PART VI

( SPECIFICATION )

22/11 KV XLPE CABLES

22/11 KV XLPE CABLES

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22&11kV XLPE Cables

LIST OF CONTENTS FOR TECHNICAL SPECIFICATIONS FOR

22/11 KV XLPE CABLES
INDEX
SECTION

TITLE

1.

SCOPE

2.
2.1
2.2

APPLICABLE STANDARDS
International Standards
Internal Standards

3.
3.1.
3.2.
3.3.
3.4.
3.5.
3.6.
3.7.
3.8.
3.9.
3.10.
3.11.
3.12.
3.13.
3.14.

DESIGN AND CONSTRUCTION

Conductors
Conductor Screen
Insulation
Insulation Non-metallic Screen
Insulation Metallic Screen
Water Sealing
Armour Bonding
Armour
Over sheath
Extrusion
Core Identification
Laying-up
Embossing
Overall Dimensions

4.

COMPONENTS AND ACCESSORIES

5.

OPERATIONAL REQUIREMENTS

6.

MAINTENANCE REQUIREMENTS

7.
7.1.
7.2.
7.3.
7.4

TYPE, ROUTINE AND FACTORY ACCEPTANCE TESTS

Type Tests
Routine Tests
Factory Acceptance Tests
Physical inspection of cable, drum and packing

8.
8.5.

COMMISSIONING REQUIREMENTS AND TESTS

Tests After Laying

9.
9.1.
9.2.

TOOLS AND ACCESSORIES

Cable length
Sealing and Drumming

10.
10.1.
10.2
10.3
10.4
10.5
10.6

RATING AND DATA SHEET

Data Sheet for 11kV Cables
System
Design Criteria
Type of Cables
Construction
Data Sheet for 22kV Cables

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1.

SCOPE

Para (1)

This section details technical specification of XLPE insulated power cables for nominal
system voltage of 11 and 22 kV.

2.

APPLICABLE STANDARDS

2.1

International Standards

Para (2)

Except where modified by this specification, cable shall be designed, manufactured, and
tested in accordance with the latest edition of IEC 60502-2 publication including
amendments and other publications quoted in these Standards.

2.2

IEC 60060

High Voltage Test Techniques - Part I: General Definitions and Test

Requirements.

IEC 60183

Guide to the selection of high voltage cables.

IEC 60228

Conductors of insulated Cables

IEC 60230

Impulse Tests on Cables and their Accessories.

IEC 60502-2

Power Cables with extruded insulation and their accessories for rated
voltages from 1kV (Um = 1.2 kV) upto 30 kV (Um = 36 kV) -Part 2:
Cables for rated voltages from 6kV (Um = 7.2 kV) upto 30 kV (Um = 36
kV).

IEC 60502-4

Power Cables with extruded insulation and their accessories for rated
voltages from 1kV (Um = 1.2 kV) up to 30 kV (Um = 36 kV) -Part 4:
Test requirements on accessories for cables with rated voltages from 6
kV (Um = 7.2 kV) up to 30 kV (Um = 36 kV)

IEC 60811

Common test methods for insulating and sheathing materials for electric
cables.

IEC 60885

Electrical test methods for electric cables.

IEC 60986

Guide to the short circuit temperature limits of electric cables with a

rated voltage from 1.8/3 (3.6) kV to 18/30 (36) kV.

IEC 60287

Electric Cables - Calculation of the current rating

Internal Standards

Site and system operating conditions as per Design Criteria 1.1.0.0.0.01

General Technical Requirements for equipment as per 1.2.1.0.0.01.
General quality assurance requirements for Equipments as per 1.3.1.0.0.01.
Quality management system as per ISO 9001

3.

DESIGN AND CONSTRUCTION

Para (3)

This specification covers the following types of cables:

Para (4)

Single core unarmored cables

Three Core armored cables.

Water protection cover over individual core.

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Para (5)

Easy to remove water barrier tubes / semi-conducting / insulation by special tools

Para (6)

Design and construction data for each type of cable is given in 'Data Schedule for Cables in
Enclosure-1.

Para (7)

Three core cable with circular, stranded copper/aluminium conductors with triple extruded
conductor screen, insulation and insulation screen of which conductor and insulation screen
are of semi-conducting materials and insulation is of dry vulcanized cross linked
polyethylene, all the individual cores laid up with non-hygroscopic Fillers, individual
metallic screens of copper tape and/or wires, armored with a single layer of galvanized steel
wires and PVC/PE sheathed overall suitable for 6.35/11 (12) and 12.7/22(24) KV working
voltage manufactured generally in accordance with IEC Publication 60502.

Para (8)

Water sealing of conductors and longitudinal and radial water sealing along the metallic
screen is applied.

Para (9)

The following conductor sizes are covered by this specification:

Type-1: 300sq.mm, Copper

Type-2: 300sq.mm, Aluminium
Type-3: 240sq.mm, Copper
Type-4: 240sq.mm, Aluminium

3.1.

Conductors

Para (10)

The conductors shall be stranded compacted circular construction. Conductor material

shall be annealed copper or aluminium with cross section as specified in Specific
Requirements and shall conform to class 2 of IEC 60228 Specifications. The wire before
shaping shall be smooth, uniform in quality, free from scale, inequalities, spills, splits and
other defects.

3.2.

Conductor Screen

Para (11)

The conductor screen shall consist of an extruded semi-conducting compound. The

screen shall fill the interstices between the outer individual strand wires forming the
conductor and provide a smooth, regular interface to the insulation layer. The extruded
semi-conducting compound shall be firmly bonded to the insulation.

3.3.

Insulation

Para (12)

Insulation shall be extruded cross-linked polyethylene (XLPE), which shall be applied

using a dry cure process designed to eliminate micro voids in the insulation.

Para (13)

The tenderer shall furnish separately material properties of XLPE as listed below:

Para (14)

Physical properties
Electrical properties
Aging properties
Anti hygroscopic properties
Heat distortion properties
Certificates of origin from Raw Material Manufacturers

The average thickness of the insulation, when determined by the method described in
IEC 60811 shall not be less than the value stated in IEC 60502-2. The thickness at any
place may, however, be less than the specified nominal value provided that the difference
does not exceed the limit specified in IEC 60502-2. The thickness of the semi-conducting
screen on the conductor or over the insulation shall not be included in the thickness of the
insulation.

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3.4.

Insulation Non-Metallic Screen

Para (15)

The insulation screen shall consist of a layer of extruded semi-conducting compound,

having a minimum thickness of 1.0 mm, compatible with insulating material. The screen
shall be designed to be easily stripped without damaging the insulation or leaving
conducting material on the insulating surface.

Para (16)

An insulation screen that requires heat for its removal is not acceptable.

Para (17)

The insulation screen shall be applied directly upon the core insulation in a manner
ensuring a uniform voltage stress across the insulation along the length of the cable.

3.5.

Insulation Metallic Screen

Para (18)

The metallic screen shall consist of a layer of copper tape and/or layer of annealed bare
copper wires. Metallic screen shall be applied on 3 individual screens, one on each core.
Layers of copper tape shall have a minimum of 15 percent overlap.

Para (19)

Effective cross-sectional area of three individual metallic screens shall be such that these
(metallic screens) in combination with Armour shall be suitable for withstanding an earth
fault current and duration as per 'Data Schedule for cables- Enclosure-1.

3.6.

Water Sealing

Para (20)

Cables shall be provided with water sealing of conductor and longitudinal and radial
water sealing along the metallic screen as described below:

Para (21)

The conductor water sealing shall consist of a swelling material provided between
conductor strands which turns into a jelly when comes in contact with water.

Para (22)

The longitudinal water sealing along the metallic screen shall be provided by a swelling
layer applied under and over the metallic screen, or by a swelling material provided
between metallic screen wires as applicable.

Para (23)

The swelling layer to be provided under the metallic screen should be semi conductive
and compatible with the extruded insulation screen and the metallic screen.

Para (24)

The radial water sealing shall be provided by:

An extruded corrosion resistant metallic sheet (corrugated if required) or

Extruded PE (Polyethylene) applied over metal laminate.

Para (25)

Radial water sealing is to be provided on individual cores

3.7.

Armour Bedding

Para (26)

An extruded bedding of PVC type ST2 shall be applied over the three-core assembly.
Interstices formed between the cores shall be substantially filled.

3.8.

Armour

Para (27)

The Armour shall consist of a single layer of galvanized round steel wires of appropriate
size conforming to the requirements of BSEN 10257-1&2: 1999.

Para (28)

Alternatively, galvanized flat steel wires may be proposed. The tenderer shall indicate the
applicable standard including the test methods and acceptance criteria with respect to
sub-clauses. When joints in the Armour are necessary, they shall be brazed or welded and
any surface irregularity shall be removed. A joint in any wire shall be not less than 1

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22&11kV XLPE Cables

meter from the nearest other wire joint in the completed cable. The Armour wire must
cover the entire periphery.
Para (29)

Provision of few copper wires in Armour in place of few galvanized steel wires to
improve conductivity will not be acceptable due to the risk of galvanic corrosion.

3.9.

Over sheath

Para (30)

The over sheath shall be an extruded layer of polyethylene type ST7. An outer
conducting coating shall be applied to the covering to serve as an electrode for the
voltage test on the over sheath.

3.10.

Extrusion

Para (31)

Conductor screen, insulation and insulation screen shall be applied by triple extrusion
process.

3.11.

Core Identification

Para (32)

The cores shall be identified in a distinct manner either by color (Red, Yellow and Blue)
or by number (1, 2 and 3).

3.12.

Laying-up

Para (33)

Three individual cores shall be laid-up in a right hand direction of lay. Where necessary,
non-hygroscopic fillers shall be employed to form a compact and circular cable.

3.13.

Embossing

Para (34)

The over sheath shall be embossed in English along two lines equally spaced around the
circumference of the cable with the name of the Manufacturer, year of manufacture, type
of insulation (XLPE), number of cores, conductor size and material followed by the
details given below:
DEWA ELECTRIC CABLE 11 000 V Contract No. CE/...../.... for 11 kV cable
DEWA ELECTRIC CABLE 22 000 V Contract No. CE/...../.... for 22 kV cable

Para (35)

The letters and figures shall be raised and shall consist of upright block characters. The
maximum size of the characters shall be 13 mm. and the minimum size 15% of the
appropriate overall diameter of the cable or 3 mm. whichever is the greater. The gap
between the end of one legend and the beginning of the next shall not be greater than 150
mm.

Para (36)

The extruded over sheath shall also be marked on the circumference of the cable
indicating cumulative marking of length of cable wound on the drum. Such marking
starting with "000" on the inner end of cable shall be made at interval of 1 or 10 meters.
The marking on outer end of cable shall indicate in integer the actual length of the cable
on the drum. The inner as well outer end of cable brought out on the drum flange shall
be clamped in such a manner to make the cable length marking easily visible.

3.14.

Overall Dimensions

Para (37)

The overall diameter of the manufactured cable shall not be more than 5% of the
guaranteed value indicated by the Tenderer in his offer.

4.

COMPONENTS AND ACCESSORIES

Para (38)

Nil

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5.

OPERATIONAL REQUIREMENTS

Para (39)

Nil

6.

MAINTENANCE REQUIREMENTS

Para (40)

Nil

7.

TYPE, ROUTINE AND FACTORY ACCEPTANCE TESTS

7.1

Type tests

Para (41)

All electrical (clause 18) and non-electrical (clause 19) type tests applicable to 22 kV
grade XLPE insulated cable as specified in IEC 60502-2 shall be carried out, including
longitudinal water tightness test (both conductor and metallic screen) in accordance with
IEC 60502-2 (clause 19.22) and its Annexure-D. Radial water tightness of the cable shall
be demonstrated by a suitable test to be proposed by the Tenderer.

Para (42)

However, these type tests need not be repeated under the contract if the manufacturer
submits satisfactory test reports/certificates, acceptable to DEWA, on tests conducted
previously on identical design and size of cable.

7.2

Routine Tests

Para (43)

Routine tests shall be carried out on random samples selected by DEWA inspector(s).
The frequency of sampling shall be two lengths (drums) per 10 kms length of cable but
limited to minimum 2 lengths (drums) and maximum 8 lengths (drums) of cable per
consignment/lot.

Para (44)

The following routine tests shall be carried out as per the requirement of IEC 60502-2.

Measurement of the electrical resistance of conductors (clause 16.2).

Partial discharge test (clause 16.3).
High voltage test (clause 16.4).
Voltage test on over-sheath (25kV, d.c.).

Sample Tests
Para (45)

Sample tests shall be carried out on cable samples selected at random by DEWA
inspector(s). Minimum number of samples shall be 2 lengths (drums) or 20% of the
number of lengths (drums) which ever is less and maximum of 8 lengths (drums) per
consignment.

Para (46)

The following sample tests shall be carried out as per the requirement of IEC-60502-2:

Conductor examination (clause 17.4).

Check of dimensions (clauses 17.5 to 17.8).
Voltage test (clause 17.9).
Hot set test for XLPE insulation (clause 17.10).

Para (47)

In addition to the above sample tests specified in IEC 60502-2, the following tests should
be carried out on samples selected as above, as per the requirements of standards
specified therein.

Para (48)

Tensile Strength of Armour Wires: Galvanized steel Armour wires shall be tested for
tensile strength. The tensile strength shall fall within the permissible range of 340 - 500
N/mm2 and elongation at break shall be above the minimum permissible value of 10% as
specified in BS EN 10275-1&2.

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Para (49)

Measurement of zinc coating of Armour Wires: Galvanized steel Armour wires shall be
tested to determine the mass of Zinc coating. Mass of Zinc coating shall be in excess of
275 g/m2, the minimum specified in BSEN 10244-2.

7.3

Factory Acceptance Tests

Para (50)

Manufacturer shall complete the routine & sample tests as per the standard specified in
this technical specification on each type and size of cables and their test reports shall be
handed over to DEWA Engineer(s) for verification during witness test & inspection.

Para (51)

Witness test and inspection shall be carried out as specified in Cl.8.1.1. 8.1.2 and Cl.8.2
of this specification in the presence of DEWA nominated inspectors.

Para (52)

Minimum of four length (drums) shall be tested for routine and special tests during the
witness test per day. Deviations, if any, in meeting this minimum requirement in testing
shall be indicated in the list of deviations during tendering stage.

7.4

Physical inspection of cable, drum and packing

Para (53)

Physical inspection shall be carried out to ascertain the compliance with the requirements
specified in clause 7.13 (embossing), 9.1 (cable length) & 9.2 (drum dimensions &
packing) of this technical specification.

Para (54)

Manufacturer shall arrange/keep the whole cable appropriately, so that DEWA

inspector(s) can verify the compliance with the above requirements conveniently.

8.

COMMISSIONING REQUIREMENTS AND TESTS

8.1

Test after laying

Para (55)

Test after laying is to be recommended by the manufacturer considering

recommendations from CIGRE WG.21.9 (Electra No.148 June 1993) and IEC 60502-2,
subject to DEWA's approval.

9.

TOOLS, SPARES AND ACCESSORIES

9.1

Cable Length

Para (56)

The cables shall be supplied in nominal drum length within 5% tolerance. The nominal
length for 3Core, 300 and/or 240 sq. mm Aluminium conductor shall be 500 m and
copper Conductor cable shall be 325 meter. The gross weight of the cable drum shall not
exceed 7500 kg.

9.2

Sealing and Drumming

Para (57)

Before dispatch, the manufacturer shall cap the ends of all cables so as to form a seal to
prevent the ingress of water during transportation, storage and installation. The cable
shall be supplied on stout wooden / steel drums, which shall be designed so as to protect
the cable from damage. The drums shall be made from best quality batten, each having
thickness of not less than 40 mm Minimum overall thickness of each flange of the cable
drum shall be 80 mm. The lagging batten shall be secured at least with two nails of each
end in addition to steel bonding straps.

Para (58)

No drum shall contain more than one length of cable. The overall dimensions of the cable
drum shall not exceed the following limiting values:

Outer distance between flanges: 1800 mm

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22&11kV XLPE Cables

Diameter of the flanges:

3500 mm

Para (59)

The cable shall be tightly wrapped on the cable drum and no turn shall be left loose.
Both ends of the cable shall be adequately secured to the cable drum. Inner end of the
cable shall be suitably fixed/gripped to the cable drum so that it will not come out during
cable laying operation. The cable shall be wrapped on drums of suitable diameter such
that the radius of bend of the innermost layers is not less than the minimum radius of
bend stipulated for installation of the cable.

Para (60)

No space shall exist between the adjacent layers of the cable and between the drum
flange and the cable.

Para (61)

Cable shall be wrapped with black polyethylene sheet inside the wood covering of drum.

Para (62)

Central lifting hole of the cable drums shall be provided with a steel pipe and the inner
diameter of steel pipe shall be from 100 mm to 115 mm. The pipe shall be welded with
steel plates at both ends and these plates shall be duly secured to the flanges of the cable
drum with suitable size bolts. The pipe and the welded end plates shall be of robust
design to withstand the weight of the cable drum during unrolling.

Para (63)

Each drum shall bear a distinguishing number on the outside of the flanges and
particulars of the cable, i.e. voltage, length, conductor size, cable type and gross weight
shall also be clearly visible. The direction for rolling shall be indicated by an arrow.

Para (64)

The size of shipping marks indicated in clause 7.3 of 'Conditions of Tendering' is not
applicable for cable drums due to limited space on cable drum flange. These marks shall
be minimum height of 7.5 cm.

10.

RATINGS AND DATA SHEET

10.1

System data

Para (65)

(Replacing System Parameters data in document 1.1.0.0.0.01)

1. Nominal System Voltage
2. Conductor Short Circuit Current (kA)
3. Short Circuit duration (sec.)
4. Earth Fault Current (kA)
5. Earth Fault duration (sec.)
(* For design of armour + metallic screen)

10.2
Para (66)

11 kV
23.5
1
*25
*0.5

Design data
(In addition to document 1.1.0.0.0.01)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Conductor normal operating temperature

Conductor overloading temperature
Conductor/Metallic Screen maximum short circuit
temperature
Conductor and metallic screen temperature before short
circuit earth fault respectively (max)
Laying depth in ground
Formation of single core cables
Bonding
No of 3 phase cables/groups in parallel
Distance between cables/groups
Laying conditions

90 oC
105 oC
250/200 oC
90/85 oC
0.9 meter
Trefoil
Both ends
* 1 or 2
* 0.4 meter
In ground / pipes /
ducts / racks

(*Unless otherwise agreed with DEWA)

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22&11kV XLPE Cables

10.3

Type of Cables

Para (67)
10.4

Single core unarmoured or 3-core armoured

Construction
TYPE OF CABLE
Sec.
Ref.
7.1
7.2
7.3
7.4
7.5
7.6
i)
ii)
iii)
7.7
7.8
7.9
7.10
7.11
7.12
7.13
7.14
8.00
8.01
x
**

10.5
A.

B.

Features

SINGLE CORE
CABLES
Individual Core

Conductor
Conductor Screen
Insulation
Insulation Screen
Metallic Screen
Water Sealing:
Conductor
Longitudinal (metallic
Screen)
Radial
Armour bedding (**)
Armour (**)
Over sheath
Extrusion
Core identification
Laying up
Embossing
Overall dimensions
Inspection
Work Tests
Applicable
Not applicable
When applicable

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

THREE CORE
CABLES
Individual
3 Core
Core
Assembly
x
x
x
x
x
x
x
x
x
x
x
-

x
x
x
x
x
x
x
x

Data Sheet For 22 kV XLPE Cables

System (Replacing System Parameters data in document 1.1.0.0.0.01)
1. Nominal System Voltage
2. Conductor Short Circuit Current (kA)
3. Short Circuit duration (sec.)
4. Earth Fault Current (kA)
5. Earth Fault duration (sec.)
* For design of metallic screen
Design Criteria (In addition to document 1.1.0.0.0.01)
1. Conductor normal operating temperature
2. Conductor overloading temperature
3. Conductor/Metallic Screen maximum short circuit temperature
4. Conductor and metallic screen temperature before Short circuit and
earth fault respectively (maximum)
5. Laying depth in ground
6. Formation of single core cables
7. Bonding
8. No of 3 phase cables/groups in parallel
9. Distance between cables/groups

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22 kV
16
3
*6
*1
90 oC
105 oC
250/200 oC
90/85 oC
0.9 meters
Trefoil
Both ends
* 1 or 2
* 0.4 meter

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22&11kV XLPE Cables

10. Laying conditions

C.

* Unless otherwise agreed with DEWA

Type of Cables

D.

Construction
TYPE OF CABLE

Sec.
Ref.
7.1
7.2
7.3
7.4
7.5
7.6
i)
ii)
iii)
7.7
7.8
7.9
7.10
7.11
7.12
7.13
7.14
8.00
8.01
X
**

Features
Conductor
Conductor Screen
Insulation
Insulation Screen
Metallic Screen
Water Sealing:
Conductor
Longitudinal (Metallic Screen)
Radial
Armour bedding (**)
Armour (**)
Over sheath
Extrusion
Core identification
Laying up
Embossing
Overall dimensions
Inspection
Work Tests
Applicable
Not applicable
When applicable

Dubai Electricity & Water Authority

In ground / pipes / ducts

/ racks
Single core unarmored
or 3-core armored

SINGLE CORE
CABLES
Individual
Core
x
x
x
x
x
x
x
x
x
x
x
x
x
x

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THREE CORE CABLES

Individual
Core
x
x
x
x
x

3 Core
Assembly
-

x
x
x
x
x
-

x
x
x
x
x
x
x
x

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