CLIENT:

Iranian Gas Engineering & Development Co.

PROJECT TITLE:
Nasrabad - e – Kashan
Underground Gas Storage Development Project Phase I
(Exploration)
PROJECT PHASE:

Project Task 5:
Master Development Plan (MDP), Front End Engineering & Design
(FEED), Preparation of Tender Documents for Project Phase II
(Execution)
PLANT:

Nasrabad -e- Kashan

MLE AST IMA
01 14.12.2021 ISSUED FOR CLIENT REVIEW
14.12.2021 14.12.2021 14.12.2021
ISSUED BY CHECKED BY APPROVED BY
REV. DATE REV. STATUS AND DESCRIPTION
CONTR. / DATE CONTR. / DATE CONTR. / DATE
GENENRAL CONTRACTOR:

DANA Geophysics Co.

SUBCONTRACTOR:

Henjes Metall- und Anlagenbau GmbH

DOCUMENT ISSUED BY:

PSE Engineering GmbH

DOCUMENT PHASE:

WBS Item 5.2.3 FEED AGF Set 6

DOCUMENT TITLE:

Specification LV Cables
DOCUMENT NUMBER:
page
NAS-ELC-GEN-SPC-001-00 1 of 15
 Specification LV Cables NAS-ELC-GEN-SPC-001-00
Iranian Gas Engineering & Development Co. DOC status: ISSUED FOR CLIENT REVIEW
Nasrabad - e – Kashan
Underground Gas Storage Development Project date: 14.12.2021
Phase I (Exploration)

revision change history

issued checked approved

rev. date Rev. status and description
by by by

01 14.12.2021 ISSUED FOR CLIENT REVEW MLE AST IMA

project related documents

description document no.

The latest edition of the above mentioned documents is valid. They are available from the DCC
of the CONTRACTOR.

appendix
description document no.

The attached edition of the above mentioned documents is valid. The revision status will not
be updated.
Specification LV Cables NAS-ELC-GEN-SPC-001-00
Iranian Gas Engineering & Development Co. DOC status: ISSUED FOR CLIENT REVIEW
Nasrabad - e – Kashan
Underground Gas Storage Development Project date: 14.12.2021
Phase I (Exploration)

TABLE OF CONTENTS

1 INTRODUCTION ................................................................................................ 5
1.1 General introduction .............................................................................................. 5
1.2 Purpose and scope of the document ................................................................... 5
1.3 Definitions and abbreviations ............................................................................... 5
1.4 Applicable Codes and standards .......................................................................... 6
1.5 Unit of measure ...................................................................................................... 7

2 SCOPE OF SUPPLY .......................................................................................... 7

3 DESIGN REQUIREMENTS ................................................................................ 7
3.1 Cable Cross Section .............................................................................................. 8

4 CABLES CONTRUCTION .................................................................................. 8

4.1 Conductors ............................................................................................................. 8
4.2 Insulation ................................................................................................................ 8
4.3 Fillers and Binders ................................................................................................. 8
4.4 Metallic Sheath ....................................................................................................... 9
4.5 Bedding ................................................................................................................... 9
4.6 Armour .................................................................................................................... 9
4.7 Over Sheath ............................................................................................................ 9

5 CONTROL CABLES CONSTRUCTION ............................................................. 9

5.1 Conductors ........................................................................................................... 10
5.2 Insulation .............................................................................................................. 10
5.3 Binder Tape ........................................................................................................... 10
5.4 Metallic Sheath ..................................................................................................... 10
5.5 Bedding ................................................................................................................. 10
5.6 Armour .................................................................................................................. 10
5.7 Over Sheath .......................................................................................................... 10
5.8 Core Identification ................................................................................................ 11

6 FLEXIBLE CABLES AND WIRES ................................................................... 11

6.1 Conductors ........................................................................................................... 11
6.2 Insulation .............................................................................................................. 11
6.3 Binder Tape ........................................................................................................... 11
6.4 Armour .................................................................................................................. 11
6.5 Over Sheath .......................................................................................................... 12
Specification LV Cables NAS-ELC-GEN-SPC-001-00
Iranian Gas Engineering & Development Co. DOC status: ISSUED FOR CLIENT REVIEW
Nasrabad - e – Kashan
Underground Gas Storage Development Project date: 14.12.2021
Phase I (Exploration)

6.6 Earthing Cables .................................................................................................... 12

7 VARIABLE SPEED DRIVE CABLE SCREENS ............................................... 12

8 CABLES INSTALLATION ................................................................................ 12
9 CABLE TEST AND INSPECTION .................................................................... 14
10 SHIPPING ......................................................................................................... 14
11 GUARANTEE ................................................................................................... 15
 Specification LV Cables NAS-ELC-GEN-SPC-001-00
Iranian Gas Engineering & Development Co. DOC status: ISSUED FOR CLIENT REVIEW
Nasrabad - e – Kashan
Underground Gas Storage Development Project date: 14.12.2021
Phase I (Exploration)

1 INTRODUCTION

1.1 General introduction

In early 2013 Client has contracted DANA Geophysics Co. in the role as General Contractor
in cooperation with its Sub-Contractor Henjes Metall- und Anlagenbau to perform the Nasrabad
-e- Kashan Underground Gas Storage Development Project Phase I (Exploration consisting of
five main Tasks, namely:
1. Geological Studies and Reports
2. Geological and Geophysical Field Works
3. Drilling of 1 Exploration Well incl. sampling of bore hole cores
4. Geomechanical/Geochemical Laboratory Investigations and Final Feasibility Study
5. Preparation of Master Development Plan (MDP), Front End Engineering & Design
(FEED), Tender Documents for Project Phase II (Execution)

1.2 Purpose and scope of the document

This specification covers the minimum requirements of design, manufacture, testing, packing
and supply of LV cables and wires suitable for the FEED of Nasrabad Underground Storage
of gas in caverns and covers Phase 5 of the contract. The relevant currently valid directives,
laws and standards must be observed.
Some of the data are preliminary due to unfinished process investigations, cavern data,
number of caverns and unknown government permissions. These data shall be implemented
from the EPC contractor in a later stage of the project.
It shall be understood that this document shall apply for the leaching station, gas plant and
related facilities.

1.3 Definitions and abbreviations

CLIENT: Iranian Gas Engineering & Development Co.

PMC: Client’s Project Management Consultant
GENERAL CONTRACTOR: DANA Geophysics Co.
SUB-CONTRACTOR: Henjes Metall- und Anlagenbau GmbH
issuer of the FEED
PROJECT: Nasrabad -e- Kashan UGS Development Project
EPC CONTRACTOR: Contractor for Engineering, Procurement and Construction
in Project Phase II (Execution) t.b.d.
SUPPLIER: The supplier of equipment / package / services etc.
 Specification LV Cables NAS-ELC-GEN-SPC-001-00
Iranian Gas Engineering & Development Co. DOC status: ISSUED FOR CLIENT REVIEW
Nasrabad - e – Kashan
Underground Gas Storage Development Project date: 14.12.2021
Phase I (Exploration)

ANSI American National Standards Institute

ASME American Society of Mechanical Engineers
ATEX Explosive Atmospheres
FEED Front End Engineering & Design
IPS Iranian Petroleum Standards
ISO International Organization for Standardization
LV Low Voltage
SI Système Internationale
SOW Scope Of Work
UGS Underground Gas Storage

1.4 Applicable Codes and standards

As a minimum, the LV Electrical Power Cables shall be designed, manufactured, tested and
delivered in accordance with the relevant sections of the latest editions of the international
codes and standards. Codes and Standards used for this project shall be the latest revisions
including all addenda available at the time of purchase order placement.
The list of standards below is not intended to be complete, but does indicate the main
standards which shall be complied with.

Document Number Description

IEC 60028 International Standard of Resistance for Copper

IPS-M-EL-271 Low Voltage Cables and Wires

IEC 60038 Standard Voltages

IEC 60173 Colours of the cores of flexible cables and cords

Polyvinyl Chloride Insulated Cables of Rated Voltages up to and

IEC 60227
Including 450/750 V

IEC 60228 Conductors of Insulated Cables

IEC 60245 Rubber insulated cables of rated voltage up to 450/750 V

IEC 60287 All parts Electric Cables - Calculation of the Current Rating

Tests for Electric Cables Under Fire Conditions –Circuit Integrity-

IEC 60331 Part 11 Part 11: Apparatus – Fire alone at a flame temperature of at least
750°C
 Specification LV Cables NAS-ELC-GEN-SPC-001-00
Iranian Gas Engineering & Development Co. DOC status: ISSUED FOR CLIENT REVIEW
Nasrabad - e – Kashan
Underground Gas Storage Development Project date: 14.12.2021
Phase I (Exploration)

Document Number Description

Tests for Electric Cables Under Fire Conditions - Circuit Integrity

IEC 60331 Part 21 - Part 21: Procedures and requirements - Cables of rated voltage
up to and including 0.6 / 1.0kV

IEC 60332 Part 3 Tests on Electric Cables under Fire Conditions

IEC 60502 All parts Power Cables with Extruded Insulation

IEC 60702 Mineral insulated cables and their-rated voltage 500 V to 750 V

Common test methods for insulating and sheathing materials of

IEC 60811
electric cables

Calculation of Thermally Permissible Short-Circuit Currents,

IEC 60949
Taking into Account Non-Adiabatic Heating Effects

Any deviation from this specification and the above mentioned references shall be clearly
mentioned in the vendor’s proposal. National legislation and national technical regulations shall
take precedence as appropriate.
Acceptable Standards for surface facilities shall be IGS (Iranian Gas Standards) and IPS
(Iranian Petroleum standards). In some cases, European and/or American standards might be
used in addition to the Iranian Standards.

1.5 Unit of measure

Units shall be in accordance with the ‘System International’ (SI, ISO 80000-1) form of units
unless otherwise stated.

2 SCOPE OF SUPPLY
The scope of work shall include, but not be limited to, the following:
 The detail design, manufacture, supply and installation of Electrical LV cables and wires;
 The factory testing of all cables. This includes the provision of appropriate test
certification and report to be included in the Data Book;
 Preparation for transport and shipping. All items shall be securely packed and fully
protected against damage.

3 DESIGN REQUIREMENTS
LV cables are cables with voltage <1000V.
The low voltage levels used in Iranian Petroleum Industry is:
 400V for 3 phase systems;
 230V for single phase systems;
 Specification LV Cables NAS-ELC-GEN-SPC-001-00
Iranian Gas Engineering & Development Co. DOC status: ISSUED FOR CLIENT REVIEW
Nasrabad - e – Kashan
Underground Gas Storage Development Project date: 14.12.2021
Phase I (Exploration)

 110V for instrumentation and control.

Neutral for low voltage system is solidly earthed.
The voltage at incoming terminal shall not deviate more than ±5% and the system frequency
shall not deviate from the rated frequency more than ±2%. the total harmonic distortion shall
not be more than 8% and each harmonic distortion shall not be more than 5%. Health safety
and environment
Conductors of cables shall not have joints and shall be fully continuous.

3.1 Cable Cross Section

For 3 phase, 4 wire circuits, multicore cables the neutral conductor shall not be smaller than
50% of the size of the phase conductors. Reduced sizing of neutral conductors should not be
applied where there is likely to be serious load imbalance, significant harmonic distortion in
normal service or in any circuit where the load is predominately discharge lighting.
The maximum cross section area is:
 3x240mm² for three core LV cables;
 1x400mm² for single core LV cables;
Cables shall be replaced by bus-duct if the section is higher than 240mm² or shall be divided.
The minimum cross section area for control cables and low voltage power cables shall be
2.5mm² while for signaling cables 1.5mm² cables can be used.
When the present specification is used in an EPC contract, the contractor shall size the cables
considering all the external influences that affects the cables current carrying capacity.

4 CABLES CONTRUCTION
The low voltage cables shall be copper conductor with PVC insulation 600/1000 V grade, lead
sheathed, single wire armoured, with PVC overall jacket. Lead sheath may be eliminated for
some applications only with Company approval.

4.1 Conductors
Conductors shall be Class 2 high conductivity, concentric stranded plain copper manufactured
from fully annealed, circular, non-compacted plain copper wires free from slivers, splinters,
scales or other imperfections. All conductors shall comply with IEC 60228.
Conductor sizes up to and including 10mm² can be solid copper.

4.2 Insulation
PVC insulation will be used (XLPE can be quoted as alternative and needs Client approval).

4.3 Fillers and Binders

When fillers are needed, polypropylene or jute string shall be used.
 Specification LV Cables NAS-ELC-GEN-SPC-001-00
Iranian Gas Engineering & Development Co. DOC status: ISSUED FOR CLIENT REVIEW
Nasrabad - e – Kashan
Underground Gas Storage Development Project date: 14.12.2021
Phase I (Exploration)

Cable fillers and binders shall be solid, non-hygroscopic type and fill the cross section such
that the transmission of gas and hydrocarbons along the length of the cable, under normal
pressure, is not possible (part of the cables will be installed within classified hazardous areas).

4.4 Metallic Sheath

The metallic sheath shall consist of lead or lead alloy and shall be applied as a reasonably
tight fitting seamless tube. The nominal thickness of lead sheath shall be calculated by the
formulas recommended in IEC 60502-1 and shall in no case be less than 1.2 mm.
With Client approval, lead sheath may be eliminated for cables which will be installed on trays
or will be buried in places where the presence of hydrocarbon is not foreseen.

4.5 Bedding
The bedding or inner covering shall be extruded or lapped layers of PVC or synthetic tapes of
manufacturer standard, with the approximate thickness as specified in IEC 60502-1.

4.6 Armour
The armour shall be galvanized round steel wire supplemented by a helix of galvanized steel
tape to keep the armour wires tight. Only with Company approval galvanized steel tape may
be eliminated. Flat wire armour is not desirable, however it could be considered upon the
approval of company representative. The minimum dimensions of the armour wires shall be in
accordance with the requirements of IEC 60502-1. The thickness of the galvanized steel tape
shall be 0.3 mm. For single core power cables the armour shall be made of non-magnetic
materials.

4.7 Over Sheath

The outer sheath over the armour shall be extruded black PVC complying with the
requirements of IEC 60502-1. To protect the cables against rodent and termite attack, suitable
chemicals shall be added to PVC over sheath.

For cables to be installed on trays, the over sheath shall be flame retardant to reduce the risk
of fire spread. Flame retardant properties shall be within the limits of tests to standard IEC
60332, part 3, Category C.
Type test certificates shall be provided to confirm compliance with the above requirement.
These certificates shall be provided at the time of quotation.

5 CONTROL CABLES CONSTRUCTION

Twin and multicore lighting and control cables shall be copper conductor with PVC insulation
600/1000 V grade, lead sheathed, single wire armoured, with PVC overall jacket. These cables
shall be used for above ground and underground installations.
 Specification LV Cables NAS-ELC-GEN-SPC-001-00
Iranian Gas Engineering & Development Co. DOC status: ISSUED FOR CLIENT REVIEW
Nasrabad - e – Kashan
Underground Gas Storage Development Project date: 14.12.2021
Phase I (Exploration)

5.1 Conductors
Conductors for control cables shall be plain annealed solid or stranded copper. Conductor
sizes shall be 2.5 mm2 as minimum. Conductors shall be in compliance with class 2 of IEC
60228. Conductors in the same cable shall be all of the same size.

5.2 Insulation
Insulation shall consist of an extruded layer of PVC with rated voltage of not less than 600 volt.

5.3 Binder Tape

Control cable cores shall be lapped with suitable binder tapes as per manufacturer’s standard.

5.4 Metallic Sheath

The metallic sheath shall consist of lead or lead alloy and shall be applied as a reasonably
tight fitting seamless tube. The nominal thickness of lead sheath shall be calculated by the
formulas recommended in IEC 60502-1 and shall in no case be less than 1.2 mm.
With Client approval, lead sheath may be eliminated for cables which will be installed on trays
or will be buried in places where the presence of hydrocarbon is not foreseen.

5.5 Bedding
The bedding or inner covering shall be extruded or lapped layers of PVC or synthetic tapes of
manufacturer standard, with the approximate thickness as specified in IEC 60502-1.

5.6 Armour
The armour shall be galvanized round steel wire supplemented by a helix of galvanized steel
tape to keep the armour wires tight. Only with Company approval galvanized steel tape may
be eliminated. Flat wire armour is not desirable, however it could be considered upon the
approval of company representative. The minimum dimensions of the armour wires shall be in
accordance with the requirements of IEC 60502-1. The thickness of the galvanized steel tape
shall be 0.3 mm. For cables to be installed on trays, galvanized steel wire braid armour is
acceptable.

5.7 Over Sheath

The outer sheath over the armour shall be extruded black PVC complying with the
requirements of IEC 60502-1. To protect the cables against rodent and termite attack, suitable
chemicals shall be added to PVC over sheath.

For cables to be installed on trays, the over sheath shall be flame retardant to reduce the risk
of fire spread. Flame retardant properties shall be within the limits of tests to standard IEC
60332, part 3, Category C.
Type test certificates shall be provided to confirm compliance with the above requirement.
These certificates shall be provided at the time of quotation.
 Specification LV Cables NAS-ELC-GEN-SPC-001-00
Iranian Gas Engineering & Development Co. DOC status: ISSUED FOR CLIENT REVIEW
Nasrabad - e – Kashan
Underground Gas Storage Development Project date: 14.12.2021
Phase I (Exploration)

5.8 Core Identification

The preferred colour sheath for cables is:
 Black for LV cables;
 Orange for Fire resisting cables;
 Yellow and green stripes for earthing cables.
The control cables identification shall be achieved by numbering the cores. The numbering of
the cores shall start from number one for the wire in center.
The insulation of the cores shall be of the same color and numbered sequentially. There shall
be a clear contrast between color of cores and color of numbers. Color of cores shall be black
and color of numbers shall be white.
The height of individual numbers shall not be less than 1.5 mm, and the interval between
adjacent numbers shall not be more than 100 mm.

6 FLEXIBLE CABLES AND WIRES

Where the electrical equipment is exposed to high level of vibrations, its supply is achieved by
means of flexible cables or wires complying with the requirements of IEC 60227-2.

6.1 Conductors
The conductors for flexible cables or wires shall be plain annealed stranded copper in
compliance with class 5 of IEC 60228.

6.2 Insulation
The insulation shall consist of an extruded layer of PVC or EPR. The PVC for this purpose
shall be type PVC/D as defined in IEC 60227-3 and 4. The insulation thickness shall be
according to the recommendations of IEC 60502-1.

6.3 Binder Tape

Flexible cable cores shall be lapped with suitable binder tapes as per manufacturer’s standard.

6.4 Armour

The armour for flexible cables, where indicated in data sheet shall be galvanized steel wire
braid.

The diameter of wires in wire braiding shall be in accordance with relevant IEC
recommendations and not less than the following:
Diameter under armour Wire diameter
<10mm 0.2mm
10 to 30mm 0.3mm
 Specification LV Cables NAS-ELC-GEN-SPC-001-00
Iranian Gas Engineering & Development Co. DOC status: ISSUED FOR CLIENT REVIEW
Nasrabad - e – Kashan
Underground Gas Storage Development Project date: 14.12.2021
Phase I (Exploration)

30 to 70mm 0.4mm
>70mm 0.5mm

The armoring of single core flexible cables shall be made of nonmagnetic material.

6.5 Over Sheath

The over sheath of flexible cables and wires shall be PVC compound of the type PVC/ST5 as
specified In IEC 60227-4.

6.6 Earthing Cables

Earthing cables and wires shall be single core with plain stranded or solid copper conductor,
PVC sheathed rated voltage of 600 V, coloured green - yellow for both underground and above
ground use. The PVC sheath is a protection against electrolytic corrosion. No armouring is
required for earthing cables.

7 VARIABLE SPEED DRIVE CABLE SCREENS

Cables designated for variable speed drive duty shall have a copper tape screen providing
100% coverage to shield against the effects of electromagnetic and radio frequency
interference and complying with the requirements of IEC 61000.
The copper screen shall encompass all phase conductors and shall be located on the inside
of any cable armour protection.
These cables shall be provided with the following additional features:
 be electrically symmetrical to reduce RF emissions, including three symmetrically
located earth conductors
 provide low loss insulation and low capacitance
 have a low protective earth impedance
 have adequate ampacity with screen earthed at both ends

8 CABLES INSTALLATION
When LV cables are installed above ground, the segregation/clearances distances between
power, control and instrumentation/telecommunication cables shall be as per below table.
Power Cables Separation Distances From Other Systems
 Specification LV Cables NAS-ELC-GEN-SPC-001-00
Iranian Gas Engineering & Development Co. DOC status: ISSUED FOR CLIENT REVIEW
Nasrabad - e – Kashan
Underground Gas Storage Development Project date: 14.12.2021
Phase I (Exploration)

System System System

1 2 3

System
1 ‐ 600mm 900mm

System
2 600 ‐ 300

System
3 900 300 -

System 1 = HV Cables
System 2 = LV Cables
System 3 – Instruments/Telecoms/Signal Cables
Where power cable and instrumentation/signals cable routes cross at right angles, a reduced
separation is permissible. This shall be reviewed on a case by case basis.
The spacing distance between power cables shall be as per below table:

Cable types Cable Separation

Service
Installation Distance
No. of Core CSA
Single-core
HV and LV cables >50mm² Trefoil/Laid Flat 1D between Trefoil
Three or more
layers touching
in a bunch of 20 10mm between
Multi-core cables ≤25mm² cables bunches
Double layer
touching in a
>25mm² bunch of 20 10mm between
Multi-core cables ≤50mm² cables bunches
Single layer in a
bunch of 20 10mm between
LV Multi-core cables >50mm² cables bunches

Cable penetrations in hazardous environments which pass through walls fire separations,
electrical building cable entries, LV Switchgear/LV Panel cable entries shall be by an approved
Multi-Cable Transit (MCT) frame fitted with cable compression blocks designed to International
 Specification LV Cables NAS-ELC-GEN-SPC-001-00
Iranian Gas Engineering & Development Co. DOC status: ISSUED FOR CLIENT REVIEW
Nasrabad - e – Kashan
Underground Gas Storage Development Project date: 14.12.2021
Phase I (Exploration)

and national authority standards. They shall also be tested and have certification by a
recognized testing authority.
Cable transits shall be modular type and be of a fire retardant material. Each module shall be
able to handle various cable sizes.
Cable transits shall be provided with 20% spare entries minimum. Electrical and Instrument
cables shall be laid through separate cable transit frames.
Due to the cable installation conditions, there may be a large de-rating factor used in
calculating the cable size. This may lead to very large cables or multiple parallel cables for
relatively modest loads.

9 CABLE TEST AND INSPECTION

Routine tests, sample tests and type tests shall be carried out at manufacturer work according
to the recommendations of IEC 60502-1.
Type tests, electrical and non-electrical, shall be performed on samples from each type of
cable.
Test certificates shall be submitted to purchaser in three copies for all test performed.
Factory Acceptance Tests shall be carried out and the Company, or their appointed agent,
shall visit during all stages of manufacture.
Unless otherwise agreed between the cable vendor and the purchaser, the d.c. test voltage
shall be equal to 4Uo (Uo is voltage between phase and neutral) and shall be applied for
fifteen minutes according to the recommendations of IEC 60502-1.
All testing shall be identified within the Inspection and Test Plan (ITP) and as required by the
relevant Iranian authority.
Prior to installing/connecting cables for any voltage level all specified tests shall have been
completed.
The Contractor shall assume responsibility for replacement of any damaged cables.

10 SHIPPING

The cables shall be supplied on non-returnable drums with steel reinforced hub plates, the
inner end of cables shall be brought out through the side of the drum.

Each drum shall be durably marked on the outside of the flange, with particulars of the cable
i.e. voltage, length, conductor size, and cable type. The gross mass shall be shown and the
direction of rolling shall be indicated by arrow.

Cable drums shall be provided with a permanently attached readily visible identification tags.
Identification tags should remain intact from the time of initial dispatch at work to the final
destination.

Before dispatch the manufacturer shall seal and cap both ends of cables so that to prevent the
ingress of water during transportation and storage. The end of cables shall be protected from
mechanical damage.
 Specification LV Cables NAS-ELC-GEN-SPC-001-00
Iranian Gas Engineering & Development Co. DOC status: ISSUED FOR CLIENT REVIEW
Nasrabad - e – Kashan
Underground Gas Storage Development Project date: 14.12.2021
Phase I (Exploration)

The cables manufacturer shall be the sole responsible for adequacy of preparation for
shipment of cables.

11 GUARANTEE
All cables shall be guaranteed against defective material, poor design and workmanship.
The vendor shall guarantee the cables performance under specified conditions.
If any defect is discovered during the d.c. voltage test performed after the cable installation,
the vendor shall be responsible for replacement of the cable free of charge.