WIRING METHODS AND MATERIALS

Summary of SAES-P-104

MOHAMMED AFZAL ASIF

CONTRACTING AND TRADING COMPANY “C.A.T.”

JANUARY 21, 2020
This standard prescribes mandatory requirements for the design and installation of insulated power and control wiring (between electrical control and
monitoring devices) cable systems and minimum mandatory requirements for their outdoor enclosure. Please note, it doesn’t apply to internal wiring of
equipment and overhead distribution systems. In case of any conflict with this standard SAES-P-104 shall take precedence or should be addressed to the
EK&RD Coordinator.

For this standard only, Outdoor corresponds to wet or damp locations

Indoor corresponds to dry locations unless it contradicts with NEC

WIRE AND CABLE:

 Copper (preferred) or Aluminium (only in community areas for sizes 25mm2 or larger) conductors.
 Each power circuit should be grounded as mandated in SAES-P-111.

POWER AND CONTROL CABLES

Low Voltage Medium Voltage High Voltage
Jacketed Unjacketed
15-SAMSS-502 or 15-SAMSS- AEIC CS6 or CS9 or 15-
IEC 60227 or
Comply With NEC IEC 60502-1 NEC 503 (in case of submarine SAMSS-504 (in case of
SASO 55
power cables) submarine power cables)
Voltage Rating 600V 600/1000V 600V 450/750V 5kV through 35kV 69kV and above
Minimum Temp. 90°C (dry) / 90°C (dry) /
85°C 85°C
Rating 75°C (wet) 75°C (wet)
Flame test of Flame test of
Conform to UL Standards UL Standards
IEC 60332-3 IEC 60332-1
Suitable to use in Class 1, Division 2 and Zone 2 Class 1, Division 2 and Zone 2
Shall not be used in cable trays
Specific
duct banks involving manholes,
Requirement
or direct burial applications.
 Minimum Size: Maximum Size:
Conductors rated below 69 kV shall be 500 mm² or 1,000 kcmils.

Size of
Conductors

 Individual control wires shall be identified by two labels at each end. One to identify the connected terminal and the other to
identify the terminal on the opposite end.
 Individual phases shall be color-coded (as per SASO) or marked by other means like A, B and C, Neutral conductor should be
Identification
white/grey and grounding conductor should be green with yellow stripes.
 Wrap-around, rigid snap-on, or adhesive type markers are not permitted for wire or cable identification.
 Voltage stress relief shall be provided at terminations of cables with insulation shields.

 Tinned copper compression (crimped) type connectors shall be used.

 (a) For lighting and receptacle circuits in non-hazardous locations, and (b) in non-industrial applications spring pressure type
twist-on connectors, and pressure set screw connectors with insulating caps are permitted.
 If a different type of connector is an integral part of an equipment then it is permitted.
Connections and  Insulated ring tongue, locking fork tongue, flanged fork tongue and pin type compression (crimped) terminals shall be used for
Terminations control wiring.
 Compression terminal connectors for 4/0 and larger conductors shall be two hole design.
 All compression connectors for 8 AWG and larger conductors shall have a manufacturer's reference compression die number and
conductor size printed or stamped on the connector.
 Cable glands shall be designed to permit disconnection without the need to rotate the cable or the equipment on which the
gland is terminating.
  There are no minimum separation requirements between power and/or control conductors for DC or AC circuit voltages
less than 1,000 V, provided the insulation is rated at least 600 V or 450/750 V.
 Minimum separation (above or below ground) between a power cable operating at 1000 V or above, up to 34.5 kV, and
Cable a parallel or crossing power or control cable operating at less than 1,000 V, shall be 300 mm.
Separation  Redundant feeders, direct buried or in direct buried conduits, supplying industrial loads or other loads that are critical in
accordance with SAES-P-100, shall be separated by a minimum distance of 1.8 meters.
 Minimum separation (above or below ground) between any cable operating at above 34.5 kV, and cables operating at or
below 34.5 kV, shall be 1 m.
 Power and control conductors shall be stranded in accordance with ASTM B8 Class B or C, or ASTM B496, or IEC 60228 Class 2
 Splicing of conductors shall be kept to a minimum. In case of accidental damage, one additional splice than the maximum is
permitted.
 Armored cable shall be used for underground installations. Un-armored type cables shall be used for cable tray (TC type) and
conduit systems installations.
 Cables for security lighting (perimeter and area lighting) shall be armored or metal clad, installed underground, and rising inside
General the lighting poles.
Specifications  Metal clad cable and armored cable shall be permitted to be installed and exposed where it is not subject to damage by
vehicular traffic or similar hazards but that exposed section shall be supported at intervals not exceeding 1.8 meters. Other types
of cable shall not be installed or exposed above ground, and shall be installed in cable trays, conduit, or where flexibility is
required in flexible conduit.
 Conductors of multi-conductor control cables shall be numbered or color-coded by colors other than green, green with yellow
stripes, white or grey.
 Fireproofing of cables shall be in accordance with SAES-B-006 (onshore facilities) or SAES-B-009 (offshore facilities).
 ENCLOSURES
For plant areas/process Shall be (a) NEMA 250/NEMA ICS 6 Type 4 or (b) NEMA Type 3 manufactured copper free cast aluminium (0.4 of 1%
unit outdoor maximum), or plastic (including fiberglass); or (c) IEC 60529 Type IP54 or better.
Shall be (a) NEMA Type 4X (except galvanized and/or painted or coated carbon steel sheet metal enclosures are not
For severe corrosive permitted); or (b) NEMA Type 3 or 4, manufactured of copper free cast aluminium (0.4 of 1% copper maximum), or
environments outdoor plastic (including fiberglass); or (c) IEC 60529 Type IP54 or better, manufactured of stainless steel (Type 304 or better),
copper free cast aluminium, or plastic (including fiberglass).
For dry-type
NEMA Type 3R
transformers outdoor
CONDUITS
Underground Exposed Outdoor Exposed in severe corrosive environment
 Directly buried conduit shall be
PVC Type DB-120 or EPC-40.
Shall be threaded and hot-dip Shall be threaded, hot-dip galvanized and factory PVC
Types Used  Concrete encased conduit shall
galvanized. coated (min 1mm thick)
be PVC Type EB-35 or DB-120 or
EPC-40.
Shall be cast or forged steel, Same as normal outdoor fittings but in addition, shall
Similar to fittings of conduits cast iron or malleable iron, be protected by (a) Factory-coating with PVC or (b)
Conduit Fittings exposed in severe corrosive either hot-dip galvanized Field-coating prior to installation in accordance with
environment. (preferably), or zinc SAES-H-001 APCS-22 (offshore), or APCS-26 (onshore)
electroplated or (c) Heat-shrinkable tubes or wrap-around.
Similar to normal support but in addition, shall be
Shall be made of steel or iron, either hot-dip galvanized (preferably),
Supports protected by (a) means used to protect other fittings
or zinc electroplated
or (b) stainless steel or (c) fiberglass.
Size of conduits Minimum ¾ inch. For instrumentation wiring, prefabricated skids, and in non-industrial areas it shall be ½ inch.
 CABLE TRAYS
Indoor Outdoor
Copper-free aluminium or galvanized steel carbon (in
Copper-free aluminium (in accordance with NEMA VE 1 and
Material Used accordance with NEMA VE 1 and VE 2) or fiberglass (in
VE 2) or fiberglass (in accordance with NEMA FG 1).
accordance with NEMA FG 1).
Type Used Ladder (two side-rail) type
Rung Load Capacity Minimum individual rung load capacity = 90kgs
Working load = weight of cables + future addition (if required) + concentrated static load of 90 kg at the centre of the span. It
Maximum Working
shall not exceed the rated load capacity of the cable tray defined in NEMA VE 1 or NEMA FG 1 and the deflection of cable
Load Capacity
tray system shall not exceed L/100 (L=span length) when loaded to working load (excluding concentrated static load).
Only flanged type ventilated covers shall be used and secured with stainless steel banding (one band per ½ m of cover length,
Covers with a minimum of six bands per cover) and fasteners. Cable trays that run vertically in outdoor areas shall have covers on
both sides.
UNDERGROUND CABLE SYSTEMS
But In areas where digging must be minimized, cables may be
installed in one of the following configurations:
 PVC coated rigid steel conduit with a total cover not less than
300 mm or 150mm, which shall include a 50 mm or 100mm
respectively thick (minimum) reinforced concrete slab over the
Minimum depth of burial
conduit; or
 A reinforced concrete encased duct bank with 150 mm of total
cover, measured from the top of the upper conduit, which
shall include a minimum of 100 mm of concrete over the
upper conduit
  Shall consist of PVC conduit encased in unreinforced concrete (for no traffic, or occasional traffic areas) or reinforced
concrete (for frequent traffic areas).
 Shall consist of steel conduit encased in unreinforced concrete.
 There shall be a minimum of 75 mm of concrete from the outside surface of the duct bank to any conduit or
Duct Banks
reinforcing steel. Fabricated spacers shall be used at intervals not exceeding 2.4 meters. The spacers shall provide a
minimum conduit separation of 50 mm for 2 inch conduits and larger, and 25 mm for 1½ inch conduits and smaller.
 The top layer (5 mm minimum thickness) of the concrete shall be mixed with red dye.
 Duct banks shall have 20% spare ducts (minimum of one), unless this number is decreased by the facility Proponent.
SUBMARINE POWER CABLE
 For water depth less than 7.5 m measured at the Lowest Astronomical Tide (LAT), submarine cable shall be buried a minimum of 1 m.
 In areas within 100 m of a platform structure, submarine cable shall be (a) buried a minimum of 1 m, (b) protected with grout-filled bags, (c) by a split
tubing protection system, or (d) similar protection method.
 The axial spacing between separate circuits of the land section shall be minimum of 4.5 m. The axial spacing between cables in the submarine section,
excluding that portion of the cable within 200 m of the platform, shall be equal to the mean water depth.
 Submarine cable shall be physically protected from the bottom of the jacket leg to the point of cable armor termination, by a trough, tube or direct
mounting to the jacket leg. Cables shall not hang unprotected.