TECHNICAL DEPARTMENT

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 TECHNICAL DEPARTMENT

COMPLIANCE STATEMENT

SPECIFICATION NO. EP-MS-P4/S3-040 Issue:3 09/02/2014

1.0 SCOPE
The design, manufacture, testing, supply, delivery and performance requirements of multi-core
and single core XLPE insulated cables for use on the KAHRAMAA Low Voltage Distribution
System.
2.0 GENERAL
The details given in this specification are based on international standards and KAHRAMAA
requirements in general and for the guideline to the manufacturers. The parameters given
herewith are minimum requirements, however, manufacturer shall confirm in all aspects to
supply of best design, selection of high quality material and good workmanship in the
manufacturing for the safe and accurate installation and continuous smooth operation
throughout the life of the material stipulated herein.
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KAHRAMAA reserve the right to reject any material if found not as per International standards
mentioned hereto and KAHRAMAA requirements.
Manufacturer may offer any better product up and above the specified one herein, however,
KAHRAMAA reserves the right to accept or not.
All cables covered under this Specification should be designed for continuous operation life for
not less than 30 years under the climatic conditions specified herein.
3.0 Cable Ratings.
3.1 Rated Voltage Uo/U/Um: 0.6/1.0/1.2 kV QICC COMPLY
3.2 Max. permissible fault current of conductor for 1 second: 44 KA
4.0 CABLE CLASSIFICATION
Uo/U = 0.6/1kV
The cables shall be inconfirmity with the IEC 60502 Part 1, and subsequent amendments, except as may QICC COMPLY
be otherwise stated in this standard. The general classification of cables is mentioned below.
4.1 Multi - core cables:
- 4 shared cores of stranded compacted copper circular in shape, comprising 3 phase
conductors and a neutral conductor. QICC COMPLY
- The neutral conductor shall be of the same size as the phase conductors.
- XLPE Core insulation colored to identify cores.

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- Cores lay up with inner covering solid extruded tightly bound and without any gaps
between cores.
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- Galvanized steel wire armour, interspersed with tinned copper wires.
- PVC over sheath.
4.2 Single core cables:
- Single core circular in shape and of stranded compacted copper conductor.
- XLPE core insulation, circular in section and of a thickness appropriate to the intended
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system voltage.
- Inner cover or bed for the armor.
- The whole shall be surrounded by armor of Round copper wires and PVC over sheath.
5.0 ENVIRONMENTAL CONDITIONS
5.1 Climatic Conditions
The following conditions prevail generally throughout the State of Qatar.
Altitude : Low laying, generally close to sea level, no point exceeding 100m above sea level.
Maximum air temperature: 50 oC (46 oC typical).
Minimum air temperature: 0 oC (10 oC typical).
Mean Maximum summer air temperature: 45 oC typical.
Mean Maximum exposed
Sunlight temperature: 75 oC typical.
Solar Radiation - Peak: 1030 Watts/sq.m.
Humidity : 100% humidity is common throughout the
year and may occur at air temperature of 30 oC or more.
Rainfall : Very low on average. The winter season may bring infrequent very heavy rainfall. QICC COMPLY
General Atmospheric Condition : A hot atmosphere containing very fine, highly
penetrating dust particles. In parts the atmosphere contains a highly corrosive salt laden sea
mist. Prevailing winds generally from the northwest mostly light but occasionally gusting in excess
of 30 knots.
General Ground Conditions : Very dry limestone type, including rock with typical
o
thermal conductivity 2.0 to 4.0 C m/w, very wet, high salt and sulphate content, very corrosive.
5.2 System
LV system has 5 wires i.e. 3 phase + neutral + earth. Neutral and earth are directly shorted at
the distribution substation end. A consumer earth terminal is provided.
Nominal Voltage : 415/240V
Frequency : 50 Hz
Highest symmetrical fault level : 44 kA

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The highest fuse rating : 400 A

Fault duration is limited by HRC fuses, type J to BS 88. QICC COMPLY

6.0 CABLE CONSRTUCTION DETAILS

6.1 Multi-core Cables
6.1.1 Conductors:
Plain, stranded, compacted copper conductor with 100 % conductivity, clean smooth surface and
free from any foreign particles generally in accordance with IEC 60228 and shall be sector QICC COMPLY
shaped for sizes of 70 sq. mm and above. All cables shall have a full size neutral conductor.
6.1.2 Standard Sizes:
The nominal conductor sizes shall be 4core 300,240,185,120,70,35,16 sq.mm and 2core
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16 sq. mm.
6.1.3 Core Insulation:
Designation XLPE ( IEC 60228) Highest rated temperature 90 oC (IEC 60502).Insulation thickness
appropriate to applied voltage, IEC 60502. The process of extrusion shall have the facility at the point of extrusion
to monitor and control the thickness of insulation and the concentricity of the cable.The cable core shall be dry
cured.The phase conductor insulation for 4 core cables, shall be colored RED, YELLOW, and BLUE. For 2 core QICC COMPLY
cables, the phase conductor cables shall be RED In all cables, the neutral insulation shall be colored BLACK. The
colors should permanent and guaranteed for entire service life of cable.

6.1.4) Inner Covering :

The inner covering shall be solid extruded. The material to be used shall be for the operating temperature and
design temperature conditions and of a ,thickness in accordance with IEC
60502 and compatible with insulating material. The material should be fire retardant and
comprises of anti aging components. The cores shall be laid up with non-hygroscopic fillers and bound with a QICC COMPLY
closed helix of polymer tape of material appropriate to the cable temperature. There should not be any gap
between cores and maintain the perfect round shape of overall cable.

6.1.5) Armor:
The armor shall comprise a single layer consisting of both galvanized steel and tinned copper
round wires.
The conductivity of the copper wires alone shall be at least 50% of that of any phase conductor,
at their respective normal working temperatures. The tinned copper wire shall be of substantially
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the same diameter as, and not less than the diameter/thickness of the armor wires. They shall
comprise not less than 25% of the total number of armor wires. The whole
combination of steel and copper wires shall be laid in close contact with no discernable gaps. An

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open helix consisting of galvanized steel tape of minimum nominal thickness 0.3 mm may be
provided over round steel wire armor. Galvanizing of the wires shall be in conformity with BS EN
10257. The copper wires shall be uniformly dispersed among the steel wires. Two swallow able
water blocking tapes shall be provided one each, over and under the armor layer. These tapes
shall be capable of absorbing water and remain dry by forming into gel. The purpose of which is QICC COMPLY
to inhibit flow of water in the event of penetration of the over sheath, or inflow from a faulty joint.
The material shall be chemically inactive with the components with which it is in contact, both
with and without the presence of water. It shall be solid at the working temperature of the
adjoining components.
6.1.6) Oversheath:
PVC extruded directly over the armor and water inhibitor (water blocking tape). The material
should be fire retardant, UV resistance and comprises of anti aging components and high
resistant to soil. It shall be type ST2 in accordance with IEC 60502 and IEC 60332-1. Thickness
shall be in compliance with the above standard. The over sheath shall be colored in BLACK, and
shall be embossed with the legend:
- KAHRAMAA
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- 600/1000V LV XLPE
- CABLE SIZE AND NUMBER OF CORES
- STANDARD NO.
- YEAR OF MANUFACTURE
- NAME OF MANUFACTURER AND COUNTRY OF ORIGIN
- RUNNING SERIAL (AT INTERVAL OF 1 METER)
6.2 Single Core Cables
6.2.1) Conductors:
Plain, stranded, compacted copper conductor with 100 % conductivity, clean smooth surface and
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free from any foreign particles generally in accordance with IEC 60228.
6.2.2) Standard sizes:
300,400,630,and 800 square.mm QICC COMPLY
6.2.3) Insulation:
Designation XLPE ( IEC 60228) Highest rated temperature 90 oC (IEC 60502).
Insulation thickness appropriate to applied voltage, IEC 60502.The process of extrusion shall
have the facility at the point of extrusion to monitor and control the thickness of the insulation QICC COMPLY
and the concentricity of the cable. The cable core should be dry cured.
6.2.4) Inner Covering:

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The inner covering shall be solid extruded. The material to be used shall be for the operating
temperature and design temperature conditions and of a thickness in accordance with IEC
60502 and compatible with insulating material. The material should be fire retardant and QICC COMPLY
comprises of anti aging components

6.2.5) Armor:
This shall serve as an earthed screen to provide protection in the event of penetration. To avoid
the risk of corrosion resulting from penetration of the over sheath, and to ensure compatibility
with termination glands, this shall be of round copper wires. The copper wires shall be laid in
close contact with no discernible gaps. Two swellable water blocking tapes shall be provided one
each, over and under the armor layer. These tapes shall be capable of absorbing water and QICC COMPLY
remain dry by forming into gel. 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 material shall be chemically inactive with the components with
which it is in contact, both with and without the presence of water.
6.2.6) Oversheath:
PVC extruded directly over the armor and water inhibitor (water blocking tape). The material
should be fire retardant, UV resistance and comprises of anti aging components and high
resistant to soil. It shall be type ST2 in accordance with IEC 60502 and IEC 60332-1. Thickness
shall be in compliance with the above standard.
The over sheath shall be colored in BLACK, and shall be embossed with the legend:
- KAHRAMAA
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- 600/1000V LV XLPE
- CABLE SIZE
- STANDARD NO.
- YEAR OF MANUFACTURE
- NAME OF MANUFACTURER AND COUNTRY OF ORIGIN
- RUNNING SERIAL (AT INTERVAL OF 1 METER)
7.0 CABLE DRUMS
All cables shall be supplied on cable drums with a maximum diameter of 2.55m and a maximum
width of 1.28m. No drums with cable shall weight more than 7.5 tones. In addition the lengths of
cables on the
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drums shall be in accordance with the Schedule of Quantities.
The 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 with tubular steel insert

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shall be fitted to accept a 100mm diameter 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:
- Manufacturer's name including Country of Origin.
- Drum number/year of manufacture of cable
- Size and voltage of cable, including the designation
"Cross Linked Polyethylene (XLPE)".
- Length of cable on the drum with sequential starting & end number.
- “KAHRAMAA”.
- Order Number.
- The Contract No.
- An Arrow with the wording “Roll On this way” to indicate the direction of rolling
The nominal lengths to be as stated in the schedule below:-

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- A tolerance of +/- 5% on the length of cable per drum shall be allowed.

- As and when required for specific project, the drum length may varies to minimize the
number of joints
8.0 STORAGE AND HANDLING
All cables supplied to KAHRAMAA or other projects shall be stored and handled in accordance
with BS8512:2008.
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- Storage shall be in accordance with clause 5.1 through 5.5. This is clearly illustrated in
the figures 1a, 1b & 1c of this standard.

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- Manual handling and lifting with the fork lifter or crane shall be in accordance with clause
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6 & 7 of the standard.
9.0 TESTS:
This relates to type tests and other tests to be carried out during or after manufacture of the
specified Cables. Routine, type and special tests shall be carried out in accordance with latest
version of International standards IEC 60502-2, IEC 60228 & BSI BS EN 60811 and shall be
repeated if KM considers necessary for a particular project or supply order.
Copy of type test reports issued from reputed independent laboratories need to be submitted. QICC COMPLY
The following tests shall be carried out on each manufactured length of cable, or sample length
as instructed by KAHRA MAA.
Manufacturer has to submit test plan and schedule for Kahramaa approvals.
Kahramaa has the right to witness any test with no obligation to Kahramaa.
A. Routine Tests:
Routine tests are to be carried out each and every drum manufactured. One set of routine test
reports of each drum shall be fixed with the drum in a strong water-proof envelope. Another set
to be submitted along with drums serial numbers and details as mentioned in clause 7.0 prior to
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delivery. The following routine tests are to be carried out.
1. Electrical Resistance of Conductors.
2. Voltage Test.
B. Sample Tests:
Sample tests are to be carried out on 10 % drums of each lot. Samples to be taken from both
sides of the entire length of the drum. One set of sample test reports of shall be submitted to IEC 60811-1-1 was
KAHRAMAA for review and approval. Another set to be submitted along with drums serial replaced with
IEC 60811-201,
numbers and details as mentioned in IEC 60811-202,
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clause 7.0 prior to delivery. The following sample tests are to be carried out. IEC 60811-203
1. Conductor Examination.
2. Check of Dimensions as per IEC 60811-1-1
3. Hot Set Test.
C. Type Tests:
Manufacturer shall carry out type tests to IEC 60502 on the cable and issue certificates
confirming that the cable has conformed.
In general, following test to be carried out at International Reputed Independent Laboratory in QICC COMPLY
accordance with IEC 60502- Part -1 and IEC 60228.

Type Test - Electrical QICC COMPLY

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1. Insulation Resistance Measurement at ambient temperature.

2. Insulation resistance measurement at maximum temperature in normal operation QICC COMPLY
3. Voltage Test for 4 h.
Type Test - Non-Electrical
1. Measurement of thickness of insulation.
2. Measurement of thickness of non-metallic sheaths (including extruded separation, but
excluding inner covering). Special Bending test
is not required for this
3. Test for determination the mechanical properties of insulation before and after ageing. type of cables.As per
4. Test for determination the mechanical properties of non-metallic sheaths before and after IEC 60502-1,Special
ageing. bending test shall be
5. Additional ageing test on piece of completed cable. made on cables
6. Loss of mass test on PVC sheaths of type ST2. having collective
7. Pressure test at high temperature on insulation and non-metallic sheaths. QICC COMPLY layer in the form of
8. Test on PVC insulation and sheaths at low temperature. metallic tapes.
9. Test for resistance of PVC insulation and sheaths to cracking (heat shock test).
10. Hot set test for XLPE insulation.
11. Water absorption test on insulation.
12. Flame spread test on single cables.
13. Shrinkage test for XLPE insulation.
14. Special bending test
15. Examination of conductor per IEC 60228
10.0 TESTING, INSPECTION & DELIVERY
10.1 Before commencing the production/manufacturing of 1st lot, against KM tenders, the
manufacturer is obliged to produce samples and inform Kahramaa for inspection and
acceptance through witnessing factory acceptance tests, and routine tests.
10.2 For every subsequent lot, the manufacturer is obliged to inform Kahramaa, at least 20
days before dispatch, and obtain clearance for dispatch. KM Engineers have the option
of inspecting & witnessing all factory acceptance tests, including routine tests, at
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manufacturer’s factory premises for each lot.
10.3 Acceptance by KM Engineer(s)/Representative(s) of any Lot shall not relieve the
manufacturer from any of their responsibilities, guarantees, or from other obligations,
to comply with product requirements.
10.4 Type tests are to be carried out on Samples, essentially of same design and ratings, as
being offered. Manufacturer is obliged to provide details of test procedures being
followed, to the KM inspection team before commencing factory accepting tests.

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Kahramaa has the right to witness any test with no obligation to Kahramaa.

10.5 Each Lot needs to be subjected to all routine and sample tests at factory before
delivery. Further, each drum may be subjected to inspection on receiving them at DOHA to
verify its healthiness and its conformity with the guaranteed design data. All tests should be
performed in accordance with the latest issue of relevant IEC standards
10.6 Three sets (copies) of routine and sample tests & FAT reports to be prepared. One set to be
attached with the drum, in a strong water-proof envelope. Second copy to be sent along with
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delivery note. Third copy to be sent to the end-user department.
10.7 FAT report shall include copy of ‘quality control report’ containing ‘list of check points’
verified/inspected at factory against each drum.
10.8 Each delivery note shall include the details of ‘serial number’ and ‘month/year’ of
production of each drum.
10.9 Both the manufacturing date (i.e. month/year) and delivery date should be marked on
each drum, and the time difference between these two dates should not be more than 6-
months.
11.0 INFORMATION TO BE PROVIDED AT THE TIME OF TENDER
11.1 An illustrated drawing showing the cable cross section design, all components, dimensions
of each layer.
11.2 A specific compliance (clause by clause up to sub clause level), statement of conformity with
the specification, else details of non-conformity with justification.
11.3 Details of the method of protection against water ingress at armour level. QICC COMPLY
11.4 Permissible fault ratings of the conductors and the armour.
11.5 Type Test Report from International recognized Independent Laboratory.
11.6 Routine and sample tests plan.
11.7 Quality assurance and quality control protocol or manual.
11.8 Supply record for GCC utilities and other countries.
12.0 GUARANTEE
Supplied material shall be guaranteed against any defect for 10 (Ten) years from the date QICC COMPLY
of delivery or 8 (eight) years from the date of installation whichever comes first.
13.0 DEVIATIONS FROM THE TECHNICAL SPECIFICATION
The Bidders 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 QICC COMPLY
clause of the Specification.

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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. QICC COMPLY
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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