Specification for 33kV XLPE Single Core Cables EP-MS-P4/S3-010

EP-MS-P4/S3-010

Specification for
33kV XLPE Single Core Cables

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Specification for 33kV XLPE Single Core Cables EP-MS-P4/S3-010

Document Control
Department Document Type Document Title
EP-MS-P4/S3-010
Material
EP Specification Specification for
33kV XLPE Single Core Cables
Standards
Issue Approval
Prepared By Approved By

Consultant M/s. Ewbank Preece Limited

Head of Design & Development
Member of the Mott Mac Donald Group,UK

Signature: Signature:

Issue Record
Issue No. Date Reason for re-issuing Document

0.0 30.04.2003 First issue of Materials Specification Standards

1.0
2.0
3.0
4.0
5.0

Key Words : Specification for 33kV XLPE Single Core Cables

Review Frequency : Every 3 years

When this document is approved for publishing on the intranet, a copy of its Document Control page should be sent to
the QA section who is custodian of KM quality management system.

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Specification for 33kV XLPE Single Core Cables EP-MS-P4/S3-010

1.0 SCOPE

This specification deals with KAHRA MAA requirements for medium voltage polymeric
insulated single core cables suitable for 33 kV three phase 50 Hz underground
distributions and for the connection to overhead pole terminations.

2.0 CABLE CLASSIFICATION

Nominal system voltage, phase to phase = 33kV

Um = 36kV

The cables shall generally be in conformity with IEC 60502:1997, and subsequent
amendments, except as may be otherwise stated, and of the following generic type.

Single conductor core of circular, stranded highly compacted copper.

A semi-conducting shield extruded directly over the core, for the purpose of stress
control.

XLPE core insulation, circular in section and of a thickness appropriate to the intended
system voltage.

Core insulation layer to be covered with an extruded semi-conducting XLPE compound

shield for the purpose of stress control. Semi-conducting tape over the extruded
semiconductor.

Where the screens are inadequate to meet the specified earth fault current, a metallic
layer of copper wires of adequate cross section shall be applied over the extruded
bedding with copper binder tape.

The whole shall be surrounded by an armour of aluminium alloy wires and a PVC
oversheath.

3.0 ENVIRONMENTAL CONDITIONS

The following conditions prevail generally throughout the State of Qatar.

1 Altitude - low lying, generally close to sea level, no point exceeding 100 metres
above sea level.

2 Maximum air temperature 50°C (46°C typical)

3 Minimum temperature 0°C (10°C typical).

4 Mean maximum summer air temperature 45°C typical.

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Specification for 33kV XLPE Single Core Cables EP-MS-P4/S3-010

5 Mean maximum exposed sunlight temperature 75°C.

6 Solar radiation - peak, 1030 Watts/sq.m.

7 Humidity - 100% humidity is common throughout the year and may occur at air
temperatures of 30°C or more.

8 Rainfall - very low on average, the winter season may bring infrequent very
heavy rainfall.

9 General atmospheric conditions - a hot atmosphere containing very fine highly

penetrating dust particles. In parts the atmosphere contains a highly corrosive
salt laden sea mist.

10 Max ambient soil temperature 35oC.

11 Typical thermal resistivity with dune sands 2.1 oC m/W, quarry scalpings 1.5oC
m/W.

The cables shall be laid in close trefoil, installed direct in ground, in ducts or
formed trenches.

Above ground they shall be cleated to structures or poles at 850mm intervals.

4.0 SYSTEMS PARAMETERS

1. Nominal Voltage............................... 33kV

2. Highest System Voltage ................... 36kV
3. Short Circuit Level .......................... 31.5kA
4. Insulation Withstand (BIL) ............... 170kV (1.2/50 Impulse)
5. Power Frequency Withstand ............. 70kV
6. Frequency ........................................ 50Hz

7. Limited Earth Fault Current through

Earthing TX ..................................... 3kA

5.0 CABLE CONSTRUCTION - DETAILS

i) Conductors

Plain circular stranded, highly compacted copper in accordance with IEC 60228.
Standard size is 240 sq. mm.

ii) Conductor Screening:

Extruded semi-conducting compound. This shall be firmly bonded to the

insulation. The minimum thickness, at any point shall not be less than 0.8 mm.

iii) Insulation:

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Specification for 33kV XLPE Single Core Cables EP-MS-P4/S3-010

Extruded chemically cross linked polyethylene (XLPE) tree retardant grade

cured by a dry process.

Highest rated temperature 90oC (IEC 60502 clause 4.2 Table 3)

The minimum radial thickness of insulation shall follow IEC 60502 requirements,
viz 8mm. The maximum deviation of the insulation thickness at any point shall
not be greater than 4%, of the average thickness of six measurements.

iv) Insulation Screening

A layer of extruded semi-conducting material of the generic type ‘easy strip’.

This is of a type in which the layer can be removed by hand peeling, after
application of a simple tool, if needed. This will leave the underlying XLPE
insulation undisturbed. Where such a tool is needed, for instance a knife with
depth of cut limitation, this will be supplied in quantities at a simple ratio of 10%
of the number of joints supplied. The minimum thickness, at any point, of
insulation screen shall not be less than 0.8mm.

Semi-conducting tape shall be provided over the extruded semi-conductor for

proper bedding of screening wires.

The core shall be overlaid with a metallic screen to equalise potential along the semi-
conducting screen and to ensure correct stress control.

The screen shall be capable of withstanding the specified earth fault current of 3kA for 1
Sec. The screen will take the form of copper wires with a copper binder tape. The
minimum cross sectional area of the screen shall be 35 mm2.

v) Armour

Where specified, armour shall consist of a single layer of aluminium alloy wires to the
requirements of IEC 60502.

The armour shall be embedded in, or overlaid by a substance or material, the purpose of
which is to inhibit flow of water in the event of penetration of the over-sheath, or inflow
from a faulty joint.

The method of achieving this will be recommended by the manufacturer, and details will
be indicated at time of tender.

vi) Oversheath

The outer covering shall be of extruded PVC type ST2 according to IEC 60502.

It shall be RED in colour, and embossed with the following legends:

“KAHRA MAA/ENA 33,000V XLPE”

and the identity of the manufacturer.

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Specification for 33kV XLPE Single Core Cables EP-MS-P4/S3-010

The legends shall be repeated along the length of the cable at intervals not exceeding one
metre.

6.0 TESTS

1. This relates to type tests and tests to be carried out during or after manufacture
of the specified cables.

2. The following tests shall be carried out on each manufactured length of cable, or
sample length as instructed by KAHRA MAA. The tests shall be as outlined in
IEC 60502, IEC 60228 and IEC 60811.

1. Routine Tests:

1. Electrical Resistance of Conductors.

2. Voltage Test.
3. Partial Discharge Test.

2. Sample Tests:

1. Conductor Examination.
2. Check of Dimensions.
3. Voltage Test.
4. Hot Set Test.

3. Type Tests:

Manufacturer shall carry out type tests to IEC 60502 on the cable and issue certificates
confirming that the cable has conformed.

In addition the manufacturer shall carry out a test to prove that the metallic screens are
capable of sustaining the specified earth fault current. The design philosophy for
achieving this shall also be explained.

7.0 CABLE DRUMS

All cables shall be supplied on cable drums with a maximum diameter of 2.55m and a
maximum width of 1.28 m. No drums with cable shall weight more than 7.5 tonnes. In
addition the lengths of cables on the drums shall be in accordance with the Schedule of
Quantities.

Cable drums shall be stoutly constructed of wood and supported with steel tie bars and
shall be fully lagged and bonded. On each flange of each drum a steel plate complete
with Tubular Steel insert shall be fitted to accept 1 x 4 inch (100mm) spindle to be used
during cable installation. The steel plate shall be a minimum of 400mm x 400mm x 5mm
thick, welded to the tubular insert. The plates shall be fixed with 6 bolts through the
flange.

All drums shall be painted and engraved with:

Manufacturers Name

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Specification for 33kV XLPE Single Core Cables EP-MS-P4/S3-010

Year of manufacture of cable

Drum Number
Size and Voltage of the cable, including the term:
"Cross Linked Polyethylene".
The length of cable in the Drum.
“Qatar General Electricity & Water Corporation”, and the Order No.

The nominal length to be as stated in the schedule below:

Cable Size Lengths per Drum

1C x 240 mm2 500 Metres

A tolerance of ± 5% on the length of cable per drum shall be allowed.

8.0 CABLE TIES

The manufacturer shall supply suitable cable ties for securing the single core cable in
trefoil formation at one metre intervals. The cable ties shall be made of nylon and of type
Nylon 66, black finish – BB type or equivalent. The length of cable tie shall be suitable
to secure 3-x 1C 33kV 240 mm2 in trefoil information.

9.0 INFORMATION TO BE PROVIDED AT TIME OF TENDER

An illustrated drawing showing the cable design, all components and dimensions.

A specific statement of conformity with the specification, together with details of non-
conformity (where applicable).

Details of method of protection against water ingress at armour level.

Permissible fault ratings of the conductor, screen and the armour.

10.0 DETAILS TO BE SUBMITTED WITH THE ORDER

When an Order is placed with the Manufacturer he will be obliged to carry out tests, at
the appropriate points, and submit Certificates as detailed above.

11.0 DEVIATIONS FROM THE TECHNICAL SPECIFICATION

The Tenderers are required to attach a separate deviation list to their Technical Offer
and include it in the Technical Package if the offered equipments do not meet the
requirements of any clause of the Specification.

Offers without any deviation list attached to the Technical Offer and included in the
Technical Package shall mean that the offer meets the requirements of the
Specifications on all the clauses.

Offers with deviations listed out shall mean that the offer meets the requirements of the
Specification on all the other clauses not included in the deviation list.

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