STANDARDS PUBLICATION

KOC RECOMMENDED PRACTICE

FOR
SELECTION AND INSTALLATION OF
ELECTRIC CABLES
DOC. NO. KOC-E-008
(REV. 5)

STANDARDS TEAM
 DOC. NO. KOC-E-008 Page 2 of 43 REV. 5

TABLE OF CONTENTS
PAGE No.

FOREWORD 5

1.0 SCOPE 6

2.0 APPLICATION 6

3.0 TERMINOLOGY 6
3.1 Definition 6
3.2 Abbreviations 6

4.0 REFERENCE CODES AND STANDARDS 8

4.1 Conflicts 8
4.2 List of Standards, Codes and Specifications 9

5.0 ENVIRONMENTAL CONDITIONS 12

6.0 HEALTH, SAFETY AND ENVIRONMENT 13

7.0 HAZARDOUS AREA CLASSIFICATION 14

8.0 CABLE SYSTEM DESIGN 14

8.1 General 14
8.2 Voltage Rating of Cables 14
8.3 Cable Sizing 14
8.4 Minimum Conductor Size Requirements 17
8.5 Computer-Aided Cable Design 18
8.6 Control and Pilot Wire Cables 18

9.0 SELECTION OF CABLES 18

10.0 SPECIAL APPLICATION CABLES 19

10.1 Fire Resistant Cables 19
10.2 Low Smoke Zero Halogen and Oil Resistant Cables 19
10.3 Mineral Insulated Cables 20
10.4 Cables for Offshore Facilities 20
10.5 Cables for Variable Speed Drive (VSD) Applications 20

11.0 CABLE STORAGE AND HANDLING 20

12.0 CABLE INSTALLATION METHODS 21

13.0 ROUTING AND SEGREGATION OF CABLES 22

13.1 Routing of Cables 22
13.2 Cable Grouping and Segregation 22
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14.0 CABLE INSTALLATION PREREQUISITES 23

14.1 EOD Clearance 23
14.2 Drawings and Documents Required Prior to Cable Installation 23
14.3 Cable Route Survey 24
14.4 Cable Installation Plan / Schedule 26
14.5 Inspection and Test Plan (ITP) 27

15.0 INSTALLATION OF CABLES 27

15.1 General 27
15.2 “Direct Buried” Installation of Cables 29
15.3 Cable Installation on Trays / Ladders 31
15.4 Cable Installation in Concrete Troughs / Trenches 31
15.5 Cable Installation in Duct Banks 32
15.6 Cable Installation in Cable Tunnels 32
15.7 Specific Requirements for Installation of Mineral Insulated Cable 33

16.0 CABLE TRAYS / LADDERS 33

17.0 CONCRETE CABLE TROUGHS / TRENCHES 34

18.0 DUCT BANKS 34

19.0 CABLE TUNNELS 35

20.0 CABLE JOINTING WORKS 35

21.0 CABLE TERMINATION WORKS 36

22.0 TESTING OF CABLES 37

22.1 General 37
22.2 Safety Requirements during Cable Testing 37
22.3 Insulation Resistance Testing of Cables 38
22.4 High Voltage Testing of Electric Cables 38
22.5 Testing of Optical Fibre Cables 39

23.0 IDENTIFICATION TAGS AND ROUTE / JOINT MARKERS 39

23.1 Identification Tags 39
23.2 Cable Route / Joint Markers 39

24.0 QUALITY ASSURANCE 39

25.0 DOCUMENTATION 40
25.1 General 40
25.2 Cable System Design Details 40
25.3 Drawings 40
25.4 Cable Installation Records 41
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26.0 APPENDIX - 1: CHECKLIST FOR INSPECTION AND TESTING OF

ELECTRIC CABLE (TYPICAL) 42

ACKNOWLEDGEMENT 43

Revision Table: Summary of Major Changes in Rev. 5

Sl. No. Clause No. Description of Major Changes

1 Foreword Updated.
2 1.0 “INTRODUCTION” Clause deleted and subsequent Clauses renumbered.
3 3.0 3.1 “Definitions” and 3.2 “Abbreviations” updated.
4 4.0 4.1 “Conflicts” and 4.2 “List of Standards, Codes and Specifications” updated.
5 8.0 Sub-Clause 8.6.2 revised.
Sub-Clause 10.3.1 deleted and subsequent Sub-Clauses renumbered.
6 10.0
Sub-Clause 10.3.2 revised.
7 15.0 Sub-Clauses 15.1.20, 15.1.22, 15.3.2 and 15.5.4 revised.
8 Acknowledgement Updated.
 DOC. NO. KOC-E-008 Page 5 of 43 REV. 5

FOREWORD I5I

This document “KOC Recommended Practice for Selection and Installation of Electric Cables”
(KOC-E-008, Rev. 5) provide minimum requirements for the selection, sizing, installation and testing
of electric cables at various KOC Facilities within Kuwait. The earlier document KOC-E-008 (Rev. 4)
issued in December 2019 has been revised for incorporation of Cost Optimisation Recommendations,
revisions of relevant International / National Standards and latest technological developments in this
field.

This Recommended Practice has been approved by the Standards Team in consultation with the
ESTC Sub-Committee (Technical) for use throughout the Engineering and Operational Functions of
Kuwait Oil Company (K.S.C.).

This Recommended Practice sets out to achieve the following objectives:

a) To provide technical guidance and establish a base document for the selection, sizing,
installation and testing of electric cables with a view to achieve uniformity, safety, quality,
reliability and efficiency in an economical manner.

b) To assist the Project Engineers by providing best practices and methods for installation and
testing of electric cables.

c) To maintain the Health, Safety & Environment (HSE) Management, including Process Safety
Management (PSM) requirements as applicable, to ensure the safety, integrity and protection
of personnel, environment and assets.

Feedback as well as any comments or suggestions derived from the application of this Standard at
any stage of design, installation or operation are invited and should be directed to:

Team Leader Standards Team

(Chairman, ESTC Sub-Committee - Technical)
Projects Support Services Group, K. O. C.
P. O. Box - 9758, Ahmadi - 61008
State of Kuwait.
 DOC. NO. KOC-E-008 Page 6 of 43 REV. 5

1.0 SCOPE

1.1 This Recommended Practice (RP) specifies the minimum requirements for the selection,
sizing, installation and testing of electric cables at various KOC Facilities within Kuwait.

1.2 This RP does not cover any specific requirements associated with electric cables of rating
above 11 kV.

2.0 APPLICATION

2.1 The selection, sizing, installation and testing of electric cables shall fully comply with all
relevant requirements specified in this Recommended Practice and the reference
Standards / Codes mentioned herein.

2.2 Any exceptions or deviations from this RP, along with their merits and justifications, shall
be brought to the attention of KOC Controlling Team for their review, consideration and
amendment by Standards Team (if required).

2.3 Compliance with this KOC Recommended Practice does not of itself confer immunity from
legal or statutory obligations.

3.0 TERMINOLOGY

3.1 Definitions

For the purpose of this Recommended Practice, the following definitions apply.

3.1.1 Electrically Safe Working Conditions

A state in which an electrical conductor or circuit part has been disconnected from
energised parts, locked / tagged in accordance with KOC HSE Procedures and
established Standards, tested to ensure the absence of voltage and earthed.

3.1.2 Offsite Cable Routes

Cable routes established outside the fences of KOC Facilities (Gathering Centres,
Booster Stations, other Operating Facilities, Substations, Offices, Buildings etc.).

3.2 Abbreviations I5I

For the purpose of this Recommended Practice, following abbreviations apply:

AC Alternating Current

BS Booster Station / British Standards

DC Direct Current

DOL Direct On-Line

DOC. NO. KOC-E-008 Page 7 of 43 REV. 5

EOD Explosive Ordnance Disposal

ETAP Electrical Transient Analysis Programme

FAT Factory Acceptance Test

GC Gathering Centre

GPS Global Positioning System

H2S Hydrogen Sulphide

HAC Hazardous Area Classification

HDD Horizontal Directional Drilling

HSE Health, Safety and Environment

HSSE Health, Safety, Security and Environment

HV High Voltage

IEC International Electrotechnical Commission

IMP Infrastructure Master Plan

IR Insulation Resistance

ISD Inherently Safer Design

ISO International Organisation for Standardisation

ITP Inspection and Test Plan

JSA Job Safety Analysis

KNPC Kuwait National Petroleum Company

KOC Kuwait Oil Company (K.S.C.)

KPC Kuwait Petroleum Corporation

kV kilovolt

LSZH Low Smoke Zero Halogen (cables)

LV Low Voltage

MEWRE Ministry of Electricity & Water & Renewable Energy

 DOC. NO. KOC-E-008 Page 8 of 43 REV. 5

MPW Ministry of Public Works

NFPA National Fire Protection Association

NOx Nitrogen Oxides

OFC Optical Fibre Cable

OTS Operations Technical Services

PAI Public Authority of Industry (Kuwait)

PPE Personal Protective Equipment

PSM Process Safety Management

PTW Permit to Work

ROW Right of Way

RP Recommended Practice

SAT Site Acceptance Test

SI International System of Units (Le Systéme International D'unités)

SOx Sulphur Oxides

SRC Sulphate Resistant Cement

UPVC Unplasticised Polyvinyl Chloride

VSD Variable Speed Drive

XLPE Cross-Linked Polyethylene

4.0 REFERENCE CODES AND STANDARDS I5I

4.1 Conflicts

In the event of conflict(s) between this Recommended Practice and the Standards /
Codes, Specifications referred herein, or other technical, purchase / contractual
requirements specified in the Project Documents, the subject shall be brought to the
attention of KOC Controlling Team for resolution.
 DOC. NO. KOC-E-008 Page 9 of 43 REV. 5

4.2 List of Standards, Codes and Specifications

The selection, sizing, installation and testing of electric cables shall conform, except where
otherwise specified, with the current issues and amendments of the applicable Codes
and Standards, including but not limited to the following:

4.2.1 International Standards

IEC 60079 Explosive Atmospheres

(Various Parts)

IEC 60183 Guidance for the Selection of High-Voltage A.C. Cable

Systems

IEC 60287 Electric Cables - Calculation of the Current Rating

(Various Parts)

IEC 60331 Tests for Electric Cables under Fire Conditions - Circuit
(Various Parts) Integrity

IEC 60332 Tests on Electric and Optical Fibre Cables under Fire
(Various Parts) Conditions

IEC 60364-5-52 Low Voltage Electrical Installations - Part 5-52: Selection and
Erection of Electrical Equipment - Wiring Systems

IEC 60502 Power Cables with Extruded Insulation and their Accessories
(Various Parts) for Rated Voltages from 1 kV (Um=1.2 kV) up to 30 kV
(Um=36 kV)

IEC 60702 Mineral Insulated Cables and their Terminations with a Rated
(Various Parts) Voltage not Exceeding 750 V

IEC 61537 Cable Management - Cable Tray Systems and Cable Ladder
Systems

IEC 61892 Mobile and Fixed Offshore Units - Electrical Installations

(Various Parts)

IEC 61914 Cable Cleats for Electrical Installations

IEC 62275 Cable Management Systems - Cable Ties for Electrical

Installations

IEC 62440 Electric Cables with a Rated Voltage not Exceeding

450 / 750 V - Guide to Use

IEC 62444 Cable Glands for Electrical Installations

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ISO 1461 Hot Dip Galvanised Coatings on Fabricated Iron and Steel
Articles - Specifications and Test Methods

ISO 9000 Quality Management Systems

Series of Standards

ISO 14001 Environmental Management Systems - Requirements with

Guidance for Use

ISO 45001 Occupational Health and Safety Management Systems -

Requirements with Guidance for Use

ISO 50000 Series Energy Management Systems

(Various Parts)

4.2.2 National Standards

API RP 11S5 Recommended Practice for the Application of Electrical

Submersible Cable Systems

BS 7671 Requirements for Electrical Installations. IET Wiring

Regulations

NFPA 70E Standard for Electrical Safety in Workplace

NFPA 70EH Handbook for Electrical Safety in the Workplace

4.2.3 KOC Standards and Recommended Practices

KOC-C-002 KOC Recommended Practice for Engineering Design Basis

of Civil and Structural Work

KOC-C-004 KOC Recommended Practice for Topographical

Survey (Onshore)

KOC-C-005 KOC Standard for Materials and Workmanship - Site

Preparation and Earthworks

KOC-C-027 KOC Standard for Fireproofing of Structural Steelwork

KOC-C-030 KOC Recommended Practice for Blast Resistant

Design of Buildings

KOC-C-033 KOC Standard for Bund Walls for Storage Tanks -

Materials and Workmanship

KOC-E-003 Part 1 KOC Recommended Practice for Design Basis and

Selection of Electrical Systems
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KOC-E-003 Part 2 KOC Recommended Practice for Installation and

Testing of Electrical Equipment

KOC-E-004 KOC Recommended Practice for Selection,

(Parts 1 - 6) Installation and Maintenance of Electrical Equipment in
Hazardous Areas

KOC-E-017 KOC Recommended Practice for Lighting and Small Power

Supply Systems

KOC-E-023 KOC Standard for Electric Cables

KOC-E-024 KOC Recommended Practice for Earthing and Bonding

KOC-G-002 KOC Standard for Hazardous Area Classifications

KOC-G-004 KOC Standard for Packing, Marking and Documentation

KOC-G-007 KOC Standard for Basic Design Data

KOC-L-002 KOC Recommended Practice for the Protection of KOC

Services: Clearance Requirements for Buried Pipelines &
Piping, Cables, Underground Structures and Buildings

KOC-L-010 KOC Standard for Personal Protective Equipment (PPE)

KOC-Q-014 KOC Standard for Project QA / QC General Requirements

KOC-T-006 KOC Standard for Optical Fibre Cables

KOC-T-008 KOC Recommended Practice for Installation Optical

Fibre Cable

4.2.4 KOC Health, Safety and Environment (HSE)

KPC HSSE Policy

KOC Life Saving Rules

KOC.EV.008 Waste Management Procedure

KOC.GE.028 HSE Training, Awareness and Continued Learning Process

KOC.GE.034 Housekeeping Procedure

KOC.HE.003 Gas Testing Procedure

KOC.PS.001 Process Safety Management Manual

 DOC. NO. KOC-E-008 Page 12 of 43 REV. 5

KOC.PS.006 Guidelines for Inherently Safer Design (ISD)

KOC.SA.003 Manual Handling of Loads

KOC.SA.004 Permit to Work Procedure

KOC.SA.007 Entry into Confined Spaces

KOC.SA.010 Procedure for Personal Protective Equipment (PPE)

KOC.SA.013 Mobile Equipment Procedure

KOC.SA.022 Electrical Multi-Lockout and Tagout Procedure

KOC.SA.024 Job Safety Analysis (JSA) Procedure

KOC.SA.025 Procedure for Handling of Explosive Materials, Substance

and EOD

KOC.SA.026 Excavation Safety Procedure

KOC.SA.027 Electrical Work Safety Procedure

KOC.SA.029 Safety Procedure for Mechanical Handling of Loads

KOC.SA.031 Working at Height Procedure

Other relevant and applicable KOC HSE / PSM Documents (Latest) as per the pertinent
requirements.

4.2.5 Other KOC Documents

EG-DO-C-001 Engineering Drawing Practice Code

5.0 ENVIRONMENTAL CONDITIONS

5.1 The environmental conditions in Kuwait are severe and shall be considered carefully while
installation of electric cables. The atmosphere shall be considered to be dusty, corrosive
and may contain traces of Hydrogen Sulphide (H2S), SOx / NOx gases & airborne
chemical contaminants.

5.2 For detailed design information regarding the environmental, site and utility supply
conditions prevailing throughout the KOC Facilities, refer to KOC-G-007 “KOC Standard
for Basic Design Data”.
 DOC. NO. KOC-E-008 Page 13 of 43 REV. 5

6.0 HEALTH, SAFETY AND ENVIRONMENT I5I

6.1 All applicable HSE, including PSM, requirements as per the relevant International and
National Standards, especially Inherently Safer Design and environmentally sustainable
requirements, shall be considered while selection, installation & testing of electric cables
to be installed in KOC Facilities. Any material containing asbestos shall not be used in
the manufacture and / or packing of electric cables.

6.2 KPC HSSE Policy shall be adhered to while working within KOC areas at all times. All
relevant and applicable KOC HSE / PSM documents shall be adhered to during the
design, engineering, material selection, installation and performance testing of electric
cables and during all on-site work activities within KOC Facilities to safeguard and protect
personnel, environment and assets.

6.3 Appropriate Permit to Work (PTW) with applicable Job Safety Analysis (JSA) document
for the work to be carried out shall be prepared by the Contractor in accordance with KOC
HSE Procedures “Permit to Work Procedure” (KOC.SA.004) and “Job Safety Analysis
Procedure” (KOC.SA.024) and submitted to KOC Controlling Team for approval prior to
commencement of on-site work activities / surveys. All precautionary measures stipulated
by the electrical equipment manufacturer shall be complied. Care shall be taken to ensure
proper electrical isolation while terminating electric cable to electrical equipment / system
in existing Operating Facilities.

6.4 All personnel engaged in site works shall have successfully undergone all the applicable
trainings and awareness courses as per KOC HSE Procedure “HSE Training, Awareness
and Continued Learning Process” (KOC.GE.028).

6.5 All personnel carrying out site works, including Supervisors, shall use appropriate
Personal Protective Equipment (PPE) during the execution of works as identified by the
job requirement and in line with the requirements of “Procedure for Personal Protective
Equipment (PPE)” (KOC.SA.010) and KOC-L-010 “KOC Standard for Personal Protective
Equipment”.

6.6 The tools and equipment used for the works shall be periodically inspected and certified
for safe use in all KOC areas. Contractor’s mobile plant / equipment entering KOC areas
shall be certified “Fit for Service” by Third Party Inspector and shall obtain clearance
certificate as per KOC HSE Procedure “Mobile Equipment Procedure” (KOC.SA.013).

6.7 The Contractor personnel shall take all necessary precautionary measures to ensure safe
handling of loads during loading, unloading and transfer of materials (especially cable
drums) as per KOC HSE procedures “Manual Handling of Loads” (KOC.SA.003), “Safety
Procedure for Mechanical Handling of Loads” (KOC.SA.029) and “Mobile Equipment
Procedure” (KOC.SA.013).

6.8 The Contractor shall manage all wastes (hazardous / non-hazardous) arising out of work
activities in a safe and environmentally responsible manner in accordance with the KOC
HSE Procedure “Waste Management Procedure” (KOC.EV.008). All personnel engaged
at site work in KOC areas shall be fully aware of the need for good housekeeping and
shall adhere to KOC HSE Procedure “Housekeeping Procedure” (KOC.GE.034) during
all work activities.
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6.9 All relevant HSE information and precautionary measures shall be provided to KOC,
including HSE / Safety Manual(s), pertaining to the safe handling, installation, testing and
repair of the electric cable.

7.0 HAZARDOUS AREA CLASSIFICATION

7.1 The classification of hazardous areas shall be based on the requirements of

KOC-G-002 "KOC Standard for Hazardous Area Classification" and the latest edition of
relevant International / National Standards / RPs / Code of Practices. For Hazardous Area
Classification (HAC) of existing KOC Operating Facilities, KOC’s HAC drawings of the
relevant Facility shall be referred.

7.2 The equipment and accessories to be used in hazardous area shall be certified for use in
those areas by a testing authority of an International recognition. The list of testing and
certifying agencies acceptable to KOC are given in “KOC-E-004 Part 2”.

8.0 CABLE SYSTEM DESIGN

8.1 General

8.1.1 The cable system shall be designed taking into consideration of the voltage rating of the
System, cable installation method, the maximum power demand / current rating of the
equipment to be connected, short-circuit rating of the System, type of earthing, voltage
drop limitations, derating factors etc.

8.1.2 The derating factors due to the type of installation (in air, direct buried underground etc.),
grouping of cables, clearances between cables, soil thermal resistivity etc. shall be taken
into consideration while designing the cable system.

8.2 Voltage Rating of Cables

8.2.1 The voltage rating of cables shall be appropriate to the operating voltage of the
equipment / System and the power supply system earthing arrangement. KOC-E-023 “KOC
Standard for Electric Cables” shall be referred for details of voltage rating of electric cables
used in KOC applications.

8.2.2 For details of Standard Voltages and Phase Sequences used in KOC Facilities, KOC-E-003
Part 1 “KOC Recommended Practice for Design Basis and Selection of Electrical
Systems” shall be referred.

8.3 Cable Sizing

8.3.1 The following parameters shall be considered for sizing of cables:

a) Maximum Power Demand (kVA) / Current rating of the equipment,

b) Voltage Drop,

c) Short-Circuit Rating of the System,

 DOC. NO. KOC-E-008 Page 15 of 43 REV. 5

d) Tripping Time of Protection Devices,

e) Derating Factors,

f) Effects of Harmonics (for VSD cables etc.).

Note: For details of Maximum Power Demand and additional spare capacity requirements,
KOC-E-003 Part 1 “KOC Recommended Practice for Design Basis and Selection of
Electrical Systems” shall be referred.

8.3.2 Current Rating of Cables

The permissible current rating of cable shall be calculated in accordance with the
requirements of relevant parts of IEC 60287 and the recommendations of Manufacturer.
The various factors that influence the cable design, while calculating the permissible
current rating includes, but not limited to the following:

a) Ambient temperature.

An ambient temperature of 50 ºC shall be considered for aboveground installation

and 40 ºC for buried underground installation, unless otherwise specified in the
Project Documents.

The ambient temperature for Electrical Submersible Pumps (ESPs) motors shall
be as specified in the Project Documents.

b) Thermal resistivity of the medium (air / soil) in which the cable is installed.

The value of soil thermal resistivity shall be as per the Soil Resistivity Report for
the project under consideration. However, the minimum Soil Resistivity value for
design purpose shall not be less than two (2) K.m / W (Kelvin metre per watt).

c) Method of cable installation (aboveground, direct buried underground etc.).

d) Grouping and proximity to other cables.

Where cables of different types, sizes are laid in groups, the current carrying
capacity of cable shall be derated, taking into consideration of the thermal effects
of cables in the group depending upon the type of installation and the clearance
maintained between cables.

e) Thermal resistivity of the cable constituents (insulation / sheathing etc.),

f) Depth of buried cables.

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8.3.3 Short-Circuit Rating

a) The short time current carrying capacity of the cables shall take into account the
current-time characteristics of the circuit protection device to ensure that the cables
do not suffer damage due to overheating under fault conditions. The short-circuit
current withstand time (t) of the cable shall be suitably selected such that the
maximum allowable thermal stress on the cable (I2t) shall be higher than the
maximum “let-through” energy by the protective device to which the cable is
connected.

Note: The power cables connected to Circuit Breaker Feeders shall be designed
for short-circuit current capacity of one (1) second, unless otherwise
specified / approved by KOC.

b) For details of standard short-circuit ratings, KOC-E-003 Part 1 “KOC

Recommended Practice for Design Basis and Selection of Electrical Systems”
shall be referred.

8.3.4 Voltage Drop

a) Cables shall be sized so that the maximum voltage drop between the supply
source and the load, when carrying the design current, does not exceed the value
that will ensure safe and efficient operation of the associated apparatus or the
following, whichever is lower:

(i) For HV motors, the voltage drop at the motor terminals shall not exceed
3 % at full load current and 15 % during starting.

(ii) For LV motors, the voltage drop at the motor terminals shall not exceed
5 % at full load current and 15 % during starting.

(iii) The voltage drop on LV Power / Lighting circuits shall be limited to a

maximum of 2.5 %, unless otherwise specified in the Project Documents.
The total voltage drop at the farthest light fitting (including branch circuit)
shall not exceed 5 %.

Note: The starting voltage drop limits for motors as mentioned above need not be
applied for motors driven by Variable Speed Drive (VSD) Systems, which
are not provided with a Direct On-Line (DOL) bypass arrangement.
 DOC. NO. KOC-E-008 Page 17 of 43 REV. 5

b) While carrying out electrical system design, the voltage drop on 11 kV feeders shall
be kept to the lowest level possible to meet all other design criteria / future
additions. The maximum limits specified below have to be used judiciously by the
designer where transmission of bulk power over a long distance is considered at
11 kV, provided all other design criteria could be met:

(i) 11 kV feeders to Gathering Centre (GC) / Booster Station (BS) / Other

Facilities:

The Voltage drop on 11 kV feeders from Bulk Intake (Primary) Substation

to Plant Substation (Substation near the GC / BS etc.), fed directly or via
Area Substation shall be limited to a maximum of 2 %.

(ii) 11 kV Ring fed system for Oil / Water Wells:

Where the bulk power is used to supply Electrical Submersible Pumps

(ESPs) fed through individual Unit Transformers provided with tap
changers to maintain the voltage at required levels, the maximum voltage
drop on 11 kV feeders from Bulk Intake (Primary) Substation to 11 kV
substation for distribution of ring circuits shall be upto 3 % and the total
voltage drop at the farthest point of the 11 kV ring main feeder shall be
upto 5 %.

Note: The above voltage drop limits shall also apply for similar applications where
high voltage feeders upto 11 kV are employed.

8.3.5 Overcurrent Protection of Cables

The overcurrent protection device shall be set not to exceed the current carrying capacity
of the selected cables under the installed conditions.

8.4 Minimum Conductor Size Requirements

The minimum conductor sizes for cables shall be calculated based on the requirements
mentioned in this RP or based on the following, whichever is larger:

a) Cables for 3.3 kV and 11 kV System : 35 mm²

b) Cables for 600 / 1000 V System

(i) For motors and power feeders : 4 mm²

(ii) For CTs and Control circuits : 2.5 mm²

Note: For the requirements of conductor sizes for lighting & small power supply systems,
“KOC-E-017” shall be referred.
 DOC. NO. KOC-E-008 Page 18 of 43 REV. 5

8.5 Computer-Aided Cable Design

Where computer-aided design tools are used for designing of cable systems, “ETAP” or
similar programs approved by KOC shall be employed. The details of computer-aided
design calculations shall be submitted to KOC for review and approval.

8.6 Control and Pilot Wire Cables

8.6.1 Cables used for control and monitoring devices associated with power systems such as
control cables between Switchgears, Local Control Stations, Relay Interface Panels etc.
shall be suitably selected by taking into account of the type of application, current carrying
capacity, voltage drop, etc.

I 5 I 8.6.2 The multi-core control cables shall have 15 % spare cores (with a minimum two (2) spare
cores) in addition to the actual design and known future requirements, unless otherwise
specified in the Project Documents.

8.6.3 Colour coding of multi-core control cables shall be in accordance with the requirements
of KOC-E-023 “KOC Standard for Electric Cables”.

8.6.4 For long distance transmission of electrical control signals, Optical Fibre Cables (OFC)
shall be used, where specified in the Project Documents. For details of Optical Fibre
Cables, KOC-T-006 “KOC Standard for Optical Fibre Cables” and for OFC installation
details, KOC-T-008 “KOC Recommended Practice for Installation of Optical Fibre Cable”
shall be referred.

8.6.5 For differential protection signal transmission, Optical Fibre Cables or pilot wire cables
shall be used. Where pilot wire cable is used, it shall be with copper conductor and have
insulation capable of withstanding upto 5 kV, unless otherwise specified in the Project
Documents. Where pilot wire cables are installed for longer distances and run in close
proximity to HV cables, the insulation of pilot wire cables shall be suitably rated to
withstand higher induced voltages (say 15 kV), as specified in the Project Documents.

9.0 SELECTION OF CABLES

9.1 The cables shall be suitably selected based on its application and intended operating
conditions taking into account of the mechanical properties (toughness / flexibility of outer
sheath, resistance to impact & abrasion), chemical properties (stability of materials when
exposed to oils, flame & chemicals), ambient temperature and environment conditions
prevailing in Kuwait.

9.2 Cables used for normal applications in KOC shall be XLPE insulated, steel wire armoured
with PVC sheath, unless otherwise specified in the Project Documents. The PVC outer
sheath used for cables shall be flame retardant type, meeting the test requirements in
accordance with IEC 60332.

9.3 Cables laid in the ground shall have an appropriate lead sheath, where there is a
possibility of the cables coming into contact with hydrocarbon or other organic solvents
due to spillage etc. Direct buried cables inside Operating Facilities handling hydrocarbon
shall be lead sheathed, unless otherwise specified in the Project Documents.
 DOC. NO. KOC-E-008 Page 19 of 43 REV. 5

9.4 Single core cables shall have non-magnetic armour (Aluminium) to avoid induced armour
currents.

9.5 The use of unarmoured cables (power / control) shall be limited to short runs such as for
installation in internal areas of Substations / control rooms / buildings etc. Suitable
mechanical protection shall be provided for such cables by installing in UPVC ducts, cable
trays / ladders with cover etc.

9.6 KOC-E-023 “KOC Standard for Electric Cables” shall be referred for details of power,
control and pilot wire cables.

10.0 SPECIAL APPLICATION CABLES

10.1 Fire Resistant Cables

10.1.1 Fire Resistant cables shall be used for power supply to “Emergency Systems / Circuits”,
which include but not limited to the following:

a) Emergency Shutdown (ESD) Systems,

b) Fire and Gas Systems,

c) Fire pump control / alarm circuits,

d) “Emergency” and "Escape" lightings,

e) CCTV and other Security Systems,

f) Life safety ventilation system in buildings / office complexes,

g) Any other “Emergency Systems / Circuits” as specified in the Project Documents.

10.1.2 For details of fire resistant cables, KOC-E-023 “KOC Standard for Electric Cables” shall
be referred.

10.2 Low Smoke Zero Halogen and Oil Resistant Cables

10.2.1 The cables installed in “Human Occupied Buildings” such as control rooms, office
buildings and other areas specified in the Project Documents shall be “Low Smoke Zero
Halogen (LSZH)” type. For details of LSZH Cables, KOC-E-023 “KOC Standard for
Electric Cables” shall be referred.

10.2.2 Cables used for motors of Electrical Submersible Pumps (ESPs) shall be selected in
accordance with the recommendations of the ESP Manufacturer and shall comply with
the requirements of API RP 11S5.
 DOC. NO. KOC-E-008 Page 20 of 43 REV. 5

10.3 Mineral Insulated Cables I5I

10.3.1 Mineral insulated cable, due to its inherent fire resistant properties is suitable for
“Emergency Systems / Circuits” and high temperature circuits. When exposed to high
temperatures under normal operation, mineral insulated cables without an external PVC
sheath shall be used.

10.3.2 Use of mineral insulated cable shall be avoided, where the connected equipment is
susceptible to vibration, where the cable requires to be disconnected regularly for
maintenance and for outdoor applications.

10.3.3 For details of Mineral Insulated Cables, KOC-E-023 “KOC Standard for Electric Cables”
shall be referred.

10.4 Cables for Offshore Facilities

For the selection of power and control cables to be installed in “Offshore” applications,
IEC 61892 (various parts) shall be referred.

10.5 Cables for Variable Speed Drive (VSD) Applications

The cables used for Variable Speed Drive (VSD) applications shall be selected in
accordance with the recommendation of VSD Manufacturer / Vendor and approved by
KOC.

11.0 CABLE STORAGE AND HANDLING

11.1 Storage, transportation and handling of electric cables before & during installation shall
be as per the requirements of this RP and in accordance with the recommendations of
Manufacturer.

11.2 The cable drums shall be stored under shaded areas for protection from direct sunlight.
The cable storage area shall be selected in such a way that water seepage or spillage of
chemicals / petroleum products could occur.

11.3 The floor at cable storage site shall be hard and dry. The floor shall be flat to resist any
inadvertent movement of drum. Necessary fire protection measures shall be provided at
the cable storage site.

11.4 Cable drums shall always be kept upright to avoid cable layers getting entangled. The
drums shall not be stacked over one another. Adequate spacing shall be ensured
between drums for circulation of air and ease of handling.

11.5 Where cables are supplied on wooden drums, these shall be protected from termites.
Care shall also be taken to protect cables from rodent attacks.

11.6 While lifting cable drums using crane, suitable slings and spreader bars shall be used as
per Manufacturer’s recommendations. Care shall be taken to ensure that cable drum is
not damaged during lifting.
 DOC. NO. KOC-E-008 Page 21 of 43 REV. 5

11.7 The cable drums shall be firmly fastened to the base and appropriate measures shall be
taken to prevent its movement during transportation. It shall be ensured that cables are
not damaged, while loading / unloading of cable drums using forklifts.

11.8 The direction of rotation as indicated by the arrow mark on the drum shall be adhered,
while rolling the drum.

11.9 It shall be ensured that cable ends are always capped or sealed suitably to prevent the
ingress of moisture.

12.0 CABLE INSTALLATION METHODS

12.1 The various methods of cable installation commonly used for KOC applications are given
below:

a) Underground Cable Installation (Direct buried or laid in concrete troughs /

trenches, in duct banks, cable tunnels etc.),

b) Aboveground Cable Installation (On cable trays / ladders etc.).

12.2 The types of cabling shall be suitably selected to protect the cables from external
influences like high temperature, corrosive chemical contaminants, mechanical stress
due to vehicle movement etc., as applicable. Typical methods of cable installation for
various areas / Facilities are given below for guidance:

Table 1: Methods of cable installation

Cabling in Offsite Cable Routes, Incoming

cables to Substations, Cabling in Tank Farms - Direct Buried.
etc.

Inside the fencing of Operating Facilities Direct Buried / Laid in Concrete Troughs /
-
(GC / BS / Other Facilities) etc. Trenches / On Cable Trays / Ladders.

Inside Substations / Control Rooms / Laid in Concrete Troughs / Trenches / On

-
Buildings / Offices etc. Cable Trays / Ladders.

Cabling in Jetties / Offshore. - On Cable Trays / Ladders.

12.3 While installation of multiple cables between buildings in Office Complexes (located other
than in Operating Facilities), for the purpose of effective utilisation of aboveground space,
cable tunnels shall be used where specifically called for in Project Documents / approved
by KOC. Sub-Clause 15.6 and Clause 19.0 of this RP shall be referred for more details
on cable tunnels.

Note: The method of cable installation for a particular area shall be judiciously selected
to suit the application, with prior approval from KOC.
 DOC. NO. KOC-E-008 Page 22 of 43 REV. 5

13.0 ROUTING AND SEGREGATION OF CABLES

13.1 Routing of Cables

13.1.1 Cable routes shall be selected in liaison with other projects being executed in the same
area. Wherever practicable, common cable routes shall be established and the route
details shall be submitted to KOC for review & approval.

13.1.2 Oil contaminated areas and high water table locations shall be avoided, while selecting
the direct buried offsite cable routes.

13.1.3 Prior to finalisation of offsite cable route, approval from “Infrastructure Master Plan”
(IMP - a unit of OTS Team) of respective KOC Asset Groups shall be obtained.

13.1.4 Where aboveground cable routing is planned in Operating Facilities, it shall be selected
alongside main pipe racks, vehicle access ways etc., to provide unobstructed direct
routes to the equipment, wherever practicable. The clearances from other Services / hot
surfaces etc. specified in Sub-Clause 13.2.6 of this RP shall be maintained.

13.1.5 Prior to finalising the routing for aboveground cabling, it shall be ensured that sufficient
accessibility is available for installation / maintenance of cables. Areas prone to
mechanical damages to cables and leakage / spillage of contaminants etc. shall be
avoided, while selection of aboveground cable route.

13.1.6 The space for tray modifications / additions, availability of headroom, routes of other
Services etc. shall be considered while finalising the cable tray / ladder route. For details of
head clearance requirement of cable trays / ladders to be installed in the cable alley of
elevated Substations, KOC-E-003 Pt. 1 “KOC Recommended Practice for Design Basis
and Selection of Electrical Systems” shall be referred.

13.1.7 Different cable routes shall be used for critical equipment / loads provided with duplicate
feeders, unless otherwise specified / approved by KOC.

13.2 Cable Grouping and Segregation

13.2.1 The following clearances (horizontal / vertical) shall be maintained while installation of
cables, unless otherwise specified in the Project Documents:

a) Between High Voltage (HV) cables - 150 mm

b) Between High Voltage (HV) and

Low Voltage (LV) cables - 300 mm

c) Between Low Voltage (LV) cables - 75 mm

Note: In cases where the cables are to be installed with clearances other than specified
above, the Correction / Reduction factors specified in relevant IEC Standards shall
be used.
 DOC. NO. KOC-E-008 Page 23 of 43 REV. 5

13.2.2 Single core cables used for transmission of three (3) phase supply shall be installed in
trefoil formation using suitable trefoil cleats as per Manufacturer’s recommendations. For
details of cable cleats, IEC 61914 shall be referred.

13.2.3 Where electric cables are running alongside the Instrumentation cable routes, clearance
requirements as specified in KOC-I-002 “KOC Standard for Instrument Installation” shall
be followed.

13.2.4 For details on clearance requirements between Electric cables and Telecommunication
cables / other Services, KOC-L-002 “KOC RP for the Protection of KOC Services:
Clearance Requirements for Buried Pipelines, Cables, Underground Structures, Buildings
and Housing Projects” shall be referred.

13.2.5 For details on clearance requirements between Electric Cables and Optical Fibre Cables,
KOC-T-008 “KOC Recommended Practice for Installation Optical Fibre Cable” shall be
referred.

13.2.6 While installation of electric cables alongside the pipe racks in Operating Facilities, there
shall be a minimum of 500 mm separation between any cable and steam / hot process
piping to protect the cables from heat radiation, unless otherwise specified in the Project
Documents.

14.0 CABLE INSTALLATION PREREQUISITES

Prior to commencing the cable installation works, EOD Clearance (as applicable), PTW &
JSA documents, necessary clearances / approvals from KOC and other agencies, relevant
KOC approved drawings etc. shall be made available at the work spot.

14.1 EOD Clearance

Explosive Ordnance Disposal (EOD) clearance shall be obtained from HSE Team of
respective Asset Groups of KOC, prior to commencement of any survey / excavation work
along the proposed “Offsite Cable Route”. If any explosive substance is found along the
cable route, steps mentioned in the HSE Procedure “Procedure for Handling of Explosive
Materials, Substance and EOD” (KOC.SA.025) shall be followed.

14.2 Drawings and Documents Required Prior to Cable Installation

Drawings and Documents required for successful execution of the works, in line with the
guidelines provided in this Recommended Practice shall be submitted to KOC for review
and approval prior to commencement of cable installation, which shall include but not
limited to the following:

a) Cable Route Survey Reports along with Route Drawings,

b) EOD clearance for “Offsite Cable Routes”,

c) Approval for cable route from “Infrastructure Master Plan” (IMP - a unit of OTS
Team) of respective KOC Asset Groups (as applicable),
 DOC. NO. KOC-E-008 Page 24 of 43 REV. 5

d) Cable sizing calculations with applicable derating factors,

e) Cable Drum Schedule and Cable Schedule with information such as voltage
rating / type / size of cable, number of cores, estimated length, jointing / glanding /
termination details of cables etc.,

f) Cable installation methods (underground / aboveground),

g) Cable trench Excavation and Backfilling Procedures,

h) Cable tray / ladder system design calculations,

i) Drawings with constructional details of cable tray work and cable tray support
systems,

j) Dimensions of concrete troughs / trenches / duct banks / tunnels etc.,

k) Cable Layout Drawings for underground / aboveground cable installations with all
relevant details showing routes / sizes / types / number of cables,

l) Details of crossing of other underground Services (if any) including GPS

coordinates, as applicable,

m) Drawings of cable routes showing the arrangement of cables with grouping and
clearance requirements,

n) Spare availability in cable trays / ladders / duct banks / concrete troughs /

trenches / cable tunnels etc.,

o) Cable jointing procedure and details showing experience of HV Cable Jointer,

p) Tagging / Numbering Methodology for cables,

q) Drawings of Cable Route / Joint Marker and Cable Tiles with relevant details,

r) Factory Acceptance Test (FAT) reports of electric cables,

s) Inspection Report of cables (including Insulation Resistance & Core Continuity

tests) delivered at site,

t) Details of testing equipment such as Model No., Make, Description etc. along with
valid calibration certificates.

14.3 Cable Route Survey

14.3.1 Cable route survey shall be carried out for the selection of shortest possible route between
the destinations in order to ascertain the cable length for carrying out cable sizing
calculations. The cable route survey report along with route drawings shall be submitted to
KOC for review and approval.
 DOC. NO. KOC-E-008 Page 25 of 43 REV. 5

14.3.2 Use of available spare capacity in the existing cable routes shall be considered while
selecting the cable routes.

14.3.3 Prior to commencement of the survey works, EOD Clearance, PTW including JSA,
Excavation Notification, Approval for excavation to make slit-trenches etc. shall be obtained
from competent authorities. KOC-C-004 “KOC Recommended Practice for Topographical
Survey (Onshore)” shall be referred for details of surveying.

14.3.4 All existing underground Services in the intended cable route shall be identified with details
of the type of Services with its dimensions, direction, depth, clearance with the proposed
cable route etc., prior to finalising the cable route. Underground Services shall be identified
by using suitable electronic and ultrasonic equipment.

14.3.5 Underground Services shall also be identified by slit trenching / excavating test pits, as
required. Underground Services shall be exposed by means of careful manual excavation.

14.3.6 Necessary precautions and safety regulations shall be strictly adhered while exploring the
buried services, so that no damage and / or injury is caused to any of the existing Services
or to the personnel involved in such activities.

14.3.7 The entire offsite cable route shall be carefully selected to avoid obstacles / hindrances such
as Oil Lake / contaminated area, hard soil / rocky area, locations of high underground water
table, locations where heavy congestion of underground services exists etc.

14.3.8 Cable route survey shall record the GPS coordinates of relevant zones of proposed cable
route and identify the type, position, depth etc. of existing Services, which are found in the
vicinity of the cable route.

14.3.9 The “Offsite Cable Route” Survey Report shall be submitted to “Infrastructure Master Plan”
(IMP - a unit of OTS Team) of respective KOC Asset Group (as applicable) for review and
approval. Cable route survey report shall include but not limited to the following:

a) Drawings of Site Layout, Piping Route, Pipeline Corridor etc.,

b) Drawings of the proposed cable route showing cable schedule details, distance
measurements, cable entry arrangements into Operating Facilities, Substations,
control rooms, buildings etc.,

c) Locations of any other existing installations, routes of existing Power /

Control / Instrumentation / Communication cables along the route, Road Crossings,
Rig Crossings, Pipeline Corridors, Utilities Crossings etc. with GPS coordinates,

d) Locations of proposed cable duct banks,

e) Drawings of existing Services (underground / aboveground) along the cable route

with all relevant details including GPS coordinates,

f) Details of utilisation of reserved space in the existing cable corridor, available spare
capacity in existing duct banks etc. (as applicable).
 DOC. NO. KOC-E-008 Page 26 of 43 REV. 5

14.3.10 While new direct buried “Offsite cables route / corridor” is planned, an additional space of
not less than 100 % of the current requirement and any known future projects shall be
reserved for future use to avoid infringement of pipelines / other Services, unless otherwise
specified in the Project Documents. Necessary approvals from the “Infrastructure Master
Plan” (IMP - a unit of OTS Team) of respective KOC Asset Groups (as applicable) shall be
obtained for the reservation of “Offsite cables route / corridor”.

14.3.11 Cable route survey in Operating Facilities shall be carried out on the basis of site layout, plot
plan, route sketches, piping route drawings and any other associated requirements as
specified in the Project Documents. The survey report as specified in Sub-Clause 14.3.9 of
this RP with relevant information (as applicable) shall be submitted to KOC for review and
approval.

14.4 Cable Installation Plan / Schedule

14.4.1 Cable Installation Plan / Schedule shall be prepared with all activities listed in a systematic
manner with the order of priority and shall be submitted to KOC for review & approval.

14.4.2 Approvals from other concerned agencies, such as MEWRE / KNPC / MPW /
PAI (Kuwait) / Kuwait Municipality etc., as applicable, shall be planned in advance for
unhindered execution of work.

14.4.3 Floor / wall openings and cable entry arrangements into Substations, control rooms,
buildings etc. for electric cables shall be finalised as specified in the Project Documents. All
such information shall be provided to Civil Engineers sufficiently in advance, so that the
construction can be carried out as per design requirements.

14.4.4 The Installation Plan / Schedule shall take into consideration of all activities / items, which
shall include but not limited to the following points:

a) Installation Schedule with details of activities and duration,

b) Method of cable installation, excavation / backfilling of cable trenches including the

material used for backfilling, disposal of excavated material, locations and methods
of road crossings involved in the approved cable route, installation of duct bank /
concrete trough / cable tray / ladder, construction of cable tunnel etc.,

c) Details of approvals / clearances required from KOC & other external agencies for
crossings of roads / Right of Way (ROW) for other Services (as applicable),

d) Power isolation requirement schedule with details of area and equipment (as
applicable),

e) Impact of power isolation on critical loads (as applicable), mitigation measures etc.

f) Number / type of underground Services, obstacles / hindrances encountered in the

approved cable route and method of mitigating them,

g) Drum / Cable Schedule with details of number and arrangement of cables,

 DOC. NO. KOC-E-008 Page 27 of 43 REV. 5

h) Number and Location of cable joints for various types of cables,

i) Schedule of glanding and termination,

j) Inspection and Test Plan (ITP) for cables comprising test report forms, testing and
commissioning schedule etc.

14.5 Inspection and Test Plan (ITP)

14.5.1 The Inspection and Test Plan (ITP) along with schedule of tests, site testing procedures,
inspection notification form, inspection checklist forms, test report forms etc. shall be
submitted to KOC for review and approval, prior to commencement of cable installation
works.

14.5.2 Inspection notification in the KOC approved format shall be submitted to KOC well in
advance, prior to carrying out cable testing.

14.5.3 The typical checklist provided in the Appendix - 1 of this RP shall be referred for guidance.

15.0 INSTALLATION OF CABLES

15.1 General

15.1.1 The cable installation shall be carried out in accordance with the KOC approved drawings
stamped as “Approved For Construction (AFC)”.

15.1.2 The KOC approved cable test report with insulation resistance values and core continuity
shall be available at worksite prior to the commencement of cable installation works.
Approvals obtained from external agencies such as MEWRE / KNPC / MPW /
PAI (Kuwait) / Kuwait Municipality etc. (as applicable) for road crossing / cuttings shall also
be made available at worksites.

15.1.3 All cables to be installed in KOC shall be new and the use of old and damaged cables are
not allowed.

15.1.4 It shall be ensured that the various clearances / factors already considered during cable
system design stage shall be followed, while installation of cables.

15.1.5 The cable drums shall be placed on suitable size drum stand using appropriate metal shaft
for cable pulling. Excessive pulling force shall not be exerted on the cable to avoid damages
to the cable.

15.1.6 While installation of new cables in the existing Operating Facilities, care shall be taken to
avoid keeping the cable drums inside the Operating Facilities.

15.1.7 Cable rollers shall be used for ease of cable pulling. Utmost care shall be exercised to avoid
excessive bending or twisting of cable which may result in bird caging of armour and / or
damage to core insulation, sheaths etc.
 DOC. NO. KOC-E-008 Page 28 of 43 REV. 5

15.1.8 While multiple cables are installed in parallel formations, care shall be taken to avoid
crossings or inter-twining of cables.

15.1.9 Where heavier / larger diameter cables are to be installed in long and straight routes, suitably
designed cable pulling equipment / winch as per the recommendations of Manufacturer shall
be used, with prior approval from KOC. The cable pulling equipment / winch shall have an
adjustable tensioning device with indicator and shall be operated by a trained operator.
While pulling the cable using power winches, cable sock or other devices approved by
KOC shall be fitted to the pulling end.

15.1.10 The bending radius recommended by the Manufacturer shall be maintained, where change
of direction (horizontally or vertically) occurs in the cable route.

15.1.11 Where cable is to be unwound from drum and coiled prior to installation, it shall be coiled in
Figure “8” formation (as large as practicable). The unwound cables shall be protected
against damage from vehicular traffic or by any other means.

15.1.12 Cables shall be run in continuous lengths and joints shall be avoided unless the route length
exceeds the maximum manufactured drum length. Where jointing of the cables is required,
it shall be as specified in the “Cable Installation Plan / Schedule” approved by KOC. Cable
joints shall not be carried out at cable bends or within three (3) metres from the cable bends,
unless otherwise approved by KOC.

15.1.13 During cable installation, it shall be ensured that minimum two (2) metres of extra length
cable loop is available after termination or jointing of cables. In the case of Substations /
buildings, the extra length cable loop shall be kept outside before the cable entry points to
Substations / buildings.

15.1.14 Cable cutting shall be carried out as per the recommendations of Manufacturer and care
shall be exercised to minimise wastages.

15.1.15 Cable ends shall be sealed with PVC tape or KOC approved caps as soon as the cable has
been cut, to protect from moisture.

15.1.16 Where cables are required to pass from a non-classified area to a classified area in
buildings, suitable cable transits shall be utilised to prevent the propagation of hazardous
gases etc.

15.1.17 Cable entry into the Blast Resistant Buildings shall be using suitably rated accessories,
approved by KOC, to prevent entry of blast waves, fire etc. For more details, KOC-C-030
“KOC Recommended Practice for Blast Resistant Design of Buildings” shall be referred.

15.1.18 While installation of cables in the duct banks, each cable shall be run through the duct as
indicated in the KOC approved drawings. The ducts shall be properly sealed after installation
of cables.

15.1.19 Cables shall be installed through the openings provided in the floor / ceiling, while passing
from inside to outside or one level to another in Substations, buildings etc. The cables laid
on cable trays / ladders shall be suitably tied to avoid movement / sagging.
 DOC. NO. KOC-E-008 Page 29 of 43 REV. 5

I 5 I 15.1.20 Such cables when surface from below ground or floors, shall be protected against damage
using permanently fixed galvanised steel pipe (fitted with insulated galvanised steel end
bushing) to a length of minimum 150 mm below and 150 mm above the ground / floor level.
These pipes shall have 60 % extra space after cabling.

15.1.21 Power cables shall be individually taken through separate protective pipes. The control
cables can be bunched together and installed in suitably sized protective pipes. The
protective pipe shall be positioned in such a way not to cause trip hazard to personnel.
These pipes shall be sealed with non-setting and non-flammable compound, approved by
KOC.

I 5 I 15.1.22 Where cable is coming from underground for connection to the equipment, (for ex.: motors,
push button control stations etc.), it shall be protected using suitably sized galvanised steel
pipe to a length of minimum 150 mm below and above the ground / grade level.

15.1.23 Motor feeder cables, which are susceptible to movement / vibration during operation shall
be properly supported to avoid the risk of damages to the cable termination.

15.1.24 After completion of installation and testing of all cables, cable entry holes / openings in
Substations, control rooms, buildings etc. used for cables to pass through floors and walls
shall be sealed to inhibit the propagation of fire using non-setting, non-flammable compound
approved by KOC.

15.1.25 Where cables are laid parallel to the roads, minimum distance of four (4) metres from road
kerb shall be provided, unless otherwise specified in the Project Documents.

15.1.26 Where open-cutting of road is required for installation of cable duct banks, it shall be carefully
planned to cause minimum inconvenience to traffic. Adequate danger signs, barriers and
warning lights shall be provided until the completion of road restoration after cable
installation. Necessary approvals from concerned authorities as mentioned in
Sub-Clause 14.4.2 of this RP shall be obtained, as applicable, prior to carrying out road
cutting.

15.1.27 For major road crossings such as Express Highways, trenchless crossing methods
(Horizontal Directional Drilling (HDD) / Thrust Boring) shall be opted with required approvals
from concerned authorities (KOC and other external agencies), as applicable.

15.1.28 Where trenchless crossing is used for crossing major roads, concrete encased UPVC ducts
of proper diameter shall be installed for cable laying, as specified in the Project Documents.

15.2 “Direct Buried” Installation of Cables

15.2.1 Cable trench excavation for “Direct Buried” installation of cables shall be carried out as per
approved cable route drawings complying with the requirements of HSE Procedure
“Excavation Safety Procedure” (KOC.SA.026).

15.2.2 Inside Operating Facilities, only manual excavation shall be carried out for the installation of
cables.
 DOC. NO. KOC-E-008 Page 30 of 43 REV. 5

15.2.3 Mechanical excavation using heavy machineries shall be considered for trenches in “Offsite
Cable Routes”, with prior approval from KOC.

15.2.4 Cable trenches shall be cut to the specified dimensions with firm sides and level base as
per KOC approved drawings. The excavated cable trenches shall be inspected and
approved by KOC prior to laying of cables.

15.2.5 The trench shall be filled using sifted sand, levelled and well-compacted upto a height of
100 mm for installing the cables.

15.2.6 The depth of underground cables for various voltage levels from the top of grade shall be
as follows:

Systems upto 1 kV : 0.75 metre (minimum)

Systems above 1 kV : One (1) metre (minimum)

Note: The depth of the cable shall be measured from firm ground level and not from top
of any temporary sand accumulations.

15.2.7 Unless otherwise specified in the Project Documents, number of cable layer in the trench
shall be limited to one (1). Where there is space constraints and specifically called for in
Project Documents, the number of cable layers in trench shall be increased to two (2).

15.2.8 For the protection of “Direct Buried” cables, Sulphate Resistant Cement (SRC) concrete
cable tiles with relevant information inscribed in English and Arabic shall be laid 100 mm
above the top layer of cables all along the route. The tiles shall cover the cable runs
overlapping 50 mm on both sides.

15.2.9 The backfilling of trenches shall be carried out in layers of 100 mm over the top layer of
cables and shall be firmly compacted. Cables shall be tested and the results approved by
KOC, prior to backfilling the cable trench.

15.2.10 Cable warning tape shall be provided at a depth of 300 mm from the surface level to identify
the cables running below. Additional cable warning tapes shall be provided where the trench
width is greater than one (1) metre to enable easy identification of cable route.

15.2.11 For backfilling the cable trench, sifted sand / good quality backfill material / excavated soil,
approved by KOC shall be used. In case the excavated soil is contaminated and not suitable
for backfilling, it shall be disposed-off as per the requirements of KOC.EV.008 “Waste
Handling Procedure”. For details of backfill materials, KOC-C-005 “KOC Standard for
Materials and Workmanship - Site Preparation and Earthworks” shall be referred.

15.2.12 The trench shall be backfilled to firm ground level. Adequate quantity of water shall be added
in order to make the density of the backfill material / soil correspond to the density of the soil
around. Suitable power rammers shall be used for compaction after backfilling over cable
tiles in safe areas, with prior approval from KOC.
 DOC. NO. KOC-E-008 Page 31 of 43 REV. 5

15.2.13 Wherever the roads are cut for cable installation, backfilling shall be carried out immediately
after completion of duct bank installation works and asphalting shall be reinstated after
proper compaction.

15.3 Cable Installation on Trays / Ladders

15.3.1 Cables of various voltage levels (HV / LV / Control cables) shall be installed in distinct cable
trays / ladders, unless otherwise specified in the Project Documents.

I 5 I 15.3.2 The cable tray / ladder shall be designed to take care of the current project requirements
and any known future requirements in the same area. In addition to this requirement, 15 %
space capacity shall be provided in cable trays / ladders, unless otherwise specified in the
Project Documents.

15.3.3 All cable trays / ladders installed in open areas shall be fitted with ventilated covers to
prevent overheating by direct sunlight. Cable trays / ladders installed in internal areas of
buildings shall be fitted with covers for protection of cables from damages due to falling
objects etc., unless otherwise specified in the Project Documents.

15.3.4 While installation of single core cables of a 3-phase circuits in trefoil formation on trays /
ladders, it shall be securely clamped together using suitable cable cleats approved by KOC
to withstand the mechanical force produced by a short-circuit fault. The spacing between
adjacent cable cleats shall be one (1) metre on straight runs and 500 mm on the bends,
unless otherwise recommended by the cable Manufacturer.

15.3.5 Cables, which leave main cable trays / ladders for connection to motors, motor control push
button stations, luminaires, earthing points etc., shall be properly supported upto the
equipment using suitable tray / steel supports approved by KOC.

15.3.6 While installation of cables on cable trays / ladders, suitable cable rollers shall be used to
avoid damages to the protective sheathing of cable.

15.3.7 Cables shall be securely tied to trays or ladders at intervals of 500 mm for horizontal runs
and 350 mm for vertical runs using suitable cable ties approved by KOC. Cable ties shall
comply with the requirements of IEC 62275.

15.3.8 For details of cable trays / ladders, Clause 16.0 of this RP shall be referred.

15.4 Cable Installation in Concrete Troughs / Trenches

15.4.1 Prior to installation of cables in the concrete cable troughs / trenches, the troughs / trenches
shall be filled with sifted sand upto a height of 75 mm (minimum).

15.4.2 Concrete cable troughs / trenches constructed inside the Operating Facilities shall be filled
with sand after installation & testing of cables and shall be covered with reinforced concrete
covers.

15.4.3 Concrete cable troughs / trenches constructed inside buildings shall be provided with
suitable cable trays / ladders fitted on sides for cable installation. For details of cable
installation on trays / ladders, Sub-Clause 15.3 of this RP shall be referred.
 DOC. NO. KOC-E-008 Page 32 of 43 REV. 5

15.4.4 For details of concrete troughs / trenches, Clause 17.0 of this RP shall be referred.

15.5 Cable Installation in Duct Banks

15.5.1 Where a number of cables pass under major roads / rig roads, bunds or enter buildings /
offices etc. the cables shall be installed in duct banks. In case the number of cables entering
buildings / offices, crossing roads etc. are less, concrete encased UPVC ducts shall be used
with prior approval from KOC, with a minimum of one (1) spare duct.

15.5.2 The UPVC ducts shall be cleaned by air blowing or with appropriately sized mandrels and
a galvanised steel draw-wire shall be inserted in each duct prior to cable pulling.

15.5.3 Care shall be taken to ensure that the outer sheath of the cable is not damaged while
installing cables in the ducts. Separate duct sections shall be used for different voltage
grades of cables.

I 5 I 15.5.4 The duct bank shall be designed to cater the current project requirements and any known
future requirements in the same area. In addition to this requirement, at each duct bank,
25 % spare ducts shall be provided with a minimum of two (2) spare ducts to avoid frequent
cutting of concrete pavement / road for installation of future cables. Each duct shall be filled
only upto 60 % of its cross sectional area.

15.5.5 Where electric cables cross pipeline / piping, instrument cables, communication cables etc.,
UPVC ducts shall be provided at the crossing locations and the crossing shall be carried out
horizontally as near to right angles as practicable.

15.5.6 Where cutting of the road is required for the installation of duct bank, procedures mentioned
in Sub-Clauses 15.1.26 and 15.1.27 of this RP shall be followed, prior to road cutting.

15.5.7 All duct ends, including spare ducts, shall be sealed with suitable sealant made of
non-setting, non-flammable compound approved by KOC after completion of cable testing.

15.5.8 For details of duct banks, Clause 18.0 of this RP shall be referred.

15.6 Cable Installation in Cable Tunnels

15.6.1 Where cables are to be installed inside cable tunnels, it shall be suitably supported on cable
trays / ladders. Cable trays / ladders shall be fitted on one side or both sides of the tunnel
depending on the walkway for installation of cables.

15.6.2 The cable installation on trays / ladders shall be carried out as per the methods specified in
Sub-Clause 15.3 of this RP.

15.6.3 The cable entry / exit points of the tunnel shall be protected against water ingress, using
non-setting and non-flammable sealing compound approved by KOC.

15.6.4 Care shall be taken not to accommodate any other Services such as oil, gas, water, steam,
chemical pipelines etc., inside cable tunnels.
 DOC. NO. KOC-E-008 Page 33 of 43 REV. 5

15.6.5 For specific details to be considered during the design / construction of cable tunnels,
Clause 19.0 of this RP shall be referred.

15.7 Specific Requirements for Installation of Mineral Insulated Cable

15.7.1 The installation, glanding, termination etc. of mineral insulated cable shall be carried out by
technicians who are trained and experienced in this field, in accordance with the
recommendations of the Manufacturer.

15.7.2 Mineral insulated cable shall be installed on trays or fixed to walls using cable cleats suitable
for the application.

15.7.3 Bending and fixing of mineral insulated cable shall be carried out using special tools and the
minimum bending radius shall be as per Manufacturer’s recommendations.

15.7.4 Extra length of mineral insulated cable shall be provided at each termination point in the
form of a loop to facilitate future re-glanding.

15.7.5 Joints in mineral insulated cable shall be avoided, unless the route lengths are in excess of
the maximum manufactured length. For jointing of mineral insulated cables, procedures
recommended by Manufacturer shall be followed.

15.7.6 Cable glands (Hexagonal type) and other accessories used shall be fully compatible with
the mineral insulated cable and provided by the same Manufacturer. The cable glands shall
be certified for use in the hazardous area classification of the installation area.

16.0 CABLE TRAYS / LADDERS

16.1 The Cable trays / ladders shall be suitably designed to cater the number of cables to be
installed. Cable trays / ladders shall be installed as per the KOC approved drawings.

16.2 Cable trays / ladders and their accessories shall be manufactured of heavy-duty iron / steel
in accordance with the requirements of IEC 61537. The cable trays / ladders shall be
minimum two (2) mm thick and hot-dip galvanised in accordance with the requirements of
ISO 1461.

16.3 For highly corrosive environments, the cable trays shall be made of deep galvanised
“Weathering Steel” or Type SA 316 grade stainless steel, unless otherwise specified in the
project document.

16.4 Cable trays / ladders shall be capable of supporting a point load of 90 kg at the centre of a
span without permanent deformation.

16.5 Where trays / ladders exceed 300 mm in width, the angle iron frame shall be reinforced by
bracing with steel straps at 450 mm centres. The protective finish of the additional bracing
shall be equal to that of main supports.

16.6 Cable trays / ladders shall be provided with side rails on both sides with adequate
arrangements for locking / fastening the trays / ladders together to make continuous lengths.
 DOC. NO. KOC-E-008 Page 34 of 43 REV. 5

16.7 Where the cable tray / ladder route is changing direction or dimension, standardised
prefabricated couplers, bends, tees, crosses, reducers / expanders and other accessories
shall be used, as applicable.

16.8 For cable installation below the raised floors in control rooms, buildings etc., cable trays /
ladders shall be installed in the void and supported from the floor.

16.9 Each tray / ladder length shall be bonded using suitable bonding jumper / earth cable with
adjacent tray / ladder to maintain electrical continuity throughout the cable route. The tray /
ladder route shall be connected to the main earth grid at minimum two (2) locations.

17.0 CONCRETE CABLE TROUGHS / TRENCHES

17.1 Concrete cable troughs / trenches shall be pre-fabricated or cast in-situ as per project
requirements. Reinforced concrete shall be used for the walls and base of cable troughs.
The depth of concrete troughs / trenches shall not exceed 750 mm, unless otherwise
specified in the Project Documents.

17.2 The trough / trench shall be suitably designed to have proper arrangement for holding the
cover, fitted with steel angle to reduce the chances of caving in of covers. The covers shall
be designed to prevent lateral movement and shall have lifting facilities. Reinforced concrete
covers shall be installed over troughs / trenches installed outside buildings and chequered
plate covers shall be used inside buildings.

17.3 The concrete covers for the cable troughs / trenches shall have adequate strength to
withstand the maximum anticipated direct loading by movement of persons or vehicles.

17.4 The concrete covers shall fit closely together and be effectively sealed with compound
approved by KOC to prevent the ingress of debris and vermin, as specified in the Project
Documents.

17.5 For details of concrete cable troughs / trenches, KOC-C-002 “KOC Recommended Practice
for Engineering Design Basis of Civil and Structural Work” shall be referred.

18.0 DUCT BANKS

18.1 Duct banks shall be embedded with UPVC ducts having 150 mm (minimum) diameter. All
duct banks shall be concrete encased (cast in-situ or pre-cast type) to a minimum thickness
of 75 mm.

18.2 All accessories used in duct banks such as bell mouth ends, joints etc. shall be approved
by KOC.

18.3 All ducts in the duct bank shall be temporarily sealed until cable laying, to prevent entry of
sand and water.

18.4 For details of concrete encased UPVC ducts, KOC-L-002 “KOC RP for the Protection of
KOC Services: Clearance Requirements for Buried Pipelines, Cables, Underground
Structures, Buildings and Housing Projects” shall be referred.
 DOC. NO. KOC-E-008 Page 35 of 43 REV. 5

19.0 CABLE TUNNELS

The following minimum requirements shall be considered, while design / construction of

cable tunnels:

a) Internal height of cable tunnel shall be 2000 mm (minimum) between the floor and
ceiling,

b) Walkway shall be provided in the middle or on any side,

c) Normal / emergency and exit lightings shall be installed,

d) Smoke / fire detection and alarms shall be installed,

e) Installation of fire protection system approved by KOC,

f) Ensure adequate ventilation arrangements and storm water removal system,

g) Remote monitoring of smoke / fire detection and alarms, ventilation and drainage
systems etc.,

h) Any other requirements as specified in Project Documents.

20.0 CABLE JOINTING WORKS

20.1 The cable jointing works shall be carried out by personnel trained & experienced in the field
and approved by KOC.

20.2 For jointing of cables, KOC approved cold-shrinkable / heat-shrinkable jointing kits shall be
used. The use of heat-shrinkable joint kits shall be limited to cable joints in safe areas outside
the Operating Facilities, with prior approval from KOC.

20.3 Cable jointing inside Operating Facilities shall be avoided, unless otherwise approved by
KOC. Where cables are to be jointed inside Operating Facilities, it shall be using
cold-shrinkable type jointing kit.

20.4 Prior to commencement of cable jointing works using heat-shrinkable sleeves, gas testing
shall be carried out to identify the presence of explosive / hazardous gas at the cable jointing
work location and ensure safe working conditions, in accordance with the requirements of
HSE Procedure “Permit to Work Procedure” (KOC.SA.004).

20.5 Adequate fire protection and precautions shall be taken prior to commencement of any hot
jointing works.

20.6 Cable jointing shall be carried out in clear weather conditions. In case the cable jointing is to
be carried out in adverse weather due to unavoidable reasons, prior approval from KOC
shall be taken. It shall be ensured that suitable measures are taken to protect the jointing
location from harsh weather (dust / rain etc.).
 DOC. NO. KOC-E-008 Page 36 of 43 REV. 5

20.7 While jointing of two (2) cables, it shall be ensured that both cables are of same voltage
rating, type, size and correct core identification is maintained.

20.8 In cases where cables of different types are to be jointed, appropriate jointing procedure as
recommended by the Manufacturer shall be adopted, with prior approval from KOC.

20.9 All cable conductors shall be fitted with a correctly sized compression type cable socket or
connectors, while jointing the conductors. Appropriate and precise compression tools shall
be used for crimping.

20.10 Lead sheaths of cables shall be plumbed and wire armouring clamped to joint
boxes with an adequately sized copper bonding conductor between clamps to ensure earth
continuity.

20.11 While carrying out jointing works on existing cables, it shall be ensured that cables are
isolated / disconnected from both supply and load circuits prior to carrying out the cable
jointing.

20.12 All cable joints shall be checked and approved by KOC Representative, prior to applying
insulation over the joints.

21.0 CABLE TERMINATION WORKS

21.1 The cable termination works shall be carried out by trained and experience personnel,
approved by KOC.

21.2 For cable terminations, suitable cable glands / termination kits approved by KOC shall be
used.

21.3 The cable glands shall have earth tag for providing earthing connection between equipment
and cable through bonding conductor.

21.4 Tinned-copper lugs shall be crimped to conductor for connection to the equipment.
Appropriate and precise compression tools shall be used for crimping the lugs to the cable
core.

21.5 It shall be ensured that the ingress protection of cable glands shall have the same degree
of protection as that of the equipment enclosure.

21.6 The cable glands to be used for hazardous area certified equipment shall be Ex’d’ certified,
irrespective of its use in Hazardous Zones 1 or 2.

21.7 For termination of single core power cables, non-magnetic gland plate of suitable thickness
to bear the load of cables shall be used.

21.8 The cables shall be suitably supported so that the weight of the cable do not strain the cable
gland or equipment. Cable shall not be left unsupported for more than 500 mm at termination
points.
 DOC. NO. KOC-E-008 Page 37 of 43 REV. 5

21.9 Cable termination and connection to the equipment shall be carried out to permit freedom
of its movement under all operating conditions, during maintenance / replacement works
without exerting undue stress on the cable and / or cable terminations.

21.10 Where 11 kV cables are connected to overhead lines, heat-shrinkable cable termination kits
suitable for the environment shall be used. Where core crossing is unavoidable, a minimum
clearance of 10 mm shall be provided between cores.

21.11 The metallic armour and sheath of cables shall be earthed at two (2) separate points, at
supply end and load end, as specified in KOC-E-024 “KOC Recommended Practice for
Earthing and Bonding”.

21.12 All cable terminations shall be checked and approved by KOC prior to energisation.

21.13 Control cables with multi-stranded conductors shall be terminated using pin-ended, crimped
lugs.

21.14 The spare cable entry holes, if any, in hazardous area certified equipment shall be sealed
using appropriate type of plugs or blanking elements that maintain the same degree of
protection of the equipment.

21.15 For details of cable glands for electrical installations, IEC 62444 shall be referred. For more
details on hazardous area certified glands, IEC 60079 (relevant parts) shall be referred.

22.0 TESTING OF CABLES

22.1 General

All cables shall be tested at site after installation of cables and the test reports shall be
submitted to KOC for review. The cable test reports shall be approved by KOC, prior to
connection of the cable to electrical equipment.

22.2 Safety Requirements during Cable Testing

22.2.1 Necessary precautions shall be taken to ensure the safety of personnel involved, prior to
commencement of testing of electric cables.

22.2.2 All personnel involved in testing of electric cables shall thoroughly familiarise themselves
with applicable electrical safety procedure. Appropriate PPEs shall be used by the personnel
engaged in testing works.

22.2.3 The area, where electric cable is under testing, shall be cordoned-off using warning tape, to
prevent entry of unauthorised personnel.

22.2.4 While testing the cables inside Operating Facilities, gas test shall be carried out to ensure
electrically safe working conditions.

22.2.5 Testing of electric cables in hazardous area shall not be permitted to avoid safety hazards.
 DOC. NO. KOC-E-008 Page 38 of 43 REV. 5

22.3 Insulation Resistance Testing of Cables

22.3.1 Insulation Resistance (IR) value of each “power cable” shall be measured using suitable
insulation resistance tester before energisation (with neutral-ground disconnected) as
follows:

a) Line to Line,

b) Line(s) to neutral,

c) Line(s) to Earth,

d) Neutral to Earth.

22.3.2 While measuring IR values of feeder cables, care shall be taken to ensure the following
conditions:

a) Feeder cable shall be tested keeping its load disconnected with circuit breakers open
at both ends,

b) Lighting feeders shall be tested with feeder breaker open and isolation switch for
lighting distribution panel disconnected.

22.3.3 IR values of all cores of “control cable” shall be measured between core to core and core to
armour (as applicable).

22.4 High Voltage Testing of Electric Cables

22.4.1 The cables to be subjected to high voltage testing shall be isolated / disconnected from
supply end and load end prior to carrying out the testing.

22.4.2 High Voltage DC (HVDC) tests shall be carried out between each phase and earth with the
remaining phases connected to earth. The HVDC tests shall be performed under the
following conditions:

a) Cables shall have been installed in its final position,

b) Cable preparation for terminations have been completed but not terminated to the
equipment so that the equipment is not subjected to the test voltage.

22.4.3 The test voltage shall be gradually applied to minimise harmful surge currents on the cable.
IEC 60502-2 shall be referred for various test voltage levels of cables.

22.4.4 Where HV tests carried out at Manufacturer’s Facilities are repeated at site, it shall be
performed at 80 % of the test voltage, unless otherwise specified / approved by KOC.
 DOC. NO. KOC-E-008 Page 39 of 43 REV. 5

22.5 Testing of Optical Fibre Cables

For details of OFC testing, KOC-T-008 “KOC Recommended Practice for Installation of
Optical Fibre Cable” shall be referred.

23.0 IDENTIFICATION TAGS AND ROUTE / JOINT MARKERS

23.1 Identification Tags

23.1.1 All cables shall be fitted with a permanent identification tags in accordance with the KOC
approved tagging methodology. The identification tags shall be inscribed with details of
Cable Number, Cable Route, Power Source & Connected Equipment, Project Name &
Number etc. as specified in the cable schedule approved by KOC.

23.1.2 Cable identification tags shall be using non-corrodible materials approved by KOC. The
identification tags shall be fitted to the cables at both ends, adjacent to each jointing and
termination, at all points where they enter or leave ducts and buildings, at all changes of
direction and at intervals of not more than 30 metres.

23.1.3 Each core of control cable shall be identified with suitable plastic type ferrules, in accordance
with the approved wiring diagram.

23.2 Cable Route / Joint Markers

23.2.1 For “Offsite Cable Routes”, cable route marker posts inscribed in English and Arabic shall
be installed along the cable trenches to identify the cable routes.

23.2.2 Inside the Operating Facilities, where vertical posts would cause interference to human /
vehicle movement, concrete route markers with engraved stainless steel plate shall be
installed at grade level directly over the centre line of the trench.

23.2.3 The route markers shall be installed at intervals of 30 metres along the entire cable route,
at all points where they enter or leave ducts / buildings, at all changes of direction etc., unless
otherwise specified in the Project Documents.

23.2.4 All cable joints shall be provided with suitable “Cable Joint Markers” for the identification of
joints.

24.0 QUALITY ASSURANCE

24.1 The Contractor shall operate a quality system to ensure that the requirements of this
Recommended Practice are achieved. The quality system shall be preferably based on
ISO 9000 Series of Standards, certified by internationally reputed inspection agencies.

24.2 Verification of the Contractor’s quality system is normally part of the pre-qualification
procedure and therefore not detailed in this Recommended Practice.

24.3 For details of quality requirements, KOC-Q-014 “KOC Standard for Project QA / QC General
Requirements” shall be referred.
 DOC. NO. KOC-E-008 Page 40 of 43 REV. 5

25.0 DOCUMENTATION

25.1 General

25.1.1 All correspondences, drawings, instructions, data sheets, design calculations or any other
written information shall be in English language. In the case of dual languages, one (1)
language shall be English.

25.1.2 All dimensions, units of measurements, physical constants etc. shall be in SI units.

25.1.3 In addition to the hard copies, electronic files of all documents (texts, specifications,
datasheets, drawings etc.) shall be provided in software (MS Word, Excel, Auto-CAD etc.)
approved by KOC. Design calculations shall be submitted in the approved and widely used
software, agreed by KOC.

25.2 Cable System Design Details

The cable sizing / system design along with calculations, carried out based on the
requirements of this RP, shall be submitted to KOC for review and approval.

25.3 Drawings

25.3.1 All drawings shall comply with the requirements of KOC-EG-DO-C-001 “KOC Engineering
Drawing Practice Code”. The drawings shall be in Auto-CAD format.

25.3.2 For the details of drawings to be submitted prior to commencement of cable installation,
Sub-Clause 14.2 of this RP shall be referred.

25.3.3 After installation and testing of cables, "As-Built” drawings shall be prepared and submitted
to KOC for review and approval. The "As-Built” drawings shall be marked with actual
installed details, which shall include but not limited to the following:

a) Exact location / placement of cables (GPS coordinates for offsite cable routes),

b) “Offsite Cable Routes / Corridor” indicating reserved space for future use,

c) Dimensions and locations of cable trays / ladders, trench, concrete troughs, cable
tunnels etc. including spare capacities,

d) Duty, voltage, size, number of cores, type, length between terminations etc. of each
cable installed,

e) Cable route details showing cable identification number, type of installation, depth of
buried cables, clearance between adjacent cables / Services, locations of route / joint
markers etc.,

f) Glanding and termination details,

g) Earthing details of cable trays / ladders etc.,

 DOC. NO. KOC-E-008 Page 41 of 43 REV. 5

h) Any other details as specified in Project Documents.

25.4 Cable Installation Records

A copy of the “As-Built” drawings / cable installation details including Factory Acceptance
Test (FAT) and Site Acceptance Test (SAT) Reports shall be kept for future reference.
 DOC. NO. KOC-E-008 Page 42 of 43 REV. 5

26.0 APPENDIX - 1: CHECKLIST FOR INSPECTION AND TESTING OF ELECTRIC CABLE

(TYPICAL)
Project Title: Project Number:
Cable Identification No.: Cable Drum No.:
Cable Drum Length: Manufacturer:
Type of Cable: Rated Voltage:
No. of cores: Core Colour Coding:
Cable Route - From: Cable Route - To:
Reference KOC Standard KOC-E-008 Reference International Standard
Sl. Check
Checklist Description Remarks
No. Mark
I Pre-Installation Checks
1 Check the nameplate details fixed on the Cable Drum and details embossed on the Cable.
2 Check for damage of drum and subsequent damage of cable.
3 Check that cables ends are capped and sealed.
4 Check the Insulation Resistance and continuity of the cable while on drum.
II Underground Cables: Post-Installation Checks Prior to Back Filling
1 Verify the compliance of cable route with cable schedule as per KOC approved drawings.
Check whether all cables are fitted with identification tags at each end & at intervals of
2
30 Meters.
3 Verify the installation of Single Core Cables in trefoil formation using approved cable cleats.
4 Check whether Cable Protection Tiles, Warning Tape and Route Markers / Joint Markers are installed.
5 Check the clearance between adjacent electric cables / other Services.
Check the availability of spare ducts in duct banks and space in the ducts in which cable is installed.
6
Also, check whether all ducts including spare ducts are sealed.
7 Check the Insulation Resistance of the cable after installation.
III Aboveground Cables: Post-Installation Checks of Cables Installed on Trays / Ladders
1 Check the clearances between cables and availability of spare capacity in cables trays.
2 Verify the installation of Single Core Cables in trefoil formation using approved cable cleats.
3 Check the cables are tied with cable trays using appropriate type of cable ties.
4 Check whether the open area cable trays are fitted with suitable tray covers (as applicable).
5 Check the vertical runs of cables are properly supported.
6 Check the sealing of cable entry points in Substations and buildings.
7 Check the Insulation Resistance of the cable after installation.
IV Checks after Cable Joints
1 Check whether minimum two (2) metres of cable loop is provided at the cable jointing points.
2 Check the Insulation Resistance and continuity of the cable after jointing.
V Commissioning Checks / Tests of Cables
1 Check the Insulation Resistance and continuity of the cable prior to connecting to equipment.
2 Check the tightness of the cable lugs.
3 Check the suitability of gland plate for single core cable.
4 Check the suitability of cable glands to the area classification.
5 Check the earthing connections of glands.
6 Perform HVDC test on the cable prior to final connection to the equipment.
7 Check for correct matching of phase sequences of cable and connected equipment.
REMARKS:

Tested by (Manufacturer / Vendor / Contractor

Witnessed by (KOC / PMC Representative)
Representative)
NAME:
DESIGNATION:
SIGNATURE:
DATE:
 DOC. NO. KOC-E-008 Page 43 of 43 REV. 5

ACKNOWLEDGEMENT I5I

The draft of this document “KOC Recommended Practice for Selection and Installation of Electric
Cables” (KOC-E-008, Rev. 5) has been circulated to nominated discipline Focal Point Engineers from
various KOC User Teams for their review & comments and the responses received were suitably
resolved and incorporated into the document.

The Team Leader Standards (Chairman - ESTC S-C Technical) would like to thank the nominated
discipline Focal Point Engineers and ESTC S-C (Technical) Members for providing Technical Inputs
and Valuable Comments for the successful revision of this document.