Electricity Directorate – Asset Management ‫دائرة الكهرباء – إدارة األصول‬

Form Name: Technical Specifications ‫ المواصفات الفنية‬:‫اسم النموذج‬

11kV CROSS LINKED POLYETHYLENE (XLPE) INSULATED

CABLES TECHNICAL SPECIFICATION

ETIHADWE-DS-CABL-TS-0721, Rev 3, 2023

PROCESS NAME: MAINTAIN ENGINEERING SPECIFICATIONS

FEWA-ED-L2-AM-P05-F01 REV. NO. 0 REV. DATE: 17.02.2015 PAGE 1 OF 7
11kV Cross Linked Polyethylene (XLPE) Insulated Cables ETIHAD WATER & ELECTRICITY
TECHNICAL SPECIFICATIONS

1. STANDARD SPECIFICATION

The cables shall conform and comply with the latest revisions of the appropriate IEC standards (IEC
60502-2, IEC 60811, IEC 60228, HD 36153/2002 – System for cables identify, IEC 60885– Testing
methods, HD 603 S1 - DISTRIBUTION CABLES OF RATED VOLTAGE 0.6/1 KV) or any other
equivalent international standard with all its latest addendum and amendments and shall be subject to
the approval of ETIHADWE.

2. SITE CONDITIONS AND FAULT LEVEL

The cables shall be suitable for continuous duty under specified system conditions and under short
time fault conditions of system fault level of 500 MVA in the hot, humid and salty climate prevailing in
the area. The maximum values of humidity and temperature experienced in this country are 100% and
0
50 C respectively.

3. SCOPE AND NATURE OF WORK

The specification provides for the design, manufacture, test at manufacturer's works in the presence of
two ETIHADWE representatives, suitable packing, transportation and off loading at site of works or
ETIHADWE stores in satisfactory conditions and proper stacking as directed by ETIHADWE.

4. CONSTRUCTION
The cable shall be either of three cores or single core construction made up of highly compacted
stranded conductor of high grade aluminum or copper wires, XLPE insulated, suitable for use in system
with nominal system voltage of 11kv, highest system voltage of 12 kV. The materials of conductor and
number of cores depend on the bill of quantities of individual tender documents. The life time of cables
will be minimum 40 years.

The conductor shall be clean, smooth and free from burrs and surface imperfections likely to damage
the conductor screen or cause uneven electrical stress distribution.

5. CONDUCTOR SCREENING
Conductor screening shall be non-metallic and shall consist of a black layer of extruded semi-
conducting compound, which shall be firmly bonded to the inner surface of the insulation. The contact
of the semi-conducting shields with the cable insulation must be perfect without void creation at the
inner surfaces. The interfaces must be smooth in a regular geometric shape and the semi conducting
compound must have homogeneous structure particularly at the interfaces. The semi conducting
screen must be mechanically stable under load cycling of the po w er . and shall have operating
temperature equal or higher than that of the insulation.

The contact surface between conductor screen and insulation shall be smooth and free from protrusion. The
protrusions at the surface between the conductor screen and insulation shall be limited to 0.075 mm into the
insulation and 0.175 mm into the conductor screen. The screen material shall adhere to the conductor surface but
not penetrate into the conductor.
The conductor screen (non-strippable) shall be firmly bonded to the insulation and the bonding shall not be
affected due to the effects of bending, load cycling and short circuit. The screen material shall adhere to the
conductor surface but not penetrate into the conductor.
The volume resistivity of the conductor screen material shall not exceed 1000 .m at the nominal
service temperature ± 2°C.

However provision of additional semi-conducting tape in between semi-conducting compound and the
conductor would be preferred.

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 11kV Cross Linked Polyethylene (XLPE) Insulated Cables ETIHAD WATER & ELECTRICITY
TECHNICAL SPECIFICATIONS

The outer surface of the conductor screen shall be cylindrical, smooth and free of protrusions and
irregularities.

6. INSULATION
Electrical grade cross linked polyethylene (XLPE) shall be extruded in simultaneous extrusion of
conductor screening layer and insulation screening layer and shall be suitably cured.

The nominal thickness of the XLPE insulation shall be 3.4 mm and shall be guaranteed by the
manufacturer to withstand the specified system voltages.

THE INSULATION SHALL BE FREE FROM MICRO VOIDS, CONTAMINANTS,

PROTRUSIONS AND MOISTURE CONTENT.

7. INSULATION SCREEN (NON – METALLIC)

the insulation screening shall consist of a black layer of an extruded semi-conducting compound provided
over the insulation simultaneously with the extrusion of the insulation or in combination with semi-
conducting tape with suitable overlap over the extruded semi-conducting layer extruded simultaneously
with extrusion of insulation. phase identification shall be provided on the screen in color code, red, yellow
and blue.

The contact surface between insulation and insulation screen shall be smooth and free from
protrusion. The protrusions at the surface between the insulation and insulation screen shall be limited
to 0.125 mm into the insulation and 0.125 mm into the insulation screen.

The inner surface of the insulation screen shall adhered continuously to the outer surface of the
insulation and shall have no tendency to separate from the insulation due to the effect of bending
during installation, load cycling and short circuit under service conditions.

The insulation screen shall be a cold strippable layer and capable of being removed without any
special tools or applying heat, without impairing the performance of insulation

The volume resistivity of the insulating screen material shall not exceed 500 .m at the
nominal service temperature ± 2°C.

Phase identification shall be provided, by means of thin colored tape Red, Yellow and Blue and placed
between the non-metallic insulation screen and the metallic core tape. The phase identification tape
shall be heat resistant, suitable for continuous operation at 90°C and the colour shall not fade when
exposed to heat or organic chemicals.

The thickness of the insulation screen shall be as specified in the Technical Data Sheets or Related
standard, but shall have a minimum thickness of 0.8 mm. The inner surface of the insulation screen
shall be smooth and free of protrusions and irregularities.

Conductor screen, insulation and insulation screen shall be vulcanized by triple extrusion method.

8. METALLIC SCREENING
The metallic layer shall be applied over the individual cores.

ETIHADWE-DS-CABL-TS-0721, Rev 3, 2023 PAGE 3 OF 7

11kV Cross Linked Polyethylene (XLPE) Insulated Cables ETIHAD WATER & ELECTRICITY
TECHNICAL SPECIFICATIONS

The standard constructions of the metallic layer must be as per following:

• For single core unarmored cables, there will be a layer of copper wires applied helically.

• For single core and three core armored cables, there will be a layer of copper tape
applied with an overlap and in contact with each other.

• For both single core and three core cables, the total cross-sectional areas of copper
metallic screen shall not be less than 25mm2 for cable sizes up to and including 300mm2
and the cable sizes beyond 300mm2 of cross sectional area the metallic screen shall not
be less than 35mm 2 .

The above cross section areas are the minimum required cross section areas however the
manufacturer should submit the calculations to ensure
that the Earth Fault short circuit current in the screen shall not be less than 3
KA. For 1 second , If as per the calculations,
more cross section areas are required to achieve 3 KA, manufacturer to follow the highest
cross section areas.

9. ASSEMBLY
The three insulated cores shall be laid up with necessary non-hygroscopic fillers and bound with non-
vulcanisable tape to form a compact circular assembly. Metallic screen over each individual core shall
be in good contact with each other along the cable

10. INNER SHEATH

Sheath shall be extruded layer of PVC – TYPE ST-2 complying with IEC 60502-2.

11. ARMOUR
Three core cables must be armored with a layer of galvanized steel wires and the mass of coating
2 2
shall not be less than 215 g/m for the cables sizes less than 185 mm and 245 g/m for the cables
sizes 185 mm and above and the single core cables are to be armored with a layer of aluminum wires
according to IEC 60502-2. Unarmored cables may also be used according to the requirement in the
BOQ of the tender documents.

12. OUTER SHEATH

The outer sheath shall be of fire and termite resistant of extruded PVC-Type ST-2 material over the
armor. PVC material shall conform to IEC 60502-2 or to any other equivalent standard.

The Outer sheath shall be black colour

13. IDENTIFICATION
The following identification marks shall be permanently embossed on both sides (if possible) of the outer
sheath of the cable (diagonally opposite side) in the same sequence by digit size not less than 6 mm at
2,
suitable intervals. 11000 Volts …..mm No. of cores … copper/ Aluminum cable, XLPE insulated property
of ETIHADWE - UAE - Year of Manufacture, Manufacturer's Name.

Length of cable on one meter intervals shall be embossed on outer jacket with digit size not less than
6 mm. Marking on the over sheath shall indicate cumulative length of the cable, wound on the drum

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11kV Cross Linked Polyethylene (XLPE) Insulated Cables ETIHAD WATER & ELECTRICITY
TECHNICAL SPECIFICATIONS

such marking starting with “000” on the inner end and accumulative length on top layer of the drum.

14. PACKING
The cables shall be wound on a suitable non-returnable strong drum to prevent damage during storage
and transport. On the side of the drum, necessary description, such as Order No., type, voltage, size,
material of conductor, gross and net weight of the cable, length, direction of rolling and drum number
etc., shall be clearly marked. Drum Name plate should contain also all these details printed with
indelible suitable clear colour. Completed cable shall be sealed at both ends to avoid any ingress of
moisture, foreign bodies etc. No drum shall contain more than one length of cable. The diameter of
bore for the cable drum for inserting the shaft shall not be less than 120 mm. The cable drums must
be closed with wooden planks and to be strapped with at least 3 metal straps to prevent cable damage
during storage and transportation and to be arranged with wooden pieces down the drums for easy
loading the drums and to prevent rolling of the drum during storage.

15. CURRENT RATING AND TEMPERATURE RISE

0
The cable shall be capable of withstanding the maximum conductor temperature of 90 C in continuous
0
operation and a temperature of 130 C for a limited period. Under fault conditions the cable shall be
0
rated to withstand a final temperature of 250 C.

0
Guaranteed current carrying capacity at 35 C soil temperatures and thermal resistivity of filling sand shall
be considered 2.0 cm/w and shall be mentioned in the appropriate column of the schedule of guaranteed
particulars.

16. TEST CERTIFICATE

Certified copies of the type and routine test certificates, as per relevant clauses of IEC 60502-2, shall
be supplied along with the offer.

If acceptable type test certificates are not enclosed along with the offer, Authority reserves its
right to ask the tenderer to conduct all or any of the following type tests in presence of
ETIHAD-WE representatives at no extra cost to ETIHAD-WE

Certified copies of sample tests certificates, as per relevant clauses of IEC 60502-2, which are related to
the ETIHADWE contract should be submitted for acceptance prior to cables delivery.

16.1. ROUTINE TEST

Routine tests shall be carried out as per IEC 60502-2 at manufacturer's works on all lengths of ordered
cable during manufacture and the certified copies of these routine test certificate shall be forwarded to
ETIHADWE.

Witnessing test at manufacturer's works

The following tests (routine and sample as mentioned in IEC 60502-2) will be carried
out in presence of ETIHADWE inspectors at the manufacturer's works.

A) Electrical resistance measurement of conductor and metallic screen.

(as per IEC 60502-2).

B) Partial discharge test on cables having cores with conductor screens and insulation screens as
per IEC 60502-2. magnitude of discharge at 11kV should not exceed 5 PC.

C) High voltage test : 23kV AC between conductors and screen for 5 minutes.

D) Electrical test on over sheath, if required (as per IEC 60502-2).

E) Conductor examination.

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11kV Cross Linked Polyethylene (XLPE) Insulated Cables ETIHAD WATER & ELECTRICITY
TECHNICAL SPECIFICATIONS

F) Check of dimensions.

G) Voltage test for 4 hours: 25kV AC between conductor and screen for 4
hours.

H) Hot set test for XLPE insulation.

I) Test on armour wires

i) Measurement of resistance.
ii) Measurement of total cross-section.
iii) Galvanizing test.
iv) Elongation at break point.

Etihad- WE reserves the right to require the presence of its representatives on any tests from the group of
required routine and sample tests.

The supplier shall make provision in his offer to bear all costs that are incurred in carrying out these tests
to the satisfaction of ETIHADWE. However,for routine tests, costs towards travel, accommodation, etc. of
ETIHADWE representatives shall not be included in the quoted price.

16.2. TYPE TESTS

Type test are before supplying in order to demonstrate satisfactory performance characteristics to meet
the intended application. Results of type tests shall be forwarded to ETIHADWE.

List of electrical type tests that shall be performed, is as per requirements of the latest version of IEC
60502-2: (As applicable)

A) Partial discharge test.

B) Bending test, followed by a partial discharge test (as per IEC 60502-2).

C) Power factor (tan delta) measurement as function of the voltage and capacitance measurement
(as per IEC 60502-2).

D) Power factor measurement as a function of temperature.

E) Heating cycle test, followed by a partial discharge test (as per IEC 60502-2).

F) Impulse test, followed by a power frequency voltage test (as per IEC 60502-2).

G) Voltage test for 4 h (as per IEC 60502-2).

H) Test on resistivity of semi-conducting screens (as per IEC 60502-2).

List of non-electrical type tests that shall be performed, is as per requirements of the latest version of IEC
60502-2 and IEC 60811

I) Measurements of thickness (as per IEC 60502-2).

J) Measurement of thickness of non-metal sheaths (including extruded separation sheaths, but

excluding inner coverings) (as per IEC 60502-2).

K) Tests for determining the mechanical properties of insulation before and after ageing (as per
IEC 60502-2).

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11kV Cross Linked Polyethylene (XLPE) Insulated Cables ETIHAD WATER & ELECTRICITY
TECHNICAL SPECIFICATIONS

L) Tests for determining the mechanical properties of non-metal sheaths before and after ageing (as
per IEC 60502-2).

M) Additional ageing test on pieces of completed cables (as per IEC 60502-2).

N) Pressure test at high temperature on insulations and non-metal sheaths (as per IEC 60502-2).

O) Hot set test (as per IEC 60502-2).

P) Water absorption on insulation (if applicable) (as per IEC 60502-2).

Q) Shrinkage test for XLPE insulation (as per IEC 60502-2).

R) Shrinkage test (if applicable ) for PVC over sheaths (as per IEC 60502-2).

S) Water penetration test (if applicable) (as per IEC 60502-2).

16.3. ELECTRICAL TESTS AFTER INSTALLATION (NOT IN THE SCOPE OF SUPPLY CONTRACTOR)

Electrical tests after installation are made to demonstrate the integrity of the cable and its accessories as
installed. After installation of cable and its accessories has been completed list of following tests will be
performed:

- Phasing Tests
- Conductor resistance test
- Capacitance measurement test
- Insulation resistance measurement
- AC high voltage (VLF) test
- DC voltage test of the over sheath if applicable (as per IEC 60229:2007).

• AC insulation voltage test (as per IEC 60060-3 and IEC 60502-2) or DC voltage equal
to 4U0 (U0 = 6350 V) shall be applied for 15 minutes. DC voltage test shall be applied
only if AC insulation voltage test cannot be applied.

17. CABLE DRUM LENGTH

The length of cable drum shall be according to the following table. A variation of ±5% of the cable drum
length may be acceptable.

Cable size Drum length

3 x 400 sq.mm 500 metres

3 x 300 sq.mm metre
500
3 x 185 sq.mm s
metre
500 "
3 x 95 sq.mm s500 "
1 x630 sq.mm 500 "
1 x 300 sq.mm 500 "

All cable lengths cut and used for various tests shall be to the Contractor ’s account and shall not be
included in the cable lengths to be supplied to ETIHADWE

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