GES 60741

Technical Specification of GECOL

Cross Bonding Link Box

(Revision history)
- Issued on: Jan. 01, 2007

General Electricity Company of Libya

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 Contents

1 SCOPE AND SERVICE CONDITIONS...............................................................................................4

1.1 SCOPE...................................................................................................................................................4
1.2 SERVICE CONDITIONS...........................................................................................................................4
1.2.1 Normal service conditions...........................................................................................................4
1.2.2 Unusual service conditions.........................................................................................................4

2 NORMATIVE REFERENCES...............................................................................................................4

3 DEFINITIONS.........................................................................................................................................5

3.1 RATED VOLTAGE...................................................................................................................................5

3.2 RATED OPERATING VOLTAGE................................................................................................................5
3.3 SHEATH VOLTAGE LIMITER (SVL)........................................................................................................5

4 KINDS AND RATINGS..........................................................................................................................5

4.1 KINDS...................................................................................................................................................5
4.2 RATING.................................................................................................................................................5
4.2.1 Voltage and Frequency................................................................................................................5
4.2.2 Earthing.......................................................................................................................................5

5 REQUIREMENTS...................................................................................................................................6

5.1 COMPONENTS.......................................................................................................................................6
5.2 REQUIREMENTS OF BOX.......................................................................................................................6
5.3 REQUIREMENTS OF SVL......................................................................................................................6
5.3.1 Rating..........................................................................................................................................6
5.3.2 Structure......................................................................................................................................6
5.3.3 Other requirements......................................................................................................................7

6 TESTS.......................................................................................................................................................7

6.1 TYPE TESTS..........................................................................................................................................7

6.1.1 Type test of box............................................................................................................................7
6.1.2 Type test of SVL...........................................................................................................................7
6.2 ROUTINE TESTS....................................................................................................................................7
6.2.1 Routine test of box.......................................................................................................................7

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 6.2.2 Routine tests of SVL.....................................................................................................................7

7 RATING PLATE......................................................................................................................................8

7.1 REQUIREMENTS FOR RATING PLATES...................................................................................................8

7.2 INFORMATION OF RATING PLATE OF THE BOX......................................................................................8
7.3 INFORMATION OF RATING PLATE OF SVL.............................................................................................8

8 PACKING AND DELIVERY.................................................................................................................8

9 DOCUMENTS AND CERTIFICATES.................................................................................................9

9.1 INFORMATION TO BE GIVEN WITH GECOL..........................................................................................9

9.1.1 Service conditions........................................................................................................................9
9.1.2 Rated values and characteristics.................................................................................................9
9.2 INFORMATION TO GIVEN WITH SUPPLIERS..........................................................................................10
9.2.1 Technical data sheet..................................................................................................................10
9.2.2 Certificates of type tests and routine and acceptance tests.......................................................10
9.2.3 Guidelines and manuals............................................................................................................10
9.2.4 Safety standards.........................................................................................................................10
9.2.5 Related drawings.......................................................................................................................10

10 Warranty...................................................................................................................................................10

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 GES (Technical Specification of GECOL)
Cross Bonding Link Box

1 Scope and service conditions

1.1 Scope
The specification covers the 3 phase cross bonding link boxes for armored 630mm 2 or
400mm2 single core XLPE insulated cables rated in preferred voltage of 30kV and 66kV
on distribution system in Libya.

1.2 Service conditions

1.2.1 Normal service conditions

Cross bonding link boxes shall be suitable for use under the following service
conditions:
(a) In air, including expose to direct sunlight
(b) Environmental temperatures within the range of –10℃ to +50℃
(c) Installed on underground manholes or pits or chambers or tunnels or vaults or poles

1.2.2 Unusual service conditions

Condition other than those listed in Clause 1.2.1 of this specification for cross bonding
link boxes are considered to be unusual. The manufacturer should discuss with GECOL for
the unusual service conditions.

2 Normative references
The cross bonding link boxes shall confirm to the latest edition of following
international standards:
(a) IEC 60099-4: surge arrester – Part 4: Metal-oxide surge arresters without gaps for a.c.
systems
(b) IEC 60230: Impulse test on cables accessories
(c) IEC 60270: High-voltage test techniques – Partial discharge measurements
(d) IEC 60502: Extruded solid dielectric insulated power cables
(e) IEC 61109: Composite insulators for AC overhead lines with a nominal voltage
greater than 1 000 V – Definitions, test methods and acceptance criteria
(f) IEEE Std 575: Application of sheath bonding methods for single conductor cables and
the calculation of induced voltages and currents in cable sheaths

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 (g) GES 30750: Sheath voltage limiters

3 Definitions
3.1 Rated voltage
Maximum permissible r.m.s. value of power-frequency voltage between its terminals at
which it is designed to operate correctly under temporary over-voltage conditions

3.2 Rated operating voltage

Designated permissible r.m.s. value of power-frequency voltage that may be applied
continuously between the arrester terminals

3.3 Sheath voltage limiter (SVL)

Non-linear metal-oxide type surge arresters to limit the induced voltage in cable sheaths

4 Kinds and ratings

4.1 Kinds
Kinds of the cross bonding link boxes are determined by voltage rating of sheath voltage
limiter to be applied as listed in Table 1 of this specification.
Table 1 – Kinds of cross bonding link box
Specification Voltage rating
Remarks
Number of sheath voltage limiter (kV)
6074100 None Grounding Box
6074103 3 Link Box
6074106 6 Link Box

4.2 Rating
The normal rating specified shall be the continuous rating under the worst temperature
and geographical conditions encountered in Libya.

4.2.1 Voltage and Frequency

(a) The nominal system phase to phase voltage shall be 30kV and 66kV.
(b) The system highest voltage for equipment shall be 36kV and 72.5kV respectively.
(c) The system frequency shall be 50Hz.

4.2.2 Earthing
30kV and 66kV systems are solidly earthed system.

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5 Requirements

5.1 Components
The link box shall include followings:
(a) Fabricated stainless steel box
(b) Heat shrinkable tubings for inside and outside of box
(c) Copper bus bar for earth
(d) 3 sheath voltage limiters for link box
(e) 6 sheath connector
(f) Earthing terminal and terminal lead
(g) All other items necessary to complete cross bonding

5.2 Requirements of box

(a) The box shall be 3 phase link box and compact size. The box shall be fabricated from
stainless steel and be completely explosion proof and watertight.
(b) The box shall be hermitically sealed type and resists water pressure up to 1 bar (20
psi).
(c) Front cover of the box shall be separatable from the box body and tightly jointed with
at least 4 bolts. The box shall have locking knob for locking.
(d) The box shall have 6 ducts for sheath conductor entrance. Inner diameter of each duct
shall be suitable for sheath of 630mm2 and 400mm2 XLPE cable.
(e) The box shall be suitable fixing on wall of underground structure and shall have
suitable accessories. The box shall have earthing bolt connected with inner bus bar.
(f) The surface of box and ducts shall be clean and smooth without sharp edges or surface
projections or burrs likely to damage the bonding leads.

5.3 Requirements of SVL

5.3.1 Rating
(a) Rated voltage shall be 3kV and 6kV
(b) Rated frequency shall be 50 Hz.
(c) Nominal discharge current shall be 10,000 A.
(d) Line discharge class shall be Class 1.
(e) Rated short-circuit withstand current shall be 16kA.

5.3.2 Structure
(a) Sheath voltage limiter shall have ZnO element without gap.

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 (b) Housing of SVL shall be of polymer material.
(c) The housing of the SVL shall be of non-inflammable or self-extinguishing materials
and shall not emit noxious or explosive vapor at any case.
(d) The terminals of the SVL shall be well compatible with the cable terminal lug.

5.3.3 Other requirements

Other requirements which are not defined in this specification shall comply with GES
30750.

6 Tests
6.1 Type tests

6.1.1 Type test of box

(a) Pressure test under water

6.1.2 Type test of SVL

(a) Insulation withstand tests on the SLV housing (IEC 60099-4, 8.2.6-8.2.8)
(b) Residual voltage test
- Steep current impulse residual voltage test (IEC 60099-4, 8.3.1)
- Lightning impulse residual voltage test (IEC 60099-4, 8.3.2)
- Switching impulse residual voltage test (IEC 60099-4, 8.3.3)
(c) Long-duration current impulse withstand test (IEC 60099-4, 8.4.2)
(d) Operating duty test
- High-current impulse operating duty test (IEC 60099-4, 8.5.4)
- Switching surge operating duty test (IEC 60099-4, 8.5.5)
(e) Short circuit (IEC 60099-4, 8.7)
(f) Polluted housing test (IEC 60099-4, Annex F)
(g) Internal partial discharge test (IEC 60099-4, 8.8)
(h) Bending moment (IEC 60099-4, 8.9)
(i) Environmental tests (IEC 60099-4, 8.10)
(j) Seal leak rate (IEC 60099-4, 8.11)

6.2 Routine tests

6.2.1 Routine test of box

(a) Visual inspection

6.2.2 Routine tests of SVL

(a) Measurement of reference voltage (IEC 60099-4, 9.1 (a))
(b) Residual voltage test (IEC 60099-4, 9.1 (b))

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 (c) Internal partial discharge test (IEC 60099-4, 8.8 (c))
(d) Leakage check (IEC 60099-4, 9.1 (d))

7 Rating plate
7.1 Requirements for rating plates
(a) The rating plates shall be plainly visible in the position of normal service and
installation.
(b) The rating plates and their fixings shall be weatherproof and corrosion-proof.
(c) The font, size and colors of letters shall comply with the Table 2 of this specification.
Table 2 – Letter font, size and colors of the rating plate

Font Roman
Letter type
Size 4 mm high at least
Letters Black
Colors
Background White, silver or light gray

7.2 Information of rating plate of the box

The information of rating plate of the box shall include followings;
(a) Name of the box
(b) Applicable international standard
(c) Manufacturer's name
(d) Manufacturer's serial number
(e) Year of manufacture
(f) Number of phases
(g) Rated voltage of SVL inside, if applicable
(h) Total weight
(i) Dimension of the box

7.3 Information of rating plate of SVL

The information of rating plate of the SVL shall include followings;
(a) Manufacturer
(b) Type designation and serial number
(c) Year and Month of manufacture
(d) Rated voltage
(e) Rated continuous operating voltage
(f) Rated frequency
(g) Nominal discharge current
(h) Rated short-circuit withstand current
(i) Weight

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8 Packing and delivery
The supplier shall provide packing of the Link Box as is required to prevent their
damage or deterioration during transit to their final destination and long period of storage.
The packing shall be sufficient to withstand, without limitation, rough handling during
transit and exposure to extreme temperatures, salt and precipitation during transit and open
storage.
(a) All Link Box and their components shall be shipped from the factory to the specified
site.
(b) The size and weight of packing cases shall be taken into consideration, where
appropriate, the remoteness of the Box’s final destination and the absence of heavy
handling facilities at all points in transit.
(c) Each shipment shall include a detailed packing list identifying all items by part
number, including hardware.
(d) All material shall be carefully loaded for protection during shipment.
(e) Small parts and fasteners shall be carefully boxed, crated, bagged or otherwise
containerized and protected for shipment.
(f) All materials shall be arranged to allow safe unloading at the site.
(g) There shall be handling instruction to minimize damage.

The outer packing must be clearly marked on at least four (4) sides as follows;
(a) Name of the procuring department
(b) Name of the supplier
(c) Contract description
(d) Final destination
(e) Gross weight
(f) Any special lifting instructions
(g) Any special handling instructions
(h) Any relevant pollution or environment classifications

9 Documents and certificates

9.1 Information to be given with GECOL

9.1.1 Service conditions

Excluding the normal conditions referred to the Clause 1.2 of this specification, service
conditions at which the Box will be installed shall be stated by GECOL.

9.1.2 Rated values and characteristics

The specific ratings shall be stated by GECOL.

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9.2 Information to given with suppliers

9.2.1 Technical data sheet

The technical data sheet shall be filled and provided by supplier according to the Annex
A of this specification.

9.2.2 Certificates of type tests and routine and acceptance tests

(a) The certificates of type tests according to clause 6.1 of this specification shall be
provided by supplier.
(b) The certificates of routine tests according to clause 6.2.2 of this specification shall be
provided by supplier if required by GECOL.

9.2.3 Guidelines and manuals

The supplier should provide instructions for the transport, storage, installation, operation
and maintenance of a Link Box. The instructions for the transport and storage should be
given before delivery, and the instructions for the installation, operation and maintenance
should be given by the time of delivery at the latest.
(a) The instructions for installation shall be provided by the supplier.
(b) The instructions for operation shall be provided by the supplier.
(c) The instructions for maintenance shall be provided by the supplier.
(d) The schedule for maintenance shall be specified by supplier.

9.2.4 Safety standards

The safety standards for installation, operation and maintenance shall be provided by
supplier.

9.2.5 Related drawings

The related drawings including the shape and dimensions of the Box shall be provided
by supplier.

10 Warranty
The supplier shall provide the full warranty on all equipment supplied during the period
specified below. The warranty shall cover all parts and all costs, which are directly
attributable to the supplier. Warranty coverage shall begin on the date that the equipment is
received. The warranty period shall be two years.

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Annex A

Technical Data Sheet

No. Description Particulars

A Link Box
1 Manufacturer’s name
2 Model No.
3 Applicable international standards
4 Water pressure resistance (bar)
5 Dimension
6 Weight
7 Rated voltage of SVL (kV)
8 Link box components

B SVL
1 Manufacturer’s name
2 Model No.
3 Applicable international standards
4 Rated voltage
5 Maximum continuous operating voltage
Residual voltage
6
Rated frequency
7
Nominal discharge current
8
Line discharge class
9
Rated short-circuit withstand current
10
Steep current impulse residual voltage
11 Lightning impulse residual voltage
12 Switching impulse residual voltage
13 Creepage distance of housing
14 Peak values for the high current impulse operating duty
15 Overall dimensions
16 Weight

Signature :
Designation :
Name of Tenderer :

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Date :

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