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Specification
Section 38 Part 6 11kV XLPE 3
Core Cables
Page 1


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Issue Date: April 2010

6.0 11KV XLPE 3 CORE CABLES 2
6.1. Scope 2
6.2. Cable Classification 2
6.3. System 2
6.4. Cable Construction - Details 2
6.5. Tests 4
6.6. Cable Drums 4
6.7. Information To Be Submitted 5
Lusail Particular
Specification
Section 38 Part 6 11kV XLPE 3
Core Cables
Page 2


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Issue Date: April 2010


6.0 11KV XLPE 3 CORE CABLES
6.1. SCOPE
This Section covers the design, manufacture, testing supply delivery and
performance requirements of multi-core, XLPE insulated cables for use on the
11kV Distribution System.
6.2. CABLE CLASSIFICATION
Nominal system voltage, phase to phase = 11kV
Um = 12kV
The cables shall be in conformity with IEC 60502:1997, and subsequent
amendments, except as may be otherwise stated, and of the following generic
type.
3 circular conductor cores of stranded compacted copper.
A semi-conducting shield extruded directly over each core, for the purpose of
stress control.
XLPE core insulation, circular in section and of a thickness appropriate to the
intended system voltage.
Each core insulation layer to be covered with an extruded semi-conducting XLPE
compound shield for the purpose of stress control. The compound shield shall be
covered with a metallic screen for the purpose of equalizing potential on the
semi-conducting screen and carrying earth fault currents.
The cores shall be laid up, with metallic screens in contact with each other, and
with an interstice filler of a suitable non-hygroscopic material.
The whole of the laid up cores (and filler) shall be surrounded by an inner cover
of an appropriate material.
The whole shall be surrounded by an armour of galvanised round steel wires and
a PVC over sheath.
The above description is supplemented by further requirements stated later in
this Specification.
6.3. SYSTEM
11kV system has three phase and earth.
Nominal voltage 11kV
Maximum voltage 12kV
Maximum symmetrical fault level 31.5kA
Limited earth fault current Through earthing transformer 4.5 kA.
Frequency 50 Hz
Impulse 75 kV
6.4. CABLE CONSTRUCTION - DETAILS
(a) Conductors:
Plain, stranded, compacted copper in accordance with IEC 60228.
Standard sizes are:-
70, 185, 240, 300 sq. mm
(b) Conductor Screening:
Extruded semi-conducting compound,
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Specification
Section 38 Part 6 11kV XLPE 3
Core Cables
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(c) Insulation:
Extruded solid dielectric:
Designation XLPE (IEC 60502: Para 4.2 Table 2)
Highest rated temperature 90C (IEC 60502: Para 4.2 Table 3)
Insulation thickness, as appropriate to applied voltage, to Table 6 of IEC
60502.
(d) Insulation Screening
A layer of extruded semi-conducting material of the generic type 'easy strip'. This
is of a type in which the layer can be removed by hand peeling, after application
of a simple tool, if needed. This will leave the underlying XLPE insulation
undisturbed. Where such a tool is needed, for instance a knife with depth of cut
limitation; this will be supplied in quantities at a simple ratio of 10% of the
number of joints supplied.
Each core shall be overlaid with a metallic screen, where such is necessary to
equalize potential along the semi-conducting screen, to ensure correct stress
control.
Each such screen shall be capable of supporting individually an earth fault
current of 4500 amps for 1 second. The screen will take the form of copper wires
with a copper binder tape.
Means shall be provided for core identification, either by colour, or number. A
suitably marked helical tape over each insulated core will suffice for this purpose.
(a) Inner Cover and fillers
Classification to Para 8 of IEC 60502 - an extruded layer of a material suitable to
meet the design temperature conditions, and of a thickness in accordance with
para 8 Table 8 of IEC 60502.
The interstices of the laid up cores shall be filled and compacted with a suitable
non hygroscopic material, e.g. polypropylene, and designed to inhibit the flow of
water along the cable. The material shall be suitable for the operating
temperature of the cable.
(b) Armour
This shall meet the screening requirements of IEC 60520. It will comprise of
galvanised, round steel wires, of thickness in conformity with Section 13 of IEC
60502, and laid with no discernible gaps.
Galvanising of the wires shall be in conformity with BS EN 10257. The wires
shall be embedded in and covered by water blocking tape, 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 method of achieving this shall be as recommended by the manufacturer
and approved by the Engineer..
(c) Over sheath
PVC extruded directly over the armour (and water inhibitor). It shall be type ST2
in accordance with cl 4.3 / Table-4 / IEC 60502 and of thickness in compliance
with the above standard.
It shall be RED in colour, and embossed with the following legends:
"QD/ENA 11,000V XLPE"
and shall identity of the manufacturer.
The legends shall be repeated along the length of the cable at intervals not
exceeding one meter.
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Specification
Section 38 Part 6 11kV XLPE 3
Core Cables
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Issue Date: April 2010

6.5. TESTS
(a) The following tests shall be carried out on each manufactured length of
cable, or sample length as instructed by the Engineer. The tests shall be
as outlined in IEC 60502, IEC 60228 and 60811.
(i) Routine Tests:
Electrical Resistance of Conductors.
Voltage Test.
Partial Discharge Test.
(ii) Sample Tests:
1. Conductor Examination.
2. Check of Dimensions.
3. Voltage Test.
4. Hot Set Test.
(iii) Type Tests:
Manufacturer shall carry out type tests to IEC 60502 on the cable and issue
certificates confirming that the cable has conformed.
In addition the manufacturer shall carry out tests to prove that the metallic
screens are capable of sustaining the specified earth fault current. The design
philosophy for achieving this shall also be explained.
IEC 60228 Examination of conductor: To paras 4.3.2, and 4.3.3
6.6. CABLE DRUMS
All cables shall be supplied on cable drums with a maximum diameter of 2.55m
and a maximum width of 1.28 m. 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.
Cable 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 complete with Tubular Steel insert shall be fitted to accept 1x4 inch
(100mm) 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:
Manufacturers Name
Year of manufacture of cable
Drum number
Size and voltage of the cable, including the term:
"Cross Linked Polyethylene".
The length of cable in the drum.
"QD", and the Order No.
The nominal length to be as stated in the schedule below:

Cable Size Lengths per Drum
3c x 300 mm2 250 Meters
3c x 240mm2 250 Meters
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Specification
Section 38 Part 6 11kV XLPE 3
Core Cables
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3c x 185 mm 300 Meters
3c x 70 mm2 500 Meters
A tolerance of 5% on the length of cable per drum shall be allowed.
6.7. INFORMATION TO BE SUBMITTED
An illustrated drawing showing the cable design, all components and
dimensions.
A specific 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.
.
END OF PART