01_140R3024R0025_Description_Specifications_Section_26_05_20_-_Conductors_and_Cables_0003.pdf

Hoover Dam Powerplant

Station Service Replacement

Boulder Canyon Project, Arizona, Nevada Solicitation No. 140R3024R0025

Conductors and Cables

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SECTION 26 05 20

CONDUCTORS AND CABLES

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Conductors and Cables:

1. Measurement: Length of installed permanent conductor or cable.

2. Payment: Linear foot prices offered in Price Schedules A and B for applicable conductor and cable size.

a. Items in Price Schedule A include cost of work, testing, and materials for permanent conductors and cables except as specified.

b. Does not include conductors and splices required for temporary power.

c. Items in Price Schedule B include conductor removal, replacement, and post installation testing based on switchgear DSA, DSB, DSC, DSD, and DSN conductor testing.

B. Cable Testing:

1. Payment: Lump sum price offered in Price Schedule A.

2. Includes:

a. Testing of existing cables at switchgear DSA, DSB, DSC, DSD, and DSN.

1.02 REFERENCE STANDARDS

A. ASTM International (ASTM)

1. ASTM B8-11(2017) Concentric-Lay-Stranded Copper

Conductors, Hard, Medium-Hard, or Soft

B. National Electrical Manufacturers Association (NEMA)

1. NEMA WC 57-2021 Standard for Control, Thermocouple

Extension, and Instrumentation Cables

2. NEMA WC 70-2021 Nonshielded Power Cables Rated 2000V or

Less for the Distribution of Electrical

Energy

C. National Fire Protection Association (NFPA)

1. NFPA 70-2023 National Electrical Code (NEC)

D. Underwriters Laboratories, Inc. (UL)

1. UL 486B-2018 Wire Connector

I I

Boulder Canyon Project, Arizona, Nevada Solicitation No. 140R3024R0025

Conductors and Cables

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1.03 DESIGN REQUIREMENTS

A. Determine conductor sizes, except where shown or specified, in accordance with

NFPA 70. In the event of conflict between design requirements and NFPA 70, the more stringent requirement applies.

B. Determine quantity and type of 600-volt conductors to be replaced for each secondary unit substation based on:

1. Equipment layout.

2. New conductor lengths.

1.04 SUBMITTALS

A. Submit the following in accordance with Section 01 33 00 - Submittals and

Section 01 33 26 - Electrical Drawings and Data.

B. RSN 26 05 20-1, Approval Data:

1. Manufacturer’s data.

C. RSN 26 05 20-2, Field Test Reports.

1.05 DEFINITIONS

A. Cable: Cable, cables, wire, or wires of one or more insulated conductors.

B. Power Cable: For power loads including receptacle outlets; motors; alternating- and direct-current distribution circuits; heating, ventilating, and air-conditioning and lighting circuits; and cable that is used for controlling heating, ventilating, air-conditioning, and lighting equipment.

C. Multiconductor Control Cable: For control, metering, indication, annunciation, and relaying circuits; and circuits not identified as power circuits.

D. Instrumentation Cable: For RTD and transducer output circuits.

E. Telemetry Cable: For supervisory computer control, voice communication, and logic level signals.

1.06 PROJECT CONDITIONS

A. Locations of existing cables indicated on drawings are approximate.

B. Replace failed test conductors from switchgears DSA, DSB, DSC, DSD, and DSN upon completion of testing.

C. Conductor distances listed in Price Schedule B are estimated based on a 30 percent failed cable rate.I

Boulder Canyon Project, Arizona, Nevada Solicitation No. 140R3024R0025

Conductors and Cables

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PART 2 PRODUCTS

2.01 CABLE, GENERAL

A. Manufactured no more than 24 months prior to Notice to Proceed.

B. Round, except for 2-conductor cable with parallel conductors.

C. Conductors:

1. Copper in accordance with ASTM 8, class B or C.

2. Stranded conductors.

D. AWG or kcmil designation.

E. Coverings or insulation: Suitable for installation in vertical position without injury to covering or deformation of insulation when supported in accordance with NFPA 70.

2.02 PHASE IDENTIFICATION

A. Power Cable Phase Conductors and Building Premises Wire:

1. 120/240, single-phase: Black.

2. 120/208- or 240-volt. 3-phase: Black, red, blue. Colored phase tape may be used in lieu of colored insulation.

3. 277/480-volt, 3-phase: Black with brown, orange, yellow phase tape.

B. Neutral (Grounded) Conductors: In accordance with NFPA 70.

C. Equipment Grounding Conductors:

1. 6 AWG and smaller: Green insulation.

2. Larger than 6 AWG: Green tape at both ends and visible points including junction boxes.

2.03 COLOR CODING

A. Control and Instrumentation Cable:

1. Colored insulation or jacket compound. Do not apply color coatings to insulation or jacket surface.

2. In accordance with NEMA WC 57, Table E-2.

B. Telemetry Cable: In accordance with 7 CFR 1755.390.

2.04 POWER CABLE AND MULTICONDUCTOR CONTROL CABLE

A. 600-volt rated insulation unless specified otherwise.

Boulder Canyon Project, Arizona, Nevada Solicitation No. 140R3024R0025

Conductors and Cables

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B. Type:

1. Single-conductor or multi-conductor, non-shielded type.

2. Labeled type TC when installed in cable tray.

C. Suitable For:

1. Installation in raceways.

2. Installation in cable trays when required by specifications.

D. Insulation Type:

1. Single-conductor cable: XHHW-2.

2. Multi-conductor cable: XHHW-2 for 14, 12, 10 AWG. TFFN or TFN for 18 and

16 AWG.

E. Multiconductor Overall Jacket:

1. Type: PVC (Polyvinyl chloride) or better, flame-retardant.

2. Jacket thickness:

a. 14 AWG conductors: 45 mils for 9 conductor or less. 60 mils for greater than 9 conductor.

F. Single-conductor power cable in accordance with NEMA WC 70. Multiconductor cable in accordance with NEMA WC 57. Cable UL listed and labeled.

G. Provide multi-conductor power cable with integral ground conductor. Size ground conductor in accordance with NEMA WC 70.

H. Shielding: Conform to NEMA WC 57.

2.05 ETHERNET CABLE

A. Conform to EIA 568C.1, Category 5e type.

B. Conductor Material: Copper.

C. Conductor Size: No. 24 AWG, 4 twisted pair.

D. Insulation on Individual Conductors:

1. Type: Polyolefin.

2. Color: Conform to NEMA WC57, Table E-2.

E. Shielding:

1. Aluminum Foil-Polyester Tape: 100 percent coverage.

2. Conform to NEMA WC57.

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F. Overall Flame-Retardant Covering (Jacket): Plenum rated.

2.06 ACCESSORIES

A. Single Conductor Markers:

1. Type: machine printable sleeve.

2. Color: White with black text.

3. Text size: As large as practical but at least 7 point (0.06-inch).

4. Be 1-inch in length, minimum, and have diameter suitable for installation on the intended conductor.

B. Cable Tags:

1. Type: Non-conductive, heat resistant, non-corroding similar to R&R

Identification Co. “Engraved valve tags” or Brady “Valve tags”.

2. Minimum 2-ply laminate, engraveable.

3. Round shape with attachment hole suitable for tie wraps or similar.

4. Type: Cross-laminated polyethylene film or Nomex®. Be resistant to water, oil, solvent, abrasion, and tearing.

5. Color: White with black text.

6. Text size: As large as practical but at least 16 point (0.16-inch).

C. Terminal Connectors For Control, Instrumentation, and Telemetry Cable:

1. Heavy-duty, nylon insulated sleeve, pressure-crimp-type with ring tongues.

2. Tin-plated copper.

3. Serrated inner barrel.

4. UL listed.

5. Compatible with conductor size and type of cable for which it is used.

PART 3 EXECUTION

3.01 INSTALLATION

A. When using cable ties, do not over tighten, to ensure tie does not cut conductor insulation or cable outer jacket. Do not use cable ties to support cables.

B. Block cable opening in sleeves under equipment or passing through blockouts, with silicone-foam, fire-retardant type material.

C. Use building premises wire for lighting circuits and 120-volt receptacles unless shown otherwise.

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D. Cable Splicing:

1. Do not splice control, instrumentation, or telemetry cables.

2. Power cable slices only allowed in approved splice enclosure or pull boxes.

E. Cable Installed in Raceways:

1. Do not pull cable into conduit until they have been cleaned and are free from obstructions and sharp corners.

2. Draw a clean, dry, tight-fitting rag through conduit immediately before installing cable.

3. Install cable using gradual and uniform pulling stresses. Do not exceed allowable pulling tensions and sidewall pressures as recommended by cable manufacturer.

4. Install cable to prevent cuts or abrasions in insulation or protective covering and kinks in cable.

5. When a lubricant is needed as an aid to pulling, use only soapstone or other suitable lubricant that is not injurious to cable insulation.

6. When mechanical cable pulling equipment is used, use a tension meter release mechanism to ensure pulling tension remains below tensile strength of the cable.

7. Remove and replace any cable damaged during installation.

8. Where conductors carrying alternating current are installed in ferrous metal enclosures or metal raceways, arrange to avoid heating surrounding ferrous metal by induction. Group phase conductors together.

F. Cable Installed in Vertical or Inclined Plane:

1. Install in locations shown. If not shown, install in accordance with NFPA 70.

2. Support with cable grips leaving slack spans between supports.

3. Clamp cable entering enclosures, junction boxes, or equipment with commercial cable clamps.

G. Grounding:

1. Provide one nonactive conductor grounded at both ends in each Multiconductor control cable.

2. Ground shielding of each shielded control cable on both ends directly to equipment ground bus by method indicated on Standard Drawing 40-D-4335, Figure 8.

3. Ground shielding of instrumentation and telemetry cable only to source equipment ground bus using pressure crimp type connectors with ring tongues on drain wire.

4. Ground spare conductors by wire jumpers from equipment terminal block points to equipment ground bus.

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H. Wiring Methods:

1. Terminate control, instrumentation, and telemetry cable with terminal connectors.

a. Make terminations with electric, hydraulic, or ratcheted type pressure crimper. Use of plier crimpers is not allowed.

2. At termination point of multiconductor cable, form conductors into neat packs and tie conductors with self-locking cable ties.

3. Do not combine alternating- and direct-current circuits, or current and potential transformer circuits in same multiconductor cable.

4. Clamp cable entering equipment with commercial type cable clamps.

5. Leave sufficient length cable ends to make connections conveniently to equipment, fixtures, and devices.

6. Provide 5-conductor cable for each three-phase current and each potential transformer circuit.

7. Retain sufficient length of conductors in a current transformer cable length to reach farthest terminal used to select current transformer ratios.

8. Retain spare single conductors at each end of a multiconductor cable in a length equal to longest single conductor of multiconductor cable.

9. Terminate spare conductors of multi-conductor cable at terminal blocks. Ground spare conductors by using wire jumpers between terminations and equipment ground bus.

10. Run both positive and negative leads of a direct-current circuit in same cable.

3.02 CABLE AND CONDUCTOR IDENTIFICATION

A. Power Cable:

1. Identify power conductors that are service conductors, panelboard and switchboard feeders, motor control center feeders, and motor power conductors with colored insulation or colored phase tape in accordance with this section. An additional conductor marker is not required.

2. Provide a single-line marker on the load end of feeder and branch-circuit conductors that originate at panelboards, switchboards, and motor control centers.

The marker to include designation of source equipment and circuit number.

B. Conductor Markers:

1. Text to be machine or computer generated. Hand written text is not acceptable.

2. Provide individual conductors of multiconductor control cable, instrumentation cable, and telemetry cable with conductor marker. Print conductor designation, as shown on approved schematic diagram, on first line. Print conductor destination and device terminal number on second line.

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3. A single line conductor marker will be acceptable provided the conductor designation is enclosed in parenthesis followed by the conductor destination.

4. Do not heat shrink marker onto conductor. Allow marker to rotate about the conductor.

5. Provide markers for spare conductors of multi-conductor cables. The marker to include cable designation and the word “SPARE”. Numerically sequence the spare conductor markers e.g. (1CSA-CSB-SPARE1, 2CSA-CSB-SPARE2, etc.).

C. Cable Tags:

1. Print tags with cable designations as shown on approved wiring and interconnection diagrams. Cable designation to be a single-line of text that includes cable number, originating equipment designation, and destination equipment designation. Develop cable designations when not shown. Examples of cable designations are:

a. 1MCA-DV1 – First cable from motor control center MCA to discharge valve No. 1).

b. 3MCB-ACP – Third cable from motor control center MCB to auxiliary control panel ACP.

c. Note, if the second part of the cable designation (destination equipment) would not fit on the tag, it can be eliminated for the tag marking.

2. Securely attach cable tags to multi-conductor cables near ends and single-conductor power cables, as directed. Attach to cable with standard nylon self-locking tie wraps or cable ties. Use two wraps, one firmly around cable, second used to attach tag to tie wrap on cable so tag can dangle freely. Pull tag tie wrap so that loop is approximately 1/2-inch in diameter.

3.03 CONTRACTOR FIELD QUALITY TESTING

A. Perform the following tests on existing cables at switchgear DSA, DSB, DSC, DSD, and

DSN during interruption of service window prior to connection to temporary equipment and switchgear replacement. If cable test fails, notify COR. Submit test report to

Government. After each cable test is performed, Government will decide if Contractor will be responsible for replacement of cable.

B. Perform testing of new cables after installation, but before connection to equipment.

C. Test cables in large groups to minimize number of testing sessions.

D. Notify COR, in writing, of date, time, and cables to be tested at least 5 working days before testing. Testing dates to be mutually agreeable between Contractor and COR.

E. Perform following tests:

1. Continuity Test: Test continuity of each conductor prior to performing insulation resistance test.

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2. Insulation Resistance Tests for Power, Control, and Instrumentation Cables:

a. Measure insulation resistance between each conductor and station ground with all other conductors in same cable or conduit grounded.

b. Test voltage: 1,000 volts direct-current, minimum.

c. Minimum acceptable insulation resistance: R in MΩ = (rated voltage in kV + 1) x 1000/length in ft.

3. Record following test data on test report for each conductor tested:

a. Date of test.

b. Name or names of Contractor's personnel who performed test.

c. Name of Government inspector who witnessed test.

d. Conductor identification.

e. Megohms between conductor and ground.

f. Total length of conductor.

F. If any new conductor fails continuity or insulation resistance testing, remove and replace cable and conductor.

END OF SECTION

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