Specification for XLPE Insulated Pilot Cables EP-MS-P4/S3-050

EP-MS-P4/S3-050

Specification for
XLPE Insulated Pilot Cables

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 Specification for XLPE Insulated Pilot Cables EP-MS-P4/S3-050

Document Control
Department Document Type Document Title

Material EP-MS-P4/S3-50
EP Specification Specification for
Standards XLPE Insulated Pilot Cables

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 Engineer Manager, EN Planning

Signature: Signature:

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

0.0 30.04.2003 First issue of Materials Specification Standards

03.05.2010 Review of Materials Specification Standards

1.0
2.0
3.0
4.0
5.0

Key Words : Specification for XLPE Insulated Pilot 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 XLPE Insulated Pilot Cables EP-MS-P4/S3-050

1.0 SCOPE

The design, manufacture, testing, supply, delivery and performance requirements of

multi-core XLPE insulated cables for use on Standard Pilot Wire Protection Schemes
and Telecommunication Purposes.
The cables will generally be laid in the ground, in a suitable backfill material, or in open
trenches in substations.

2.0 REFERENCES

The cables shall be inconformity with IEC 60502 Part 1, and subsequent amendments,
except as may be otherwise stated, and of the following generic types.

3.0 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.
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.

4.0 ENVIRONMENTAL CONDITIONS

4.1 Climatic Conditions

Altitude : Low lying, generally close to sea level with

no point exceeding 100 meters 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/W/sq.m.
Humidity : 100% humidity is common throughout the
year, and may occur at temperatures in
excess of 30C.
Rainfall : Very low on average.
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 Specification for XLPE Insulated Pilot Cables EP-MS-P4/S3-050

General atmospheric conditions : may be described as a hot atmosphere

containing very fine, highly penetrating
dust particles.
Ground temperature at
one meter depth in summer : 35C, and never falls to 0C.

General Ground Conditions : Very dry, limestone type, with typical

thermal conductivity 2.0 to 4.0C m/W.
Very wet, high salt content, very corrosive.
5.0 Cable Ratings.

5.1 Rated Voltage Uo/U/Um: 0.6/1.0/1.2 kV

5.2 Max. permissible fault current of
conductor for 1 second: 44 KA
Fault duration is set by BS 88 fuse protection, the fuse size being generally 400Amp
maximum. A consumer earth terminal is provided from the main cable.
6.0 CABLE CONSTRUCTION DETAILS

6.1 Conductors:
Stranded, annealed copper conductor, circular in shape in accordance
with IEC 60228.

6.2 Standard Sizes:

The nominal size shall be (4c x 4mm2 + 4 x 2c x 1.5 mm2) 4 core 4 mm2 (cores
shall be laid up together) and 4x2 core 1.5 mm2. (cores shall be laid up in four
sets of twisted pairs)

6.3 Core Insulation:

Extruded solid dielectric: Designation XLPE (IEC 60502)
Highest rated temperature 90oC (IEC 60502) Insulation thickness, as
appropriate to applied voltage, (IEC 60502).

6.4 Core Identification:

Core Identification shall be by numbers printed on the cores insulation. The
numbers shall be in clear contrast to the color of the core insulation.
The four core cable shall have the colors RED, YELLOW, BLUE & BLACK.
The four pairs of 1.5 mm2 cable shall be at the discretion of the manufacturer
subject to following.
i) The colors shall have clear contrast.
ii) Each twisted pair shall have the same color combination throughout all
manufactured length, i.e. color A & color B shall be twisted together, as
shall color C and color D in all manufacturing length.
iii) The colors should be permanent and guaranteed for entire service life of
cable.

6.5 Inner Covering and Fillers: The inner covering shall be extruded. The material
to be used shall meet 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
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 Specification for XLPE Insulated Pilot Cables EP-MS-P4/S3-050

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.

6.6 Armour: The armour shall comprise a single layer of galvanized steel wire of
diameter appropriate to IEC 60502. The armour shall be embedded in, and
covered by a material suitable to prevent the flow of water transversely and
longitudinally. 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
also remain substantially solid at the working temperature of the adjoining
components.

6.7 Oversheath: PVC extruded directly over the armour and water inhibitor (water
blocking tape). The material should be fire retardant, UV resistance, 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
- CABLE RATING
- CABLE SIZE & NUMBER OF CORES
- STANDARD NO.
- YEAR OF MANUFACTURE
- NAME OF MANUFACTURER
- RUNNING SERIAL NUMBER (at interval of 1 meter)
7.0 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.
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.
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 Specification for XLPE Insulated Pilot Cables EP-MS-P4/S3-050

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.

8.0 CABLE DRUMS

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 tubular insert. The plates shall be fixed with 6 bolts through the flange.
All drums shall be printed 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)".

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 Specification for XLPE Insulated Pilot Cables EP-MS-P4/S3-050

- Length of cable on the drum with sequential number.

- KAHRAMAA.
- The Contract No.

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

Cable Sizes Lengths per Drum
2
Pilot Cable 4c x 4mm + 4 pairs x 1.5 mm . 1000 Meters

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

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.

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 Specification for XLPE Insulated Pilot Cables EP-MS-P4/S3-050

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.

10.0 INFORMATION TO BE PROVIDED AT THE TIME OF TENDER

10.1 An illustrated drawing showing the cable cross section design, all components,
dimensions of each layer and data sheets.
10.2 A specific compliance (clause by clause up to sub clause level), statement of
conformity with the specification, else details of non-conformity.

10.3 Details of the method of protection against water ingress at armour level.
Permissible fault ratings of the conductors and the armour.

10.4 Type Test Report from International recognized Independent Laboratory. The
report must be not older than 10 years.

10.5 Complete product catalogue with all ratings, characteristics & recommended
installation procedure.

10.6 Supply record for GCC and other countries.

11.0 GUARANTEE

Supplied material shall be guaranteed against any 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 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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