Specification for LV XLPE Cables EP-MS-P4/S3-040

EP-MS-P4/S3-040

Specification for
LV XLPE Cables

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 Specification for LV XLPE Cables EP-MS-P4/S3-040

Document Control
Department Document Type Document Title
EP-MS-P4/S3-040
Material
EP Specification Specification for
LV XLPE 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

Material Standards & Specification Manager, EN Planning Dept.

Signature: Signature:

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

0.0 30.04.2003 First issue of Materials Specification Standards

19.04.2010 Review of Materials Specification Standards

1.0
2.0
3.0
4.0
5.0

Key Words : Specification for LV XLPE 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 LV XLPE Cables EP-MS-P4/S3-040

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 KAHRA MAA Low
Voltage Distribution System for buried cables only.

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 through out the life of the material stipulated herein.
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

3.2 Max. permissible fault current of
conductor for 1 second: 44 KA

4.0 CABLE CLASSIFICATION

The cables shall be inconformity with IEC 60502 Part 1, and subsequent amendments,
except as may be otherwise stated in this standard. The general classification of cables is
mentioned below.

4.1 Multi-core cables:

4.1.1 4 shared cores of stranded compacted copper conductor circular/sector (as
described herein clause 6.1.1) in shape, comprising 3 phase conductors and a
neutral conductor.
4.1.2 The neutral conductor shall be of the same size as the phase conductors.
4.1.3 XLPE Core insulation colored to identify cores.
4.1.4 Cores lay up with inner covering solid extruded tightly bound along with fillers
and without any gaps between cores.
4.1.5 Galvanized steel wire armour, interspersed with tinned copper wires.
4.1.6 PVC over sheath.

4.2 Single core cables:

4.2.1 Single core circular in shape and of stranded compacted copper conductor.
4.2.2 XLPE core insulation, circular in section and of a thickness appropriate to the
specified system voltage.
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 Specification for LV XLPE Cables EP-MS-P4/S3-040

4.2.3 Inner cover or bed for the armour.

4.2.4 The whole shall be surrounded by armour 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 : 50C (46C typical).
Minimum air temperature : 0C (10C typical).
Mean maximum summer
Air temperature : 45C typical.
Mean maximum exposed
Sunlight temperature : 75C

Solar Radiation Peak : 1030 Watts/sq.m.

Humidity : 100% humidity is common
throughout the year and may occur
at air temperatures of 30C or
more.
Rainfall : Very low on average. The winter
season may bring infrequent very
heavy rainfall.
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. 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 thermal
conductivity 2.0 to 4.0oC 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.

i) Nominal Voltage : 415/240V

ii) Frequency : 50 Hz
iii) Highest symmetrical fault level : 44 kA
iv) The highest fuse rating : 400 A
v) Fault duration is limited by HRC fuses, type J to BS 88.

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 Specification for LV XLPE Cables EP-MS-P4/S3-040

6.0 CABLE CONSTRUCTION DETAILS

6.1 Multicore 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 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 4 core 300, 240, 185, 120, 70, 35, 16
sq.mm & 2 core 16 sq.mm.

6.1.3 Core Insulation:

Designation XLPE (IEC 60502) Highest rated temperature 90oC
(IEC 60502).Insulation thickness appropriate to applied voltage, IEC 60502.The
phase conductor insulation for 4 core cables shall be coloured RED, YELLOW,
and BLUE. For 2 core cables, the phase conductor color shall be RED. In all
cables, the neutral insulation shall be colored BLACK. The colors should be
permanent and guaranteed for entire service life of cable.

6.1.4 Inner Covering and Fillers:

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 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 Armour:
The armour 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 the same diameter
as, and not less than the diameter/thickness of the armour wires. They shall
comprise not less than 25% of the total number of armour wires. The whole
combination of steel and copper wires shall be laid in close contact with no
discernable gaps. An open helix consisting of galvanized steel tape of minimum
nominal thickness 0.3 mm shall be provided over round steel wire armour.
Galvanizing of the wires shall be in conformity with BS EN 10257. The copper
wires shall be uniformly dispersed among the steel wires. Two swallowable water
blocking tapes shall be provided one each, over and under the armour layer.
These tapes shall be capable of absorbing water and 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. It shall be solid at the working temperature of the
adjoining components.

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 Specification for LV XLPE Cables EP-MS-P4/S3-040

6.1.6 Oversheath:
PVC extruded directly over the armour 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 coloured in BLACK, and shall be
embossed with the legend:
- KAHRAMAA
- 600/1000V LV XLPE
- CABLE SIZE & NUMBER OF CORES
- STANDARD NO.
- YEAR OF MANUFACTURE
- NAME OF MANUFACTURER
- RUNNING SERIAL NUMBER (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 free from any foreign particles generally in accordance with
IEC 60228.

6.2.2 Standard sizes:

300, 400, 630 and 800 square. mm.

6.2.3 Insulation:
Designation XLPE IEC 60502. Highest rated temperature 90oC IEC 60502.
Insulation thickness appropriate to applied voltage, IEC 60502.

6.2.4 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

6.2.5 Armour:
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 oversheath, 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 discernable gaps.

6.2.6 Oversheath:
PVC extruded directly over the armour. 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 oversheath shall be coloured
in BLACK, and shall be embossed with the legend:

- KAHRAMAA
- 600/1000V LV XLPE
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 Specification for LV XLPE Cables EP-MS-P4/S3-040

CABLE SIZE & NUMBER OF CORES

-
STANDARD NO
-
YEAR OF MANUFACTURE
-
NAME OF MANUFACTURER
-
RUNNING SERIAL NUMBER (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 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 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
- Drum number/year & month of manufacture of cable
- Size, number of cores and voltage of cable, including the
designation "Cross Linked Polyethylene (XLPE)".
- Length of cable on the drum with sequential number.
- KAHRAMAA.
- The Contract No.
The nominal lengths to be as stated in the schedule below:-
Cable Size Lengths per Drum
4c x 300 sq.mm. 250 Meters
4c x 240 sq.mm. 250 Meters
4c x 185 sq.mm 300 Meters
4c x 120 sq.mm 500 Meters
4c x 70 sq.mm 500 Meters
4c x 35 sq.mm 700 Meters
4c x 16 sq.mm 1000 Meters
2c x 16 sq.mm 1000 Meters
1c x 300 sq.mm 500 Meters
1c x 400 sq.mm 500 Meters
1c x 630 sq.mm 500 Meters
1c x 800 sq.mm 300 Meters
A tolerance of +5% on the length of cable per drum shall be allowed.

8.0 TESTS:

This relates to type tests and tests to be carried out during or after manufacture of the
specified cables. In addition to the type tests conducted in accordance with the
requirements of IEC 60502-Part 1. Copy of type test reports issued from reputed
independent laboratories need to be submitted.

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- Part
1, IEC 60228 and BSI BS EN 60811.

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 Specification for LV XLPE Cables EP-MS-P4/S3-040

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. 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 KAHRAMAA for review and
approval. The following sample tests are to be carried out. One set of
sample test report (wherever applicable) shall be fixed with the drum
along with routine test report.
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 accordance with IEC 60502- Part -1 and IEC
60228.
Type Test Electrical
1 Insulation Resistance Measurement at ambient temperature.
2 Insulation resistance measurement at maximum temperature in
normal operation
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).
3. Test for determination the mechanical properties of insulation
before and after ageing.
4. Test for determination the mechanical properties of non-metallic
sheaths before and after ageing.
5. Additional ageing test on piece of completed cable.
6. Loss of mass test on PVC sheaths of type ST2.
7. Pressure test at high temperature on insulation and non-metallic
sheaths.
8. Test on PVC insulation and sheaths at low temperature.
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
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9.0 TESTING, INSPECTION & DELIVERY

9.1 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.

9.2 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 manufacturers factory premises for each lot.

9.3 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.

9.4 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.

9.5 Each Lot needs to be subjected to all routine tests & 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.

9.6 All tests should be performed in accordance with the latest issue of relevant IEC
standards.

9.7 Three sets (copies) of routine tests, 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 delivery note. Third copy to be sent to the end-user
department.

9.8 FAT report shall include copy of quality control report containing list of check
points verified/inspected at factory against each drum. Each delivery note shall
include the details of serial number and month/year of production of each
drum.

9.9 Both the manufacturing date (i.e. month/year) and shipment date should be
marked on each drum, and the time difference between these two dates should
not be more than 6-months.

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 Specification for LV XLPE Cables EP-MS-P4/S3-040

10.0 INFORMATION TO BE PROVIDED AT THE TIME OF TENDER

An illustrated drawing showing the cable cross section design, all components,
dimensions of each layer and data sheets.
A specific compliance (clause by clause up to sub clause level), statement of conformity
with the specification, else details of non-conformity.
Details of the method of protection against water ingress at armour level.
Permissible fault ratings of the conductors and the armour.
Type Test Report from International recognized Independent Laboratory. The report
must be not older than 10 years.
Complete product catalogue with all ratings, characteristics & recommended installation
procedure.
Supply record for GCC and other countries.

11.0 GUARANTEE

Supplied material shall be guaranteed against any design/manufacturing defect for 5

(five) years from the date of delivery or 3 (three) years from the date of installation
whichever comes first.

12.0 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 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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