1

GOVERNMENT OF KUWAIT
MINISTRY OF ELECTRICITY & WATER
SUPPLY & INSTALLATION OF 132 KV XLPE
POWER CABLES, OPTICAL FIBER CABLES AND ACCESSORIES
GENERAL SPECIFICATIONS

3.1

Extent of Contract

The contract shall be for the manufacturing, testing in the factory, packing, shipment
and delivery CIF to Ministry of Electricity & Water, customs and import duties,
handling charges, transport to site, excavations, laying and installations, pulling
through ducts, backfilling, reinstating of the ground, jointing and terminating, testing
at site and putting to work the circuits, outlined in Detailed Scope of Work.
3.1.1 Supply
The lengths of the various circuits as indicated in Detailed Scope of Work are
approximate and will have to be worked out after the layout of the various equipment
are finalized. The payments for the supply shall be based on measured lengths of the
circuits installed.
N.B.: This contract covers the supply of all jointing materials, compounds and metals
necessary for the installation and jointing of all these cables to their respective
terminations.
The contract covers the installations and jointing of the circuits outlined in Detailed
Scope of Work.
The lengths of the various circuits as indicated in Detailed Scope of Work are
approximate and will have to be worked out after the layout of the various equipment
are finalized.
The payments for the installations shall be based on measured lengths of the circuits
installed. To facilitate easy determination of installation charges, uniform flat rates
shall be quoted for cable installation whether buried (including excavations in ground
or soil of any nature, tiling, install of protection nets and warning tapes and backfilling)
or pulled through ducts, or laid in concrete trenches or on trays or supported by cleats.
The quoted rates for installations shall be firm and shall not be subject to any variation
throughout the contract period.
The arrangement of circuits in Detailed Scope of Work does not depict the
chronological sequences of installation operations. The actual sequence of operations

will be fixed at the time of installation of the circuits with respect to the prevailing
load conditions.
The installation work shall be carried out during the normal working hours of the
Ministry of Electricity & Water. If the contractor wishes to carry out the installation
works after the normal working hours for his own convenience or to meet the contract
completion dates, he should get the approval of the purchaser.
3.1.3 Surplus Cables
Expense of surplus cables will not be paid by the purchaser. Accordingly, the
contractor shall make an accurate survey to meet the actual lengths of the cables
required to complete the items detailed in the scope of works. Disposal of excess or
scrap materials is the contractor's responsibility.

3.2

Details of Existing System

The 132kV and 33kV systems have the following characteristics:

132kV System

33kV System

a)

Voltage

132000V+10%

33000V+10%

b)

No. of Phases

Three

Three

c)

Frequency

50 Hz

50 Hz

d)

Fault Level

10000 MVA at
145 KV

1000 MVA

e)

Maximum fault duration

1.25 seconds

1.5 seconds

f)

System neutral earthing

directly earthed

Through 39 ohms
resistor.

3.3

Site Conditions

Climatic conditions in Kuwait are rigorous and during summer, the ambient
shade temperature rises to 55 C and the sun temperature to 85 C as measured
with a black bulb thermometer. Periods of high humidity are common and a
relative humidity of 100% at 30 C has been recorded. Violent sand and dust
storms occur, even on comparatively still days, fine dust is carried in
suspension in the atmosphere.
The cables will be laid partly in ducts or concrete trenches and partly buried in
the ground at a depth of 1.4 meters for 33 KV cables and 1.5 meters for 132kV

cables where the soil varies from sandy to rock-like gatch compared to dry hard
clay with a corresponding ground thermal resistivity "g" of 120 C cm/watt and
a ground temperature varying from 35 C in summer to 15 C in winter.
The cables called for in this specification shall, therefore give trouble free
service under the worst conditions encountered in Kuwait and shall carry rated
currents continuously under the worst temperature conditions which prevail
in summer and shall also withstand maximum fault current without damage or
deterioration.
The cables will be exposed to direct rays of the sun at the terminations of the
outdoor sealing ends and at the transformers. They should be capable of
withstanding such exposure continuously in service without any deleterious
effect on the insulation, sheathing or covering, by using sun shielding for cables
and sealing-ends. They should also be suitable for storage in the open for a
period of at least two years with patterns.
The soil in Kuwait is very corrosive. Sulphate reducing bacteria is common to
all soils in the Kuwait Area and as the soil is generally rich in sulphate, the
anaerobic conditions which may arise in contact with buried pipes and cables,
favors the development of these anaerobic organisms which generate
hydrogen sulphide and consequently render these areas more corrosive.
In view of the above and the high temperatures encountered in Kuwait, it
should be stressed that PVC plasticizers should be of the long chain; high
molecular weight type to reduce the loss of plasticizers in the hot and corrosion
conditions. This prevents shrinkage of the PVC with subsequent cracking of the
film.
Typical analysis of a soil sample is as follows:
-

Appearance

Wet coarse sand with some clay

Ph value of water in contact

with the sand.

10.0

Calcium sulphate as Ca SO4

25.00% dry basis

Calcium Carbonate as Ca CO3

Silica as Si O4

:
:

40.00% dry basis

22.00 % dry basis

Magnesium Sulphate as Mg SO4

6.00 % dry basis

Sodium Chloride as Na Cl

5.00 % dry basis

Iron as Fe2O3

2.00 % dry basis

Sulphate reducing bacteria

Present

Moisture

15.00 %

N.B.: The sand is not corrosive under dry aerated conditions, but under anaerobic
conditions, the sulphate reducing bacteria in the sand will result in serious
corrosion of metals in contact with the sand. The cables coverings over the
lead sheath as stated in these specifications are designed to combat this.
Where PVC (as sheath serving or overall covering) is used, the PVC should be
suitable for the above soil conditions. Tenderers should confirm in their offers
that the PVC will be suitable for these conditions.
3.4

Details and General Requirements Applicable to Power Cables & Fiber Optic
Cables, Coaxial Cables and Accessories

3.4.A

XLPE Cables

The cables called for in this specification shall have insulation levels to withstand to
voltage surges that may occur due to switching operations, sudden load variations and
faults ...etc. The cable shall satisfy the requirement of:
IEC 60502 for 33 KV cables and IEC 60840 for 132 KV Cables as a minimum:
a)

Conductors

The strands used in the making -up of different sizes of conductors shall be
plain, smooth, annealed high conductivity copper wires laid up and shaped into
circular cores complying with IEC 60228 and BSS 6480 recommendations.
Oval or sector shaped cores will not be accepted sizes and numbers of wires
shall be stated in the schedules. Also aluminum conductors will not be
accepted.
b)

Insulation

Insulation for the cables shall be of the best quality dry cured XLPE type. The
insulation for 132kV cables shall be designed for an impulse voltage level of
650kV peak and the 33 KV cables shall be designed for impulse voltage level of
195kV peak the insulation should be designed for a life time of 50 years.
c)

Sheath

To ensure the highest degree of protection against the ingress of moisture,

the cable shall have a metallic sheath consists of lead alloy type "E" (PK021S)
or C (PK012S) or tellurium lead alloy sheath ( Kb-pb Te 0.04 ) as per the
requirements of BS EN 12548 & BS EN 50307. The sheath for all types of cables

should be manufactured using continuous lead machines; sheathing with

discontinuous machines will not be accepted.

d)

Armour Wires

All armour wires shall be of the galvanized steel to B.S. 1442 Galvanizing shall
be carried out in accordance with BBS 443. Sizes and numbers of wires shall be
stated in the schedules of this specification.
e)

Compound

The compound used shall not melt or run when exposed to the temperature
conditions prevailing during transit or at site in Kuwait or during operation.
e)

Serving

The soil in Kuwait is naturally very corrosive and it is essential, therefore, that
the serving of the cables be designed to prevent corrosion. Reference should

3.4.A.1

XLPE 1000 sq.mm. 1/core 132 KV Cables

The XLPE cables for 132kV should comply generally with the requirements of latest IEC
840-88
1)

Conductor

The conductor shall consist of stranded, plain annealed electrolytic copper

wires either circular and compacted or compacted segmentally Milliken type
having a cross sectional area of 1000 sq.mm complying with IEC 60228 and BS.
6360.
2)

Conductor Water Sealing

The conductor shall be water sealed by adding a swelling material between the
conductor strands.

3)

Conductor Screen

This screen consists of an extruded layer firmly bonded to the XLPE insulation.
The material is a semi-conductive compound. The interface between the
screen and the insulation must be smooth as much as possible. The conductor
screen, the insulation and the insulation screen are to be extruded in one single

thermal and mechanical properties.

A non-hydro scopic semi conducting tape is to be applied between the
conductor and the extruded semi conducting material.
4)

Insulation

The insulation shall consist of one layer of extruded chemically cross-linked

polyethylene (XLPE) which shall be dry cured. The insulation shall be firmly
and continuously bonded to the extruded conductor screen a very clean
grade of insulation is to be employed which is conveyed from sealed boxed to
sealed extruded hopper without being exposed to atmospheric
contamination.
The insulation thickness shall be designed to have a life time of more than 50
years based on working voltage of 132 KV r.m.s., and BIL ( Basic Impulse level
of 650 KV. peak ). However, the nominal insulation thickness should not be
less than 20 mm. The insulation thickness should be measured in accordance
with IEC 60811-11 clause 8, the average of the measured valves rounded to
0.1 mm shall not be less than the specified nominal thickness. The lowest
measured value shall not fall below the specified nominal thickness by more
than 10% of the specified nominal thickness:
tm

5)

> tn - 0.1 tn mm

Insulation Screen (core screen)

The insulation screen shall consist of an extruded layer of semi conducting

compound. This core screen should be fully bonded to the insulation so that
intimate contact with the insulation is ensured. Conductor screen, insulation,
and core screen are to be extruded in one single process (the triple extrusion
process). Two layers of conductive swelling tapes shall be applied over the
extruded semi conductive compound.
6)

Metallic Screen

The metallic screen shall consist of a combination of plain annealed copper

wires applied concentrically and copper tapes applied helically semi
conducting layer to be applied over the copper tape (as bedding) The metallic
screen shall be capable to carry the return earth fault currents specified.

7)

Metallic Sheath

To ensure the highest degree of protection against the ingress of moisture,

the cable shall have a metallic sheath consists of lead alloy type "E" (PK021S)
or C (PK012S) or tellurium lead alloy sheath ( Kb-pb Te 0.04 ) as per the
requirements of BS EN 12548 & BS EN 50307. The nominal thickness of lead
sheath shall not be less than 3.3mm.
-

Short circuit current is 40 KA for 1.25 seconds

N.B: The calculation of short circuit current shall consider the flow of the
current in the metallic layers on parallel basis.
8)

Armour

The cable shall be armoured over the lead alloy sheath, using stainless steel
tapes or Tine Bronze or copper tape A suitable bedding of extruded PVC under
the armour shall be used.

9)

Anti Corrosion Covering

The following layers shall be applied over the metallic sheath:

1. Anti-corrosion protection consists of a thin layer of bitumen
compound (Coating of waterproof insulation compound) and suitable
bedding.
2. The outer sheath shall be extruded layer of HDPE type ST7 capable to
withstand the temperature and soil condition as mentioned in clause
3.3
3. The portion of cable laying in building/basements and similar areas
shall be provided with fire retardant coating. The minimum average
thickness of this sheath shall be not less than 4.0 mm.
4. A thin layer of resin bonded graphite coating is to be applied to the
anti-corrosion covering to permit electrical tests.

10)

Graphite Coating

A thin layer of resin bonded graphite coating is to be applied to the anti

corrosion

3.4.A.2

XLPE 630 sq.mm. 1/core 132 KV Cables

The XLPE cables for 132kV should comply generally with the requirements of latest IEC
840-88
1)

Conductor

The conductor shall consist of stranded, plain annealed electrolytic copper

wires either circular and compacted or compacted segmentally Milliken type
having a cross sectional area of 630 sq.mm complying with IEC 60228 and BS.
6360.
2)

Conductor Water Sealing

The conductor shall be water sealed by adding a swelling material between the
conductor strands.
3)

Conductor Screen

This screen consists of an extruded layer firmly bonded to the XLPE insulation.
The material is a semi-conductive compound. The interface between the
screen and the insulation must be smooth as much as possible. The conductor
screen, the insulation and the insulation screen are to be extruded in one single
table
thermal and mechanical properties.
A non-hygroscopic semi conducting tape is to be applied between the
conductor and the extruded semi conducting material.
4)

Insulation

The insulation shall consist of one layer of extruded chemically cross-linked

polyethylene (XLPE) which shall be dry cured. The insulation shall be firmly
and continuously bonded to the extruded conductor screen a very clean
grade of insulation is to be employed which is conveyed from sealed boxed to
sealed extruded copper without being exposed to atmospheric contamination.
The insulation thickness shall be designed to have a life time of more than 50
years based on working voltage of 132 KV r.m.s., and BIL ( Basic Impulse level
of 650 KV. peak ). However, the nominal insulation thickness should not be
less than 20 mm. The insulation thickness should be measured in accordance
with IEC 811-11 clause 8, the average of the measured valves rounded to 0.1
mm shall not be less than the specified nominal thickness. The lowest
measured value shall not fall below the specified nominal thickness by more
than 10% of the specified nominal thickness:
tm

> tn - 0.1 tn mm

5)

Insulation Screen (core screen)

The insulation screen shall consist of an extruded layer of semi conducting

compound. This core screen should be fully bonded to the insulation so that
intimate contact with the insulation is ensured. Conductor screen, insulation,
and core screen are to be extruded in one single process (the triple extrusion
process). Two layers of conductive swelling tapes shall be applied over the
extruded semi conductive compound.
6)

Metallic Screen

The metallic screen shall consist of a combination of plain annealed copper

wires applied concentrically and copper tapes applied helically semi
conducting layer to be applied over the copper tape (as bedding) The metallic
screen shall be capable to carry the return earth fault currents specified.
7)

Metallic Sheath

To ensure the highest degree of protection against the ingress of moisture,

the cable shall have a metallic sheath consists of lead alloy type "E" (PK021S)
or C (PK012S) or tellurium lead alloy sheath ( Kb-pb Te 0.04 ) as per the
requirements of BS EN 12548 & BS EN 50307. The nominal thickness of lead
sheath shall not be less than 3 mm.
8)

Short circuit current is 40 KA for 1.25 seconds

Armour

The cable shall be armoured over the lead alloy sheath, using stainless steel
tapes or Tine Bronze or copper tape A suitable bedding of extruded PVC under
the armour shall be used.
9)

Anti- Corrosion Covering

The following layers shall be applied over the metallic sheath:
1. Anti-corrosion protection consists of a thin layer of bitumen
compound (Coating of waterproof insulation compound) and suitable
bedding.
2. The outer sheath shall be extruded layer of HDPE type ST7 capable to
withstand the temperature and soil condition as mentioned in clause
3.3

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3. The portion of cable laying in building/basements and similar areas

shall be provided with fire retardant coating. The minimum average
thickness of this sheath shall be not less than 3.6 mm.
4. A thin layer of resin bonded graphite coating is to be applied to the
anti-corrosion covering to permit electrical tests.

10)

Graphite Coating

A thin layer of resin bonded graphite coating is to be applied to the anticorrosion covering to permit electrical tests.
3.4.A.3

XLPE 300 sq.mm 1/C 33kV Cable

This cable should comply generally with the requirements of latest IEC 60502-

83.
1)

Conductor

Same as 3.4.1.1 above, except that the cross sectional area of conductor is
300 sq.mm.
2)

Conductor Water Sealing

Same as 3.4.1.2 above

3)

Conductor Screen

Same as 3.4.1.3 above.

4)

Insulation

Same as 3.4.1.4 above except for the following:

a) The working voltage is 33kV r.m.s.
b) Basic impulse level is 195kV
c) The nominal thickness of insulation should not be less than 8 mm.
5)

Insulation Screen
Same as 3.4.1.5 above

6)

Metallic Screen

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Same as 3.4.1.6 above.

7)

Metallic Sheath

Same as 3.4.1.7 above except that, the nominal thickness of lead sheath
should not be less than 2.5 mm.
8)

Armour

Same as 3.4.1.8 above

9)

Anti Corrosion Covering

Same as 3.4.1.9 above except that the PVC outer covering shall be 3 mm.
10)

Graphite coating

Same as 3.4.1.10 above.

3.4.A.4

XLPE 300 sq.mm 3/C 33kV Cable

The XLPE cables should comply generally with the requirements of latest
IEC 502 - 83.
1)

Conductors

Each of the three conductors shall consist of stranded, plain annealed

electrolytic copper wires circular and compacted having a cross sectional area
of 300 sq.mm complying with IEC 228 and BS. 6360.
2)

Conductor Water Sealing

The conductor shall be water sealed by adding a swelling material between the
conductor strands.
3)

Conductor Screen

Each of the three conductors of the cable shall be separately screened.

This screen consists of an extruded layer firmly bonded to the XLPE insulation.
The material is a semi-conductive compound compatible with the insulation of
the conductor. The interface between the screen and the insulation must be
smooth as much as possible. The conductor screen, the insulation and the
insulation screen are to be extruded in one single process
properties. (Allowable operating temperature equal or higher than the
insulation).

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A non-hygroscopic semi conducting tape is to be applied between the

conductor and the extruded semi conducting material.
The extruded layer shall be easily removable from the conductor.
4)

Insulation

The insulation shall consist of one layer of extruded chemically cross-linked

polyethylene (XLPE) which shall be dry cured. The insulation shall be firmly
and continuously bonded to the extruded conductor screen a very clean grade
of insulation is to be employed which is conveyed from sealed boxed to sealed
extruded hopper without being exposed to atmospheric contamination.
The insulation thickness shall be designed to have a life time of more than 50
years based on working voltage of 33 KV r.m.s., and BIL (Basic Impulse level of
195kV. peak). However, the nominal insulation thickness should not be less
than 8 mm. The insulation thickness should be measured in accordance with
IEC 60811-1-1 clause 8, the average of the measured valves rounded to 0.1 mm
shall not be less than the specified nominal thickness. The lowest measured
value shall not fall below the specified nominal thickness by more than 10% of
the specified nominal thickness:
tm
5)

> tn - 0.1 tn mm

Insulation screen (core screen)

The insulation screen shall consist of an extruded layer of semi conducting

compound. This core screen should be fully bonded to the insulation so that
intimate contact with the insulation is ensured. Conductor screen, insulation,
and core screen are to be extruded in one single process (the triple extrusion
process). Two layers of conductive swelling tapes shall be applied over the
extruded semi conductive compound. The extruded insulation semi
conducting screen shall be removable without damaging the insulation,
leaving no conducting material that cannot readily be removed. An insulation
screen that requires heat for removal shall not be supplied.

6)

Metallic Screen

Each core shall have separate metallic screen. The metallic screen shall consist
of a combination of plain annealed copper wires applied concentrically and
copper tapes applied helically semi conducting layer to be applied over the
copper tape (as bedding) The metallic screen shall be capable to carry the
return earth fault currents specified. However, the total cross-section of
copper screen, covering the three cores shall not be less than 35 mm2.

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7)

Inner Covering and Assembly of Cores

An extruded inner covering shall be provided over the cores assembly.

The metallic screens of the cores shall be in contact with each other.
7.1)

Inner Covering and Fillers Requirements

The inner coverings and fillers shall be of materials suitable for the operating
temperature of the cable and compatible with the insulation. Fillers shall be
non- hygroscopic.
Inner covering material shall be PVC type 9 of table of BSS 67 46 - 84.
8)

Metallic Sheath

To ensure the highest degree of protection against the ingress of moisture,

the cable shall have a metallic sheath consists of lead alloy type "E" (PK021S)
or C (PK012S) or tellurium lead alloy sheath ( Kb-pb Te 0.04 ) as per the
requirements of BS EN 12548 & BS EN 50307. The nominal thickness of lead
alloy sheath shall not be less than 2.5 mm.
9)

Short circuit current is 25 KA for 1.5 seconds

Armour

The cable shall be armoured over the lead alloy sheath, using stainless steel
tapes or Tine Bronze or copper tape A suitable bedding of extruded PVC under
the armour shall be used.
10)

Anti-Corrosion Covering

The cable shall have an outer covering of PVC jacket, the PVC shall conform to
type 9 of table 1 of BSS 6746 the nominal thickness of the PVC outer covering
shall be 3.6mm.

11)

Graphite Coating

A thin layer of resin bonded graphite coating is to be applied to the anticorrosion covering to permit electrical tests.
3.4.B

Accessories for XLPE Cables

3.4.B .1 General