SPEC. No.

FS4020
Design Division FUNCTIONAL 0
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SPECIFICATION FOR
ISO – 9001:2000 SUBSEA COMPOSITE Discipline: Electrical
CABLE PAGE : 1

FUNCTIONAL SPECIFICATION FOR

SUBSEA COMPOSITE CABLE

PREPARED / TOTAL No.

REVIEWED BY APPROVED BY DATE REV. No.
REVISED BY OF PAGES

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TABLE OF CONTENTS

S.N. Title Page No.

1.0 SCOPE 3

2.0 APPLICABLE CODES, STANDARDS & 3

REGULATIONS

3.0 FUNCTIONAL DESCRIPTION 7

4.0 TECHNICAL REQUIREMENTS 8

5.0 QUALITY ASSURANCE, INSPECTION 12

& TESTING

6.0 SUB-SEA CABLE REPAIR KIT 18

7.0 INSTALLATION AIDS 18

8.0 CABLE LOAD OUT 19

9.0 DOCUMENTATION & MANUALS 20

10.0 HEALTH, SAFETY & 21

ENVIRONMENTAL REGULATIONS

11.0 CERTIFICATION 21

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1.0 SCOPE

This specification defines the functional requirements for the design,

manufacture, factory inspection, testing, load out, laying and termination of
sub-sea composite cables made up of High Voltage power cables in combination
with optical fibre unit along with all associated accessories for transmission of
electrical power, control and communication signals between an oil & gas
handling process platform and various unmanned well platforms in Indian Ocean.
The vendor’s scope of supply shall be as set out in Para 3.1 below. The vendor
may, however, draw upon his existing, pre- engineered or standard design to
satisfy the functional requirements described below and submit his offer for
Company's evaluation and approval.

2.0 APPLICABLE CODES, STANDARDS & REGULATIONS

As a minimum, all offered sub-sea cables and associated accessories shall be

designed, manufactured, tested, supplied and installed in accordance with the
applicable provisions of the latest revision of relevant National/International
Codes, Standards & Regulations listed below. In the event of a conflict between
various Codes and Standards, the one which is most stringent, shall be
applicable.

API American Petroleum Institute

ASTM American Society for Testing and Material
BIS Bureau of Indian Standards
BSI British Standards Institution
CENELEC European Standards published by CENELEC
IEEE Std 1120-2004 IEEE Guide for the Planning,Design,Installation,and Repair
of Submarine Power Cable Systems
MARPOL Marine Pollution Act

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NEMA National Electrical Manufactures Association ( USA )

NFPA National Fire Protection Agency ( USA )
NESC National Electric Safety Code ( USA )
NEC National Electric Code ( USA )
NACE National Association of Corrosion Engineer( USA)
SOLAS Convention of Safety of Life at Sea

International Electro Technical Commission( IEC) :

• IEC 60038 IEC Standard Voltages

• IEC 60228 Conductors of Insulated Cables

• IEC 60502-2/ Power Cables with Extruded Insulation and their

IEC 60840 accessories for rated voltages.

IEC 794 OFC Cable

IEC 60060-1 High Voltage Test Techniques – General Definitions and

Test Requirements.

IEC 60060-2 High voltage test techniques – measuring systems

IEC 60071-1 Insulation coordination – definitions, principles and rule

IEC 60071-2 Insulation coordination – application guide

IEC 60071-3 Insulation coordination – phase to phase insulation

coordination principles, rules and application guide

IEC 60183 Guide to the selection of high voltage cables

IEC 60228 Conductors of insulated cables

IEC 60229 Tests on cable oversheaths which have a special protective

function and are applied by extrusion

IEC 60230 Impulse tests on cables and their accessories

IEC 60287-1-1 Electric Cables – Calculation of the Current Rating

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Part 1-1 – Current Rating Equiations (100% load factor) and

calculation of losses

IEC 60287-1-2 Electric Cables – Calculation of the Current Rating

Part 1 – Current Rating Equiations (100% load factor) and
calculation of losses
Section 2 Sheath Eddy Current loss factors for two circuits in
flat formation

IEC 60287-1-3 Electric Cables – Calculation of the Current Rating

Part 1 – Current Rating Equiations (100% load factor) and
calculation of losses – Current sharing between parallel
single- core cables and calculation of circulating current
losses

IEC 60287-2-1 Electric Cables – Calculation of the Current Rating

Part 2-1 – Thermal Resistance – Calculation of Thermal
Resistance

IEC 60287-2-2 Electric Cables – Calculation of the Current Rating

Part 2-1 Thermal Resistance
Section 2 – A method for calculating reduction factors for
groups of cables in free air, protected from solar radiation

IEC 60287-3-1 Electric Cables – Calculation of the Current Rating –

Sections on operating conditions – reference operating
conditions and selection of cable type

IEC 60287-3-2 Electric Cables – Calculation of the Current Rating –

Sections on operating conditions – Economic Optimization
of power cable size.

IEC 60502-1 Power Cables with Extrude Insulation and their Accessories
for Rated Voltages from 1 kv (U[M] – 1.2 kv) upto 30 kv
(u[m} = 36 KV)
Part 1 – Cables for rated voltages of 1 kv (U[M] = 1.2 kv )
and 3 kv (U(M] = 3.6 kv)

IEC 60502-2 Power Cables with Extrude Insulation and their Accessories
for Rated Voltages from 1 kv (U[M] – 1.2 kv) upto 30 kv
(u[m} = 36 KV)

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Part 2 – Cables for rated voltages of 6 kv (U[M] = 7.2 kv )

and upto 30 kv (U(M] = 36 kv)

IEC 60502-4 Power Cables with Extrude Insulation and their Accessories
for Rated Voltages from 1 kv (U[M] – 1.2 kv) upto 30 kv
(u[m} = 36 KV)
Part 4 – Test requirements on accessories for Cables with
rated voltages from 6 kv (U[M] = 7.2 kv ) and upto 30 kv
(U(M] = 36 kv)

IEC 60811-1-1 Common test methods for insulating and Sheathing materials
of electric cables and optical cables
Part 1-1 – Methods for General application – measurement
of thickness and overall dimensions – Tests of determining
the mechanical properties.

IEC 60811-1-2 Common test methods for insulating and Sheathing materials
of electric cables and optical cables Part-1 methods for
general application – Section Two: Thermal
Ageing methods.

IEC 60811-1-3 Common test methods for insulating and Sheathing materials
of
electric cables and optical cables – methods for General
Application – Methods for determining the density – Water
absorption Tests – Shrinkage Test

IEC 60811-1-4 Insulating and Sheathing materials of Electric cables -

Common Test Methods
Part 1-4 – General Application – Tests at Low Temperature

IEC 60811-2-2 Insulating and Sheathing materials of Electric cables -

Common Test Methods
Part 2-1 – Methods specific to elastromeric compounds –
Ozone Resistance, Hot Set Mineral Oil Immersion Tests

IEC 60811-3-1 Common Test Methods for Insulating and Sheathing

materials of Electric cables - Methods to PVC Compounds
– Pressure Test at High Temperature – Tests for Resistance
to cracking

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IEC 60885-3 Electrical Tests Methods for Electrical Cables – Test

methods for partial discharge measurements on lengths of
extruded power cable
IEC 60793-2 Product specification for class A optical fibres.

IEC 60794-1 Part1: optical fibre cables,generic specifications,measurements

and tests. Part 2: Optical fibre cables,product specification.

IEC 60287 Calculation of the current rating of cables.

IEC 60304 Standard colours for insulation for low-frequency Cables and
wires

IEC 60364-5-523 Current carrying capacities

IEC 60529 Degree of protection provided by the by enclosures

3.0 FUNCTIONAL DESCRIPTION

3.1 Scope of Supply

The sub-sea cable shall be manufactured and supplied in a single lengths with no
intermediate conductor or sheath joints. The vendor shall furnish all required
information for the offered cable in the data sheet DS 4020. The vendor shall
also provide details of the maximum allowable tension during laying and pulling
operations.

The vendor shall be responsible for ensuring that all the offered cables and
accessories are suitable for the operating/site conditions specified in the bid
package. The contractor shall ensure presence of cable manufacturer’s
representative on laying barge/ vessel during offshore installation and
commissioning.

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3.2 Technical Integrity & Safety

The vendor shall be responsible for the technical integrity of the offered cables
and accessories including their design, materials, manufacture, testing,
performance and specified engineering services. All such activities shall be in
accordance with the scope of supply, this functional specification and interface
information supplied by the Company or Purchaser.

3.3 Materials, Workmanship & Suitability

All materials used in the construction of sub-sea cables and accessories shall be
of latest specifications, new and in current production. Vendor's proposal shall
be supported with detailed certified evidence of continuous and satisfactory
performance for similar application in offshore.

3.4 Design life

Unless specified otherwise, all cables/ accessories shall be suitable for a design
life of 25 years under specified operating/site conditions.

3.5 Units & Information

All quantities, measurements and dimensions shall be expressed in metric units

only. All information, manual, certificates, data and inscriptions shall be in
English language only.

4.0 TECHNICAL REQUIREMENTS

4.1 General

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The cable shall be laid unburied on seabed and subjected to large water cross-
currents. Vendor shall perform required calculation to ascertain that the
supplied cable is self stable in the seabed environmental [Link] On
Bottom Stability calculations shall be submitted for approval prior to proceeding
with cable [Link] vendor shall use the “Simplified Static Stability
Analysis” method described in section 5.3 of : DNV RP-E305,1988.
The vendor shall provide calculations for cable rating when laid in air, in ground
and on the seabed.

The system voltage at the originating platform is11KV and 6.6 KV, 3 phase, 50
HZ.

The design and material proposed shall have a demonstrated service history for
submerged environment mentioned above and elsewhere in the bid package.

The cable insulation shall be rated to withstand

• a maximum continuous conductor temperature of 900C at 100%

continuous load
• a conductor temperature of 1300C during emergency overload operation
• a conductor temperature of 2500C during short-circuit conditions.

4.2 Power Conductors

Conductors shall be of compact round, stranded, annealed uncoated copper

wires conforming to IEC-60228.

4.3 Conductor water barrier

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A continuous semi-conducting water tight sealing compound shall be applied

longitudinally in the interstices of the conductor strands.

4.4 Insulation

The insulation shall be Cross-Linked Polyethylene ( XLPE). The insulation

thickness shall conform to IEC-60502.

4.5 Conductor shielding

A layer of black, semi-conducting compound compatible with the insulation and

conductor shall be extruded over the conductor to form a stress control layer.
Tape shall not be used and the maximum operating temperature of the shielding
shall be equal to or higher than that of the insulation. The outer surface of the
shield shall be cylindrical and firmly bonded to the overlying insulation.

4.6 Insulation shielding

The insulation shielding shall consist of extruded layer of black semi-

conducting compound bonded firmly and continuously to the insulation.

4.7 Metallic Shield

The insulation shielding shall be covered with two overlapping uncoated plain
annealed copper tapes. A semi- conducting bedding tape may be applied
between the insulation shielding and the metallic shielding.

4.8 Conductor Identification

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Each conductor shall be identified by a different coloured plastic tape placed

under the metallic shield. The colour code shall be Red, Yellow and Blue.

4.9 Optical Fibre Core

4.9.1 Technical Parameters

Mode field diameter : 9.2 microns ± 10%

Cladding diameter : 125 ± 2 microns
Mode field concentricity error : less than 1 micron
Cladding non-circularity : less than 2%
Primary coating diameter : 0.4 mm ( approx.)
Nylon jacket diameter : 0.9 ± 0.1 mm
Attenuation : 0.5 dB ( max.) at 1310 nm
Chromatic dispersion : less than 3.5 ps/Km/nm ( 1288-
1339 nm )
Cut-off wavelength : 1.1 to 1.28 microns

4.9.2 Core Identification

Each optical fibre core shall be classified by colour identification and shall be
done by using the coloured jacket as per applicable Code/ Standard.

4.9.3 Stranding

The twenty four ( 24 ) optical fibre cores covered with coloured nylon jacket
shall be stranded into one optical fibre unit by laying these into the spiral
grooves of the plastic spacer made up of polyethylene having a spider shape in
its cross section and strength member ( 7 steel wire strand 7/1.2 ) in centre of
the spider as the reinforcement. The interstices of the fibre unit shall be filled

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with jelly compound. After forming, the spacer shall be wrapped with suitable
tapes so as to form an optical fibre cable core.

4.9.4 Lead Alloy Sheath

The lead alloy sheath shall be “copper tellurium lead alloy”. The minimum
thickness at any point shall not fall below the nominal value specified in the
applicable Code/ Standard.

4.10 Assembly of Cores

The three insulated power conductors and one optical fibre unit shall be laid up
to-gether with suitable non- hygroscopic fillers and wrapped with suitable
overlapping binding tapes.

4.11 Protector Tape

A double layer of stainless steel protector tape shall be installed over the
sheath assembly to provide stability. Vendor shall furnish cross- sectional area
and thickness of the SS tape.

4.12 Armour Assembly

A single layer of galvanised steel wire armour shall be provided over the inner
sheath and protective tape. An anti- corrosive compound shall be applied over
the armour. A single layer of polypropylene yarn shall be applied over the tape
armour to provide a bedding for the wire armour.

4.12 Overall Sheath

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Two layers of polypropylene yarn shall be applied over the armour and the
outer surface of cable shall be overall white- washed.

4.13 Markings

The white narrow tape printed with the following information in black shall be
applied throughout the length of the cable over the laid-up cores -
• manufacturer’s name and/or trade name
• year of manufacture

5.0 QUALITY ASSURANCE, INSPECTION AND TESTING

5.1 Quality Assurance Requirements

Unless otherwise mentioned in the purchase order, the Vendor quality system
shall be based on ISO 9000 series or equivalent and shall be described in a
quality assurance plan. Vendor shall have a quality assurance section
responsible for implementing the quality system which ensures that
requirements of this specification are achieved.

5.2 Inspection

The inspection and testing requirements for the component parts of the
submarine composite cable shall be submitted as part of the Vendor’s bid in his
Quality Plan for approval by the Company.

After Company approval of the detailed design the Vendor shall procure the
necessary components and proceed to manufacture and assembly of the
submarine composite cable.

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All material and equipment shall be inspected and tested to the requirements
of relevant standards & specification. Contractor/Company reserves the right
to witness such inspection/tests.

Company/its authorized representative or certifying agency shall have access

to inspect the equipment at any stage during manufacture. During inspection,
material certificates and shop test data, shall be furnished so as to ascertain
that the specifications and quality are complied with.

Any or all the tests, including hydrostatic tests, shall at company’s option be
witnessed by the Company/its authorized representative or certifying agency.
Vendor shall give minimum 15 days prior intimation regarding testing
schedules.

5.3 Sub-sea composite cable testing

Vendor shall carryout the factory tests specified. Contractor/Company shall

have the option of witnessing all factory testing. Contractor/Company shall be
informed at least two weeks in advance of any testing.

5.3.1 Tests during manufacture

The manufacturer shall carry out, during the manufacturing process, tests at
various stages, as set down in the approved quality control plan in order to
prove integrity and compliance with specifications, but should include testing
of each power core at approx. every five kilometre as follows:-

i) Partial discharge test

Requirements : The magnitude of the discharge at 18 kV shall
not exceed 20 pC.

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ii) HV AC Test
Test voltage : 50 KV ( higher than IEC 502 requirements)
Power frequency : 50 HZ
Time : 5 minute
Requirement : no breakdown

iii) Conductor Resistance and Capacitance

The DC electrical resistance and capacitance of each conductor and

copper tape insulation screen shall be measured and shall conform to
values as per IEC 228.

iv) Requirements : X mm² conductor

Maximum x ohm/km at 20°C copper tape insulation screen on samples : X

Ω/km at 20°C.

v) Dimensional check

Dimensional checks of following, conforming to IEC 60502 shall be

performed on one sample from each production length -

Conductor screen-semi conductor XLPE

XLPE insulation

Insulation screen-semiconductor XLPE

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vi) Manufacturer shall also consider following tests to prove healthiness of the

Submarine Composite cables as per their own standards:

- Temperature Stability Test

Cable parameters shall remain inaltered after exposure to a cycle of

extreme temperatures usually from -4 to 50 Degree C.

- Hydraulic Pressure Test

Cable parameters shall remain unaltered after withstanding a hydraulic

pressure of 250-300 m of water head.

- Mechanical Performance Test

Submarine Composite cables shall withstand maximum of the operating

forces experienced during handling at works, coiling, installation, repair
.These cables shall also withstand cyclic loading of waves that varies
between 3-5 m of waves.

- Water Ingression Test

Submarine Composite cables shall not absorb water during normal

operation or faults at the maximum operating depth of 200m.

- Corrosion Resistance Test

All the materials used in the mfr of Submarine Composite cables shall resist
corrosion during long term exposure to seawater. An accelerated test with
Cable immersed in salt bath at elevated temperature to simulate design life
of 25 years is to be conducted.

- Insulation resistance Test

A long Cable is coiled and submerged in sea water with typical system
voltage applied for a short period of time and monitoring IR values before
and after the test.

- High Voltage test

This test is conducted to prove that insulation system is suitable for the
nominal system voltage for the system designed life. This is an accelerated
test using empirical data to determine test voltage, test duration
corresponding to system voltage and system designed life.

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MV Power Cable Tests

Composite submarine cable manufaturer(s) shall carry out routine tests as per
IEC 60502-2/IEC-60840 or latest amendments.

The contractor shall furnish a certificate from a third party testing agency
acceptable to ONGC confirming that all type or qualifying tests as required
under IEC codes have been successfully completed prior to its shipment.

The following special test on finished cable shall be carried out though not

limited to same:

1. Conductor examination

2. Measurement of thickness of insulation and non-metallic sheaths

3. Measurement of thickness of metallic sheath

4. Measurement of diameters of various layers

5. Hot set test for XLPE insulation

6. Measurement of capacitance

7. Measurement of voids, contaminants and protrusions of XLPE insulation

-Type Test

Type tests for the 6.6kV /11KV

o Building under tension test

o Tensile Test

o Partial discharge Test

o Impulse voltage test followed by AC Test

o Heating cycle voltage test

o Loss angle and capacitance measurement test

o Water penetration test

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o Mechanical dimensional check

Overall dimension

5.4 Tests On Factory Joints

The Vendor shall carry out qualification tests for approval of personnel to
perform factory power joints for the power cables.

5.5 Factory Acceptance Tests ( FAT) On Sub-sea Composite cable

The total length of sub-sea composite cable shall be subjected to FAT after
completion of
manufacturing of the cable. Sub-sea cables shall be tested in compliance with
the requirements of the Standards to which they are manufactured alongwith all
optional tests. Company shall be advised at least four weeks in advance of the
scheduled date of each test and again twenty days prior to the actual test,

i) DC Resistance of Power Cable

The DC resistance and capacitance of the power cable shall be measured
on the entire length. The resistance shall be less than 0.268 ohms/km.

ii) DC High Voltage Test on Power Cable

A 72KV DC voltage shall be applied between each conductor and between
conductors and earth / screen. The leakage current shall be less then
1000µA.

iii) Time Domain Reflecto-meter Test

The power cable shall be checked by performing measurement with a Time
Domain Reflecto-meter.

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5.6 Pre Load-Out Test & Post Load-Out Tests

Vendor shall carry out the recommended tests before and after load out to
confirm the integrity of the entire cable quantity supplied. The tests shall be
witnessed by the Company or its authorised representative. The contractor shall
ensure that all material employed shall be available prior to and after the
manufacture of the cables for Company's inspection by the cable manufacturer.
Immediately after completion of the tests, certificates for the tests conducted
along with all back-up documents, log sheets, test results, etc., shall be
furnished to the Company.

The contractor shall furnish all necessary information in respect of the supply of
cables to the Company's Inspector or Representative. The Inspector shall have
free access to the manufacturer's works for the purpose of inspecting the process
of manufacture during all stages and shall have authority to reject any material
or finished product which appears to be unsuitable or of unsatisfactory quality.

6.0 SUB-SEA COMPOSITE CABLE REPAIR KIT

Vendor shall provide full details of recommended repair splice kits possibly
required during installation due to damage and future maintenance of the
submarine composite cable. Vendor shall furnish detailed procedure for
carrying out submarine composite cable repair after installation. The contents
of a complete kit shall be described in the procedure.

7.0 INSTALLATION AIDS

The Vendor shall be responsible for providing the suitably sized construction
aids as listed below -

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- Bull Nose(s) or other suitably recommended pulling arrangement

- Hanger clamp attachment to transfer the load of the cable to J tube after
installation

- Through joint kits and any protection devices for use on the offshore
platform for control and power cable break-out jointing to the platform

- Temporary test caps required to establish the integrity of the cable at all
times during installation

- Heat shrink termination kits at each end of the cable and cable lugs

- All glanding and cable earthing items

- Temporary cable abandonment device during installation.

The cable manufacturer/ vendor shall work in close co-ordination with the
contractor to firm up all aspects of cable installation in offshore. In case vendor
considers any other construction aids necessary for successful installation of the
cable, the same shall be included in the offer.

8.0 CABLE LOADOUT

Vendor shall load out the manufactured and tested cable onto contractor
supplied cable transport means, at the manufacturer’s facility using
internationally recognized and standard industry practices.

Vendor shall make available all specialized equipment and personnel necessary
to affect the load out in an efficient manner.

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The exposed cable ends shall be terminated in a pulling device and shall be
protected to prevent damage to the cable. The individual phase conductors as
well as plot wire core and fibre optic unit shall be sealed to prevent water
ingress.

The cable shall be spooled onto the transportation/laying device in a manner

that avoids twists, slack and/or over-tensioning of the cable.

Where called for in the requisition, short length of cable shall be delivered on
drums.

9.0 DOCUMENTATION AND MANUALS

Consistent with the aim to minimise documentation, only documents which

provide key interface information shall be required for review by the Company.
All such documents shall be identified, discussed and agreed by both the
contractor and vendor and shall be submitted for Company’s approval to form
the basis of an agreed document submission schedule.

However, following documents, in respect of sub-sea composite cable and cable

accessories, shall be included in the bid to form part of the Purchase
Specification -

• Design documents such as calculation for sizing, short circuits, voltage drop,
on-bottom stability under dynamic site conditions, etc.
• Type test certificates
• Cable data sheet DS 4020 and cross sectional drawings showing dimensional
details of conductor, insulation, sheathing, core arrangement, etc.

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 TO 015 02 01 01/08/2006
 SPEC. No. FS4020
Design Division FUNCTIONAL 0
Engineering Services Rev. No.
SPECIFICATION FOR
ISO – 9001:2000 SUBSEA COMPOSITE Discipline: Electrical
CABLE PAGE : 22

• Product catalogue containing technical specification, design and construction

features, etc.
• Cable installation/laying procedure
• Vendor’s standard Quality Plan
• Manufacturing & Delivery schedule
• Details of after sale services offered
• Comments/ Deviations/ Exceptions
• Manufacturer’s Operation & Maintenance Manual
• List of Sub- vendors with address and contact numbers
• Track record for the past supplies for similar applications

Vendor shall furnish drawings and data in accordance with the requirements of
the requisition and specification. Descriptive literature for all items together
with a full system description shall be provided as part of the bid.

10.0 HEALTH, SAFETY & ENVIRONMENTAL REGULATIONS

The contractor/ vendor shall be responsible for ensuring that all the goods and
services supplied meet all applicable regulations on health, safety and
environmental issues.

11.0 CERTIFICATION

All sub-composite cables and accessories of similar design and construction

features manufactured by the same vendor -

• shall have been type tested by an authority approved by the Company

• shall have been in continuous satisfactory service in offshore for a
minimum period of two years

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 TO 015 02 01 01/08/2006
 SPEC. No. FS4020
Design Division FUNCTIONAL 0
Engineering Services Rev. No.
SPECIFICATION FOR
ISO – 9001:2000 SUBSEA COMPOSITE Discipline: Electrical
CABLE PAGE : 23

• shall be having current certification/ approval/ listing by a national/

international statutory body or Company approved accredited agency.

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 TO 015 02 01 01/08/2006
Filename: FS 4020 Subsea Cable
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Title: SL
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Creation Date: 2/6/2007 5:06 PM
Change Number: 18
Last Saved On: 2/7/2007 11:10 AM
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