EPCC Pemindahan 3 Unit PLTD 18V50DF dari Pomalaa, Sulawesi Tenggara ke Buli, Maluku Utara PT Antam Tbk

Section 4, Technical Specification Page 1

E - 008 RACEWAY

1. SCOPE OF WORK

The Works shall include the design, supply, manufacturing, factory testing,
delivery to Site, installation, commissioning and testing of the cable tray
system in accordance with Section 3, Subsection 3.2 "Scope of Work".

2. CODES AND STANDARDS

The Contractor shall comply with the requirements of Section 3, Sub-section

3.4 “General Requirements”. The codes and standards of the following
organizations extracted from the Subsection 1.4 are specifically applicable to
cable tray system covered in this specification.
ASTM A 36 Standard Specification for Structural Steel
ASTM A 164 Electrodeposited Coatings of Zinc on Steel
ASTM A 386 Specifications for Zinc Coating (Hot-Dip) on
Assembled Steel Products
ASTM A 525 Specifications for Zinc Coating (Galvanized) Iron or
Steel Sheet, Coils and Cut Lengths
AWS D1.1 Structural Welding Code
NEMA VE1 Cable Tray Systems
IEEE Std 1300-1996 IEEE guide for cable connections for gas-insulated
substations.
IEEE Std 1366- 2001 IEEE guide for electric power distribution reliability
indices.

3. GENERAL.

The raceway system shall include the following components:

Cable Tray. The cable tray shall provide support to electrical cable which is
routed throughout the plant, either directly to equipment or to areas of con-
centrated electrical loads.

Cable Tray Support System. The cable tray support system shall include
hanger rods, cross member, and hanger clamps to support the cable trays
and cables. These components shall be used, as required, to provide
structural integrity to the tray system.

Conduits. Conduits shall be used to extend circuits from cable trays, duct
banks, manholes, wireways to equipment or cabinets, and for circuits
between light fixtures, wiring devices, equipment, and cabinets.

Duct Banks (if any). The duct banks shall be designed to provide an
adequate number of ducts between the plant and outlying structures and to
protect the electric cable routed through the system from mechanical
damage. Underground duct banks shall be used from the Generation
Building to manholes near the substation and other remote areas as

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necessary.

Manholes. Electrical manholes shall be provided to aid in cable installation

and shall be designed with respect to the duct bank size, location, and
orientation. Manholes shall be located where required to keep cable pulling
tensions within the maximum allowable limits, to make extreme elevation
changes, or to tie in branches of the duct bank.

Wireways. Wireways shall provide an advantageous wiring transition

between power panels or other groupings of equipment. Wireways shall be
oil tight, metallic wiring enclosures designed for weather tight installation.

Junction Boxes. Junction boxes (terminal boxes) and pull boxes shall
provide access to the conduit system, serve as a transition from one type of
raceway to another, and serve as circuit and raceway collection points.

4. DESIGN REQUIREMENTS

4.1 The cable tray system shall be suitable for installation in a power plant on a
tropical climate. Refer to Section 3, Subsections 3.1, Subsections for the Site
meteorological, seismic and environmental conditions

4.2 Separate cable trays shall be used for medium and low voltage power,
control and instrumentation cables. Low voltage power and control cables
may be run in the same cable tray with the PT Antam Tbk's written approval
in special cases.

4.3 Tray for cables of different voltage levels shall be stacked in descending
order, with the higher voltage above. Instrument cable tray, if utilized, shall be
the lowest.

4.4 Segregated cable tray runs shall be provided for each of the redundant
power distribution systems and associated control and instrumentation.

4.5 Cable trays shall not be more than 60% filled when cables are randomly laid.
The maximum depth of fill in the cable trays for power cables shall be
approximately 50 mm2. Tray fill shall have allowance for future installation of
10% more cables.

4.6 Cable tray supports shall be designed with a safety factor of not less than 2.

4.7 Two hour rated fire stops shall be installed in vertical and horizontal cable
trays where they penetrate floors or walls. The design of the fire stops shall
be subject to the review of the PT Antam Tbk. The reduction in the ampacity
of cable due to the fire stops shall be taken into account in the sizing of
cables.

4.8 The Cable tray system shall electrically continuous and grounded as
Specified in Technical Specification E-015 and shall have adequate fault
current carrying capability for the system with the maximum fault currents.

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4.9 Cable tray and accessories shall be based on types that are manufactured in
Indonesia.

4.10 All power and control trays shall be provided with a continuous grounding
conductor installed the entire length of the tray system. This grounding
conductor shall be connected to the station ground grid at multiple locations

4.11 Cable tray routing shall be coordinated with the location of piping, pipe
hangers, steel, HVAC (ductwork, fans, ventilators, air handling units, piping,
and all associated supports), bus duct, and lighting fixtures.

4.12 Cables routed in tray shall be tied to the tray rungs at intervals not exceeding
3 meters using nylon cable ties

4.13 The cable supports for the upper end of vertical tray shall be cable hanger
elbows.

4.14 Cable tray fittings shall have a 300 mm radius for instrumentation cables, 600
volt power and control cables.

4.15 Tray fittings shall be limited, in general, to 45 and 90 degrees, except where
special 30 degree or 60 degree fittings are required to satisfy special
requirements.

4.16 Power cables rated over 600 volts shall not occupy the same tray with
conductors or systems insulated for 600 volts or less, except where they are
kept physically separated by a solid, noncombustible, fixed barrier installed in
the tray. Power cables of 600 volts or less may occupy the same tray without
regard to voltage level of the individual circuits or whether the individual
circuits are alternating or direct current.

4.17 Conduit shall be of either rigid galvanized steel (RGS), intermediate metal
conduit (IMC), electrical metallic tubing (EMT), or polyvinyl chloride (PVC)
plastic construction, based on the material selection criteria outlined herein.
The following general descriptions shall apply to the design of the conduit
system
• Conduits shall not be routed parallel to hot surfaces.

• When two or more cables are to be installed in a single conduit, the total of the
cross sectional areas of the cables shall not occupy more of the cross
sectional area of the conduit than is shown below;
o 2 cables more than 30 percent
o 3 cables more than 40 percent
o 4 cables more than 38 percent
o Over 4 cables more than 35 percent
• Conduit shall be routed at least 150 mm from the hot surface.

• Conduit runs containing more than four 90 degree bends, or the

equivalent, shall be provided with an intermediate pull box. Runs of
more than 30 meters shall also be provided with either a pull box or
conduit fitting every 30 meters.

• The inside radius of conduit bends shall not be less than six times the
diameter of the conduit.

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• All equipment and devices which move in relation to the supply conduit
due to vibration, normal operation of the mechanism, or thermal
expansion shall be connected to the supply conduit using not more
than 750 mm of liquidtight flexible conduit adjacent to the equipment or
device.

• The conduit system shall be electrically and mechanically continuous.

When a change of direction is required in the conduit run, "tees" and
"elbows" shall be used. Open gaps in the conduit system to allow for
cable exits or entrances are expressly not allowed anywhere.

• Conduits cast in the foundation or separate finish slab shall be rigid

galvanized steel and shall be terminated flush with the floor with a
coupling and flush plug. The conduits shall remain plugged until the
conduit is extended later.

• Conduit installed below grade, but not as part of a duct bank, shall be
rigid gal¬vanized steel conduit encased with not less than 75 mm of
concrete, buried not less than 600 mm below finished grade elevation,
and sloped to provide drainage of water. A means for drainage of water
from the low point of the conduit shall be provided. A minimum
separation of 75 mm shall be maintained between multiple conduits
enclosed in the same concrete encasement, but not assembled as a
duct bank.

• » Conduit to wireway or cabinet connections outdoors or in wet areas

shall be made with watertight hubs.

• Large parallel runs of conduit shall be avoided by using cable tray.

• The opening around conduits that penetrate an outside wall, fire rated
wall, or floor shall be sealed with grout on acceptable seals.

• Conduit runs and entries into enclosures shall be adequately spaced to

provide for the installation of conduit fittings.

• Conduits installed outdoors or in high humidity areas where water might

enter or condense inside the conduit shall be routed into the bottom of
enclosures. Where conduits must enter the top of enclosures in such
areas, conduit seals with drain holes shall be provided.

• Conduit shall terminate directly on cabinets. Cable "glands" are

expressly not allowed and shall not be used anywhere.

• Conduit fill shall be in accordance with the applicable sections of the

latest revision of the National Electrical Code (NEC).

• General conduit criteria is as follows:

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Section 4, Technical Specification Page 5

Raceway Type Conduit Type Use

Rigid Galvanized Steel (RGS) Cast in foundations or separate finished
Conduit slab.
Raceway Type Conduit Type Use
Below grade—not part of duct bank.
Noncorrosive atmosphere in indoor,
unfinished area; hazardous locations;
and outside areas.

Duct bank elbows.

Intermediate Metal Conduit (IMC) IMC may be used in open areas

throughout the plant. IMC may be
substituted for RGS where approved by
the Owner.

Electrical Metallic Tubing (EMT) Lighting and communication in finished

areas of the plant.

Polyvinyl Chloride Construction Corrosive and wet areas of the plant.

(PVC) Inside concrete and Duct banks.
•

4.18 Duct Bank (if applicablej. Underground duct banks shall be used for cable
routed between buildings and other remote areas

4.19 Electrical manholes shall be of precast or cast- in-place, reinforced concrete

construction. Manholes shall be provided with a lift-off top for cable
installation, a manhole ring and cover for personnel access after
construction, removable access ladder, sump, pulling eyes, and concrete
inserts for cable supports.

4.20 Wireways shall be oiltight, metallic wiring enclosures designed for

weathertight installation with neoprene gasketed, hinged covers secured with
external [Link] design criteria are as follows:
• Wireways shall be provided as an advantageous wiring method
between power panels and cable trays and between other groupings
of equipment.
• Conduit connections to wireways located outdoors shall be made with
watertight conduit hubs.
• Wireways shall not be used in hazardous locations, corrosive
atmospheres, or where subject to physical damage.
• The sum of the cross-sectional areas of all conductors contained in the
wireway shall not exceed 40 percent of the usable cross-sectional
area of the wireway.
• Wireways shall be supported at intervals not to exceed 900 mm.

4.21 Miscellaneous Junction Boxes, Pull Boxes, and Cabinets. Junction boxes,
pull boxes, and cabinets shall be rigidly mounted. Mounting on concrete shall
be secured by self-drilling anchors. Mounting on steel shall be by drilled and

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tapped screw holes, by special support channels welded to the steel, or by

both. All mounting holes in the enclosure shall be used. Conduits shall be
securely fastened to all junction boxes, pull boxes, and cabinets. Threads on
metallic conduits shall project through the wall of the box to allow grounding
bushings to butt against the end of the conduit, after which locknuts both
inside and outside shall be tightened sufficiently to bond the conduit securely
to the box. Watertight hubs shall be used for terminating conduits on boxes
located outdoors and on boxes located in wet or damp areas.

4.22. Junction boxes shall be sized such that all wiring contained within the box or
terminated on tenninal blocks within the box is easily accessible. Future unit
circuits shall be included. There shall be minimum 33 percent spare ducts.
The manholes shall be sized based on the conditions stated previously.

5. DETAILED REQUIREMENTS

5.1 GENERAL

5.1.1 All cable trays for power and control cables shall be ladder bottom type with
standardized width of 300 or 450 or 600 or 800 mm2. Flerforated cable trays
150 mm2 wide may be used for a maximum of three low voltage power
cables or control cables. The width of the cable trays shall not exceed 600
mm2. The tray depth shall not exceed 100 mm2. All cable trays for
instrumentation cables shall be solid-bottom or perforated type, 100 or 150
mm2 width, with tight, fitting covers in accordance with the instrument
systems requirement.

5.1.2 Horizontal curved fittings shall have an 80 mm2 tangent beyond the curved
section. Tangential extensions for vertical curved fittings shall be provided as
required.

5.1.3 All welding procedures used in fabrication and installation of the cable tray
system shall be in accordance with AWS Structural Welding Code, AWS
D11.

5.1.4 All field welds shall be made parallel to the web or length of supporting steel.
Under no conditions shall a well be made across either flange of a beam or
column.

5.1.5 Vertical clearances between the cable trays shall not be less than 350 mm2,
lower edge to lower edge. The horizontal spacing of the cable trays and the
clearances between them shall be such that no cable tray shall be more than
600 mm from the access side of the cable tray for installation and
maintenance purposes. The access way between the cable trays or between
a wall and the cable trays shall not be less than 600 mm2.

5.1.6 The top of the highest cable tray shall have at least 350 mm2 clearance from
the ceiling, beams, or overhead structures.

5.1.7 Covers shall be provided on Ladder type cable trays, at places where failing -
objects may damage the cables, and at places advised by the PT Antam Tbk.

5.1.8 Cable trays shall preferably be located above process piping and facilities.

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5.1.9 All hardware shall be made from suitable corrosion proof materials.

5.2 LOADING REQUIREMENTS

Cable trays & supports shall be designed for the following minimum loading
requirements.

5.2.1 Design load capability, with supports on 3.5 meter centers shall be not less
than 280 kg/m2 with a safety factor of 2 when loaded as a simple beam in
accordance with NEMA VE-1-4.01 or equivalent.

5.2.2 Maximum deflection at mid-span for loading stated above with simple beam
support shall be 1/ 300 of the span of cable trays.

5.2.3 Trays and fittings shall be capable of supporting a concentrated static load
with simple beam supports on 3.5 meters on centers without permanent
deformation, as follows:

[Link] 190 kg applied vertically over a 100 mm longitudinal section at mid-span of

one side member over a connector, with tray loaded to design load, or

[Link] 90 kg applied vertically over a 100 mm section at midpoint of any rung of an

empty ladder type section or a midpoint of empty solid bottom section.
Midpoint is defined as midway between side members.

5.2.4 The wind load for cable trays mounted outdoors shall be based on a wind
velocity of 120 km/h.

5.3 CONSTRUCTION

5.3.1 Cable Trays

[Link] Cable trays shall be made up in sections, fittings, and accessories of the
ladder and solid-bottom type as defined in NEMA Standard VE-1.

[Link] All cable tray sections, verticals covers and fittings shall be fabricated from a
minimum of 2 mm thick sheet steel. Tray components, except as otherwise
noted herein, shall be hot dipped galvanized after fabrication in accordance
with ASTM A386. Covers shall be hot-dipped galvanized per ASTM A525,
Designation G-210. The yield stress of material shall be not less than be 207
MN /m2.

The average thickness of the coating shall be 64 micrometers and the

minimum thickness not less than 55 micrometers.

[Link] Cable tray covers shall be of the raised, flanged type, except for instrument
trays which shall be tight fitting to provide a continuous steel envelope
around the cables. Covers for cable tray 600 mm2 and wider shall be
provided with angle or channel stiffeners to resist deflection when loaded.

[Link] The ladder type tray rung spacing shall be not greater than 300 mm2 as
measured on the centerline of the cable bearing area. The flat bearing

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surfaces for the cables on the rungs shall be a minimum of 20 mm2.

[Link] The solid bottom or perforated cable trays shall be provided with stiffeners at
the bottom, if necessary, to prevent deflection relative to the side rails. The
maximum deflection with design uniform loading shall not exceed 5 mm2.
Bottom stiffener plates shall be shop welded to the cable tray sections.

[Link] The cable tray sides shall be flanged outward with minimum width of 25mm2.

[Link] The Contractor shall submit to the PT Antam Tbk certified material test
reports, which shall include the mechanical properties of steel sheets that are
used.

[Link] Ends of cable tray sections and fittings shall be fabricated for bolted
connections with splice plates.

[Link] Splice plates, channels, stiffener bars, etc. shall be steel in accordance with
ASTM A 36 Specifications.

[Link] Curved plates for cable protection shall be provided at angles, corners, etc.
Curved plates shall be welded at the top and bottom, on both sides.

[Link] After manufacture of cable trays and fittings is completed the pieces shall be
inspected for damage and all welds, cuts, marred surfaces etc. shall be
repaired and galvanized with a suitable galvanizing touch up material.

5.3.2 Cable Tray Support

[Link] Cable tray supports for suspended cable trays shall consist of continuously
threaded (rolled thread) rod, hexagon nuts, hex stock coupling with running
thread and steel structural members (angle and/or channel).

[Link] The rods, nuts and couplings shall be hot dipped galvanized in accordance
with ASTM A 386. The steel structural members shall be hot-dipped
galvanized after fabrication in accordance with ASTM A386.

[Link] Rods shall be minimum 1.27 mm diameter. All steel structural members shall
comply with ASTM A36.

[Link] When unequal angle horizontal supports are used, the narrow leg of the
angles shall be drilled for the support rods. When structural channels are
used as horizontal supports, the web shall be vertical. When horizontal
channel is used with rod supports, the rod shall pass through both flanges of
the channel with hexagon nuts below the bottom flange.

5.4 INSTALLATION

5.4.1 The Contractor shall assemble-and install all the cable tray sections, fittings,
support hangers, brackets, miscellaneous hardware and the required
grounding to the structural steel to form a complete and electrically
continuous cable tray system.

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5.4.2 Supports shall be installed with use of concrete expansion anchors,

couplings, inserts, embedded parts, or by fastening to building steel with
welding stud couplings.

5.4.3 Rods shall be attached to anchors with support rod couplings. When rods are
used to support more than one layer of cable tray, the lower rod shall be
joined with the upper rod with use of couplings.

5.4.4 It shall be the Contractor's responsibility to ensure that all rods are threaded
into couplings and inserts a minimum of 13 mm2. Rods shall be drawn up
tightly onto welding stud couplings, inserts and rod couplings.

5.4.5 Cable tray covers shall be installed on all instrument trays, all cable trays
installed outdoors and on all trays under or within 2 meters of a gallery or tray
crossing. Covers shall be fastened with corrosion proof hexhead self-tapping
screws.

5.4.6 Cable tray risers shall have covers up to 200 cm2 above the floor level.

5.4.7 Where cable trays are installed directly over equipment, such as MCC's,
switchgear, etc., the vertical clearance between the top of equipment and
bottom of the cable trays shall be not less than 600 mm2.

5.4.8 All cable tray sections and fittings shall be bolted together with splice plates.
No cable tray section and fitting shall be joined together by welding.

5.4.9 To ensure rigid connections and electrical ground continuity, ribbed neck
splice plate bolts shall be pulled up tight through the side-raii and splice
plates until the ribs penetrate the hole periphery, after which the nuts shall be
tightened to proper torque setting.

5.4.10 After complete erection of the cable tray system, the trays shall be inspected
all damaged galvanized surfaces shall be repaired with suitable galvanizing
touch-up material.

6. PERFORMANCE TESTING & GUARANTEES

Type test reports shall be submitted for the following items:

6.1 Cable tray loading tests as described in Clause 4.2 above.

6.2 Fire rating and hose stream tests for fire stops.

7. QUALITY ASSURANCE/QUALITY CONTROL

7.1 Quality assurance/quality control shall conform to the requirements

included in Part 2 section 2, subsection "Quality Assurance/Quality Control

7.2 The quality assurance/ quality control documentation as specified in shall

include but not be limited to the following:

7.2.1 Material certifications

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7.2.2 Test reports for tray loading and deflection for each type.

7.2.3 Electrical continuity test reports.

7.2.4 All documentation required by applicable codes and standards.

7.2.5 Welding procedures and procedure qualifications.

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