIRE RETARDATION
In addition to the requirements of the individual IEC Publications for each cable type
with regard to fire retardation, all cables shall satisfy the requirements of IEC 60331
and IEC 60332.

19 TESTS AND INSPECTION

All type tests and routine tests on each type and size of cable shall be carried out in
the factory in accordance with Clause No. 2 of this Specification.

Before dispatch each drum of cable shall be routine tested in accordance with IEC
Publications. EirGrid may choose random sample lengths of any or each size/type
of cable and instruct the supplier to carry out a full series of type tests on these
samples. In the event of failure in any test, the Supplier will be instructed to repeat
the tests on another random sample, if the second sample fails in any test the
complete consignment of cable will be rejected by the EirGrid.

The Customer shall in all cases send to the EirGrid Client Engineer for their
approval three copies of the routine test certificates, covering each drum of cable
offered for acceptance. No cable shall be dispatched from the Works until the
purchaser has approved the test certificates.

Details of the proposed routine testing shall be included with the tender. Before
carrying out routine tests on any consignment of cable, the Customer must give two
weeks advance notice to EirGrid for inspection and to witness tests being carried
out.

20 PACKING AND LABELLING

Cable drums and the outer transport covering shall be of adequate strength to
protect the cable from damage during transport. The surface and rims of the drums
shall be smooth and free of any protruding edges to prevent damage to the cable.
The ends shall be sealed securely against the ingress of moisture.

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21 GUARANTEES
The Customer shall guarantee the cable against all defects arising from faulty
design or workmanship or defective material for a period of 18 months from the date
of commissioning. The Purchaser's certificate of date of commissioning shall be
accepted.

22 INFORMATION TO BE INCLUDED WITH INITIAL SUBMISSION

22.1 THE FOLLOWING SHALL BE SUBMITTED AS PART OF THE TENDER:

1 Fully completed copy of the technical schedule.

2 Detailed dimensional drawing of cable.

3 Details including Certificate of Type Tests carried out on cable.

4 Details of all routine testing carried out on cable.

5 "Schedule of Deviations from Specification". Information in specific terms of any

parameter(s) specified herein, which the scheme offered does not meet, quoting
the relevant clause number(s) of this specification.

6 Details of manufacturer's Quality Assurance Policy/Programme/ Certification

shall be submitted.

22.2 DRAWINGS TO BE SUBMITTED WITH INITIAL SUBMISSION

The following shall be submitted to EirGrid in accordance with the agreed

programme

1 Layout and detail drawing of cable trays.

2 Drawings showing details of cable terminations including supports, terminals,

glands, earthing screened cables etc.

3 Complete cable schedule giving cable type, size, locations and labelling system

4 A cable routing layout/elevation drawings showing all cable runs showing

numbers of cables on cables trays etc.

22.3 TO BE SUBMITTED BEFORE STATION HANDOVER

Before the substation is handed over to EirGrid, the Customer shall submit drawings
and information giving details of the following

1 Final records of routes

2 Details of terminations

3 Records of all Testing carried out

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