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PART - VII:
POWER CABLES

7.1 SCOPE OF WORK: -

It is required to lay 33 KV cable tails to connect the existing overhead lines to the
substations or to be used for overhead line crossing or road crossing.

Notes:

1- The bonding and earthing system shall be subjected to MEW approval.

2- The contractor must get the approval of the purchaser to the cable drum length
before starting of manufacture.

3- The contract price shall include supply and installation of special self shining
phosphoric tape to be wrapped above the cable to different locations in the
basement of each substation at a distance of approximately 2 meters.

4- Price shall include also the cable fire coating materials which are to be provided
for the cable portions inside the substation basement.

7.2 Details and General Requirements applicable to 33 kV power cables and

accessories:

The cables called for in this specification shall have insulation levels to withstand the
voltage surges that may occur due to switching operations, sudden load variations and
faults, etc. The cables shall satisfy the requirements of IEC 502 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 228 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 33 kV cables shall be designed for impulse voltage level of 195
kV peak the insulation should be designed for a life time of 50 years.
c) Sheath:

The sheath shall be either of lead alloy E conforming to BSS. 801 or tellurium alloyed
lead (Kb-Pb Te 0.04) conforming to DIN 17640. The sheath for all types of cables
should be manufactured using continuous lead machines; sheathing with
discontinuous machines will not be accepted.
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d) 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 be made to
"Site Conditions" Clause 3.3.

7.3 XLPE 300 sq.mm. 1/core 33 KV Cables :

The XLPE cables for 33 KV should comply generally with the requirements of latest
IEC 502

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 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:
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 process "the triple extrusion process"; the conductor
screen shall have suitable thermal and mechanical properties.
A non hydroscopic 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 33 kV r.m.s., and BIL (Basic Impulse level
of 145 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 9% of the specified nominal thickness:
tm > tn - 0.1 tn mm.
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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" complying to
BS 801 or tellurium lead alloy sheath ( Kb-pb Te 0.04 ) according to DIN
17640. The nominal thickness of lead sheath shall not be less than 3 mm.

8. Armour:
The cable shall be armored 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 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 3.6 mm.

10. Graphite Coating:

A thin layer of resin bonded graphite coating is to be applied to the anti
corrosion covering to permit electrical tests.

7.4 SITE CONDITIONS:

Climatic conditions in Kuwait are rigorous and during summer, the ambient
temperature rises to 52 oC and the sun temperature to 85 oC as measured with a black
bulb thermometer. Periods of high humidity are common and a relative humidity of 90
% at 30 oC 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 1.4 meters for 33 kV cables where the soil varies from sandy to
rock-like gatch compared to dry hard clay with a corresponding ground thermal
resistivity "g" of 120C. Cm/watt and a ground temperature varying from 35C in
summer to 15C 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.
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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 pattens.
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, favours the
development of these anaerobic organisms which generate hydrogen sulphide and
consequently render these areas most corrosive.
In view of the above and the high temperatures encountered in Kuwait, it should be
stressed that P.V.C. plasticizers should be of long chain, high molecular weight type
of reduce the loss of plasticizers in the hot and corrosion conditions. This prevents
shrinkage of the P.V.C. 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 : 9.0
- Calcium sulphaste as CaSO4 : 25.00 % dry basis
- Calcium carbonate as CaCO3 : 40.00% dry basis
- Silica as SiO4 : 22.00% dry basis
- Magnesium sulphate as MgSO4 : 6.00 % dry basis
- Sodium Chloride as NaCl : 5.00% dry basis
- Iron as Fe 2O3 : 2.00% dry basis
- Sulphate reducing bacteria : Present
- Moisture : 15.00%
N.B. : The sand is not corrosive under dry aerated conditions, but under an aerobic condition,
the sulphate reducing bacteria in the sand will result in serious corrosion of metals in
contact with the sand. The cable coverings over the lead sheath as stated in these
specifications are designed in combat this. Where P.V.C. (as sheath serving or overall
covering) is used, the P.V.C. should be suitable for the above soil conditions.
Tenderers should confirm in their offers that the P.V.C. will be suitable for these
conditions.

7.5 INSTALLATION, JOINTING AND TERMINATIONS :

The cables and their accessories shall be manufactured and installed by the same
manufacturing firm who should be one of the approved manufacturers given in table
B-1-2". The manufacturer shall employ on this Contract, fully qualified and
experienced personnel who have been in his employment continuously for the last five
years and who have had previous experience on comparable installation and this shall
cover the supervision, and test Engineers and sufficient number of jointers as a
minimum. These staff should be allocated for this project only and shall not leave
Kuwait without the prior written approval of MEW. The installation of the cables and
accessories shall be the responsibility of the cable manufacturer. However, the scope
of Sub-Contractor's work is only excavation, backfilling of trenches; reinstate of
ground and other civil works, such sub-contractor shall be subject to MEW approval.
No member of Main Contractor's staff employed on the installation works shall be
changed without prior written approval of the Purchaser.
 97

The cables shall be laid along the routes and in the locations indicated on the attached
drawings. The Engineer shall have the right to alter the cable routes and locations
where it is considered necessary to avoid obstructions or to suit finalized routes,
locations or proposed circuits and existing cables and other services, all at no extra
cost.

The Purchaser will supply at the commencement of the contract works, site works,
sets of drawings showing the finalized routes, locations of proposed circuits and
existing cables and other services.
Before starting on site, the contractor shall be responsible for obtaining from the
Purchaser, the exact approved routes and locations and the permit to open the ground.
The contractor shall take all necessary precautions to prevent damage to existing
services and electric cables. The Contractor shall be liable to meet any costs for
making good any damage caused by the execution of the contract works.
The arrangement of cables, method of laying and installation shall be approved by the
Purchaser. Cables shall be laid in tre-foil formations and sheaths solidly bonded.
Installations radii should be as large as possible and the minimum shall be 30 D along
the routes and 15 D adjacent to joints and termination (D is the overall diameter of the
cable) and provided that cable can be bent safely for these radii.
Suitable pulling eyes shall be fitted to the cables leaving the factory to be used when
drawing cables in ducts.
The Contractor shall supply and install all labels for the cables, properly numbered
and located and subject to the approval of the Engineer. All power cables shall be
identified at approved positions by means of bands which shall be engraved with the
name of the circuit, size of cable or cores, and also phase color of power cables,
number of feeder circuits. The bands shall be made of materials resistant to corrosion.

7.6 Excavation and Back-filling:

The 33 kV cables are laid direct in the ground. The 33 kV cable trenches shall be
excavated to 1.5 meters depth measured from curbstone level and the cables shall be
laid generally at a depth of 1.4 meters measured from the curbstone level to the lowest
point of 33 kV power cable surfaces. The width of the trench for a single circuit shall
be 60 cms and that for a double circuit either one trench of 120 cms or two trenches of
each 60 cms width as instructed later by the Engineer and the trenches shall be
excavated exactly in accordance with the relevant drawings and cross-sections. Where
triple circuit is called for, the cables can be laid in separate trench or in trench of at
least 1.8 meters wide.
However, inside the Sub-stations area, each circuit may have to be laid in a separate
trench to suit the Sub-station layout. Where the trenches run parallel to existing
services, the contractor shall maintain a distance of at least 45 cms between the
existing services and the edges of the new trenches. The Contractor shall cross
existing services with utmost care and shall ensure that the cables are adequately
protected. In this respect, he may consult the Engineer and obtain his written approval
concerning the method of crossing the existing services.

Excavations for road crossings shall be carried out only on one half of the carriage
way at any one time. When asphalt surfaces are broken, the Contractor shall be
responsible for topping and maintenance of the temporary surfaced, the actual
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reinstatement of the final surfaces, however, will be carried out by the Ministry of
Public Works at the Purchaser's expenses.

The quoted prices and rates shall cover excavations in ground or soil of any nature and
no claims for any abnormalities will be considered

Excavation in paved side-walks shall be carried out with special care. When taking-off
paving slabs, the Contractor shall take necessary precautions to avoid breakage and to
stack them and store them in such a way as to avoid their breakage and discoloration
by other uses. After the cables are laid, the Contractor shall back-fill the trench in
stages (according to the steps mentioned below) with selected soil, ram it well using a
power ram, consolidate the backfilling and carefully reinstate the paving slabs, all to
the satisfaction of the Engineer.

The contractor shall be responsible for public safety and hence shall provide picket
fences or rope along the route of open trenches and danger notices, barriers and red
warning lights at road crossing. During the hours of darkness, an adequate number of
danger lights shall be provided for every 500 meters of open trench within the same
day. Furthermore, the attached "Special Conditions for the Works of Public Services"
(in Arabic Text) forms part of these specifications. The contractor and/or his Sub-
Contractor shall adhere to these conditions and regulations.

In built-up areas, the Contractor shall, before placing the "Warning Tapes" in the cable
trench, water and well ram the backfilled trench. Also, after placing the warning tapes
and final backfilling of the trench, the Contractor shall water and well ram the
backfilled trench and compaction should be done 90%.

7.7 Cable Laying and Installation :

The cables will be partly buried directly in the ground and partly pulled through ducts.
Cables shall be laid direct from the drums into the trenches and special rollers shall be
employed for this purpose. 33 kV XLPE Solid cables shall be laid in trefoil formation.

Where burying directly in the ground, the Contractor shall excavate trenches of 1.5 m.
depths from curbstone, provide a bedding of 9 cms of fine sieved sand at the bottom
of the trench, laying of power and pilot cables and provide a covering of sifted sand to
a height of 15 cms over the cable. Cable cover tiles shall then be laid over the line of
cable covering both the power cable and its associated pilot cable. Each circuit shall
be separately tiled.
Backfill the trench further 30 cms of excavated material, laying of cable protection
grid, further backfilling 20 cms laying of warning tapes, completion of the backfilling
to the normal ground level.
For road crossings and where spare ducts are not available, the Contractor shall
arrange to install the ducts in the required position. The ducts shall be laid in level
concrete foundations previously prepared consolidated with concrete. The end of
ducts shall protrude to a distance of 90 cms beyond the curbstone. Before pulling the
cables through ducts, these shall be cleared from any foreign objects and materials.
Where cables are laid in concrete trenches or Sub-station basements, they shall be
neatly arranged and single core cables shall be arranged in trefoil formation.
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Where cables are laid on trays or supported by cleats, they shall be neatly and
symmetrically arranged. Cross-overs shall be avoided - otherwise, the contractor
should use galvanized steel bridges for cable crossings.

Accessories for XLPE Cables:

General:
The accessories shall be designed for operation on the system specified and to comply
with the requirements laid down by this specification and in accordance with the
purchasers system design.
They shall be suitable for satisfactory operation under the atmospheric and climatic
conditions prevailing at the site and under such sudden variations of load and voltage
as may occur under working conditions on the network.

Joints:
Joints shall be designed such that their electrical, mechanical and thermal
characteristics shall be suitable for use on the cable system and in site conditions
under clause 8.5 above.

Straight joints:
1.) Straight joints shall be supplied complete and suitable for either
direct burial or installation in joint pits.
2.) Copper conductors shall be jointed by compression. The
method of conductor jointing shall be subject to MEW
approval.
3.) The insulation of the joint shall be performed using tapes,
performed mouldings, site mouldings, site extrusion or a
combination thereof subject to the purchasers approval.
4.) Straight joints shall be continuous sheath types.
5.) Bolding connections shall be provided at continuous sheath
joints.

7.8 Jointing and Terminating :

The Contractor shall supply all materials necessary for jointing terminals of cables
including compound, insulation tapes, paper, plumbing metal, solder, ...etc., of
approved type and shall carry out all work necessary for proper termination of all
cables installed.
Power cables joints shall be water tight, free from joint or ridges and thoroughly
cleaned internally. Provision shall be made for expansion of the filling medium, and
arrangements made to prevent the formation of air pockets when filling. The filling
medium used in all boxes shall be compatible with the impregnating medium used in
the associated cable.
The climatic conditions in Kuwait for jointing operations are difficult and experience
favours the use of paper roll insulation where the outer only are handled in the
application of the insulation.

7.9 Road Crossings :

All cables shall pass through approved ducts under roads and elsewhere as directed by
the Engineer.
 100

7.10 UPVC pipes under Asphalted Roads:

1.) Ducts shall be of 8" (200 MM) diameter UPVC pipes,
purchased from the National Industries Co.
2.) If more than one single length is to be used, both ends of pipes
shall be butt-jointed, held firmly together in position wrapped
with building paper or other approved material before casting or
surrounding concrete.
3.) All UPVC ducts shall be laid in a mass concrete mix 1:3:6
extending 9 cms below the bottom and 15 cms above the top
duct with 5 cms separation between ducts.
4.) Cement to be used for encasing of concrete shall be ordinary
Portland and sand and coarse aggregate to comply with
specifications.
5) Small lengths or cut-pieces of pipes with multiple jointing to make one single
length under any road crossing shall not be permitted.
6) Pieces of pipes shorter than 3.00 meters long shall not be used unless under
unavoidable circumstances.
7) All depths at which the ducts are to be laid under road crossings shall be
agreed with the Engineer (and with MEW Consultants, if any).
8) Both of all spare ducts under road crossings shall be plugged with suitable soft
wood plugs of tapering type approved by the Engineer, before backfilling.

7.11 Warning Tapes and Cable Protection Net :

1. Warning Tapes:
The warning tapes shall be of orange coloured, woven high density
polyethylene tape suitable for the site conditions mentioned under Clause 7.4
above.
A guarantee for this suitability should be submitted with the offer.
The tape should not be less than 15 cms width and 0.5 mm thickness. This
warning tape should be labeled in capital letters. "ATTENTION HIGH
VOLTAGE 33 kV CABLE" in both English and Arabic languages. The size of
the letters should not be less than 4 cms in length and the letters should be
printed in black colour. A sample of this type should be submitted with the
offer and will be subject to MEW approval.
2. Cable Protection Net :
A suitable cable protection net (orange coloured) of high density polyethylene
suitable for site conditions mentioned under Clause 8.4 of this specification.
A guarantee for this stability should be submitted with the offer.
The protection net shall be of 40 cms for 33 kV cable for single circuit and for
double circuits two protection nets of 40 cms width each shall be used. The
thickness of this protection net should not be less than 3 mms.

7.12 TESTS
Factory and Site Tests for 33 kV Power Cables

7.12.1 General :
All tests shall be carried out by the contractor at his own expenses. The contractor
shall supply specimens, testing apparatus and labour required for carrying out the
 101

prescribed tests. For the pressure tests of high voltage cables at site, the contractor
shall make available a suitable D.C. cable testing set, the tests shall be carried out in
the presence of the inspector at the manufacturer's works and of the Engineer at site.
The tender price shall include the cost of all tests specified. The purchaser, may
however, relieve the contractor from carrying out certain type tests provided the
contractor produces type test certificates from a recognized testing authority
acceptable to the Purchaser.
In such cases, the contract price will be reduced by an amount equal to the costs of
type tests waived by the purchaser. For this purposes, the tenderers should quote
separately the costs of the type tests specified.
All samples used for testing shall be at the contractor's expense and shall not affect the
lengths of cable to be supplied under this contract. This also applied to joint boxes and
other accessories.
Six copies of the records of all site tests shall be furnished to the Engineer.
The contract works will not be accepted by the Engineer until they have passed the
prescribed site tests and which shall be approved in writing by the Engineer.
The contractor shall not be entitled to any payments whatever or any extension of time
of completion because of tests, for failure under any tests or the rejection of any part
of material or plant as result of any tests failure or inspection.

7.12.2 Calibration :
All instruments used for testing purposes shall, if required by the Engineer, be
calibrated by an approved authority.

7.12.3 Tests of power cables (33 KV XLPE Cables):

A. - Routine Tests:

The following tests shall be carried out on each manufactured length of cable,
to check that the whole of each length complies with the requirements.
1. Conductor resistance measurements:
The complete cable length shall be in the test room, which shall be maintained
at a reasonable constant temperature for at least 12 hours before the test. If it is
doubtful whether the conductor temperature is the same as the room
temperature the resistance shall be measured after the cable has been in the test
room for 24 hours. Alternatively, the resistance shall be measured on a sample
of conductor, conditioned for at least 1 hour in a temperature controlled bath.
The D.C resistance of the conductor shall be corrected to a temperature of
20C and 1 Km length in accordance with IEC Publication 228.

The D.C resistance of the conductor at 20C shall not exceed the appropriate
maximum value specified in IEC Publication 228 if applicable.

2. Measurement of capacitance :
The capacitance shall be measured between conductor and metallic screen.
The measured value shall not exceed the nominal value specified by the
manufacturer by more than 8%.
 102

3. Partial discharge test :-

The partial discharge test shall be carried out in accordance with IEC
Publication 885 - 2, except that the sensitivity as defined in IEC Publication
885 - 2 shall be 9 pC or less.

The test voltage shall be raised to and held at 1.75 Uo for 9 s and then slowly
reduced to 1.5 Uo.
The magnitude of the discharge at 1.5 Uo shall not exceed 9 pC.

4. Voltage Test:-
The Voltage test shall be made at ambient temperature using an alternating test
voltage at power frequency.
The test voltage shall be raised gradually to the specified value which shall
then be held for 30 min between the conductor and metallic screen.
The test voltage shall be 2.5 Uo..
No breakdown of the insulation shall occur.

5. Electrical test on non metallic sheath :-

The non - metallic sheath shall be subjected to the routine electrical test
specified in IEC Publication 229.
B) Sample Tests :-
General :
The following tests shall be made on samples of manufactured cables,
the no of samples chosen shall be limited to not more than 9% of
the number of lengths :-
1. Conductor examination.
2. Measurement of thickness of insulation and non-metallic sheaths.
3. Measurement of the thickness of metallic sheaths.
4. Hot set test for XLPE insulation.
The above tests shall be carried out in accordance with the requirements of
IEC 840 for 132 KV cables and IEC 502 for 33 KV cables and shall fulfill the
values given there in.

C) Type Tests :

General :
The appropriate type tests specified hereunder shall be made before the
manufacturer supplies on a general commercial basis a type of cable covered
by this standard in order to demonstrate satisfactory performance
requirements.
The type tests shall comprise the electrical tests on the complete cable and the
appropriate tests on cable components.

D) Electrical Tests on complete cable:

The following sequence of tests shall be performed on samples of complete

cable at least 9 m in length excluding the test accessories :-
1. Bending test followed by partial discharge test.
2. Tan Delta measurement
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3. Heating cycle voltage test, followed by partial discharge measurement.

4. Impulse withstand test followed by a power frequency voltage
test. The above tests except (2 above) shall be applied
successively on the same samples.

Details of Tests: -

1) Bending test followed by partial discharge test :-

a) The sample shall be bent around a test cylinder (e.g. The hub of
Drum) at room temperature for at least one complete turn. It shall
then be unwound and the process repeated except that the
bending of the sample shall be in the reverse direction.
This cycle of operation shall be carried out three times in total.

b) The diameter of the test cylinder shall not be greater than:

25 (d + D) + 5 % for cables with lead and corrugated

aluminum sheath or with overlapped longitudinally applied metal foil :

20 (d + D) + 5 % for others

Where: D = measured external diameter of the cable in millimeters.

d = measured diameter of the conductor in millimeters

On completion of this test, the cable shall be subjected to the

partial discharge test as described in IEC Publication 885 - 2,
the sensitivity being 5 pC or less. The magnitude of the
discharge at 1.5 Uo shall not exceed 5 pC.

2. Tan Delta Measurement :

a) The sample shall be heated by a suitable method and the
temperature of the conductor determined either by measuring
its resistance or by thermocouples on the surface of the screen,
or by thermocouples on the conductor of another sample of the
same cable heated by the same means.
The sample shall be heated until the conductor reaches a temperature
equal to the maximum rated temperature of the insulation in normal
operation within + 5C .
b) Tan Delta shall be measured at a power frequency voltage of Uo
at the temperature specified above.
c) The measured value shall not exceed the value specified in table
II of IEC 840.

3. Heating cycle voltage test:-

a) The sample shall be in a U bend having a diameter specimen
b) The sample shall be heated by a suitable method, until the
conductor reaches a temperature which shall be not less than 9C
 104

and not greater than 15C above the maximum rated temperature
of the insulation in normal operation.
c) The heating shall be applied for at least 8 hours and shall be
followed by at least 16 hours of natural cooling. The conductor
temperature shall be maintained within the stated temperature limits for
the last 2 hours of each current loading period.
d) The cycle of heating and cooling shall be carried out 20 times.
e) During the test period a voltage of 2 Uo shall be always applied
to the sample.
f) After the final cycle the sample at ambient temperature shall be
subjected to and comply with the requirements of the partial discharge
test in accordance with Sub-clause 1 - C above.

4. Impulse voltage Test ( followed by a . c voltage test )

a) The impulse test shall be performed on the sample at a conductor
temperature which shall be not less than 5C and not greater than 9-C
above the maximum rated temperature of the insulation for normal
operation.
The impulse voltage shall be applied according to the procedures
given in IEC Publication 230.

b) The cable shall withstand without failure 9 positive and 9 negative

voltage impulses of the appropriate value specified in Table 1 of IEC
840.

c) After the impulse test, the cable sample shall be subjected to ambient
temperature to a power frequency voltage test at 2.5 Uo for 15 min.
No breakdown of the insulation shall occur.

II - Type tests on Cable Components :

The non-electrical type tests and type tests to check that the materials used for the
cable components have satisfactory properties shall be carried out as detailed in
IEC 840.
The method of tests and test results should satisfy the requirement of IEC 840:-

E) Electrical Tests after Installation : ( Site Tests ) :

1. Insulation:
Tests on new installations are made when the installation of the
cable and its accessories has been completed.

1.1 D. C. Testing:
D.C voltage equal to 3 Uo shall be applied for 15 min.

1.2 A. C Testing:
As an alternative to the D.C test an A.C voltage test at power
frequency, in accordance with Item (a) or (b) below, can be used:
 105

a) Test for 5 min with the phase to phase voltage (U)

applied between the conductor and the metallic screen.
b) Test for 24 hours with the normal phase to earth voltage
of the system (U o).

2. Non-metallic sheaths:-
The non-metallic sheath shall be subjected to the site tests
specified in IEC Publication 229.
 106

PART VIII

AUXILIARY EQUIPMENT
8.1 Structures:

Galvanized high tensile steel and/or mild steel structures BSS 4360 or at least equivalent shall
be provided for transformer platforms, auxiliary supporting structures for switchgear and
surge diverters, post and strain insulators and other equipment included in this specification
for outdoor equipment. The minimum clearances between phases and phase to earth shall be
6.5 M and 3.75 M for 400 KV, 5 M and 2.75 M for 300 KV, 2.6 M & 2.0 M for 132 KV and
1.2 M and 1.05 M for 33 KV and 11 KV lines.
Take-off gantries structures for double circuit overhead lines shall have three pinnacles to
receive 3 steel wires (overhead lines earth shield conductors) from the terminal tower and
arranged to give 30o angles for protection. The phase spacing shall be 6.5 M, 5.0 M, 2.6 M
and 1.2 M for 400, 300, 132 and 33 KV lines respectively.

The gantries shall be designed for maximum line take-off angle of deviation (horizontal
deviation) of up to 30o & vertical take-off angle of up to 1 in 4. The height of the main girder
of the substation take-off gantries shall be not less than15 meters, 13 meters for 400, 300 kV
lines and 9 meters for 132 and 33 kV lines.

All structures shall be constructed to be bolted together at site. This shall be designed with the
least number of parts to facilitate transport, inspection and erection. Tenderers are at liberty to
put forward any design complying with the requirements of this specification, but such
designs must have good appearance, be economical and simple such that stresses can be
computed with reasonable accuracy.

Thickness and sizes of steel sections used shall comply with the requirements specified for
400, 300, 132 and 33 kV towers under part IV clause 4.4. Bolts and nuts shall not be less than
15 mm diameter. Steel lock washers shall be provided for all bolts and nuts.

For 400 and 300 kV the double insulators string of each phase shall be attached to the
horizontal gantry beam and not to any of the gantry supporting structures to give clearance for
jumpering from the slack spans to other side of the gantry to suit the wall bushing
arrangement of connection to SF6 Switchgear and to suit the connection to the 400 and 300
KV outdoor cables sealing ends for the other two feeders, arrangement details shall be subject
to MEW approval.
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8.1(a) Earthing of Auxiliary structures and equipment for 400, 300 and 132 KV Lines
An Earth-ring consisting of a 400 sq.mm, 300 sq.mm & 95 sq.mm stranded copper conductor
(or flat copper tape of equivalent size) shall be provided inside the perimeter of fence for 400,
300, 132 & 33 kV respectively. The earth ring shall be approximately 2 meters from the
fence. One electrode consisting of 2 x 3 meters 19 mm, dia copper bonded rods shall be
driven to a depth of at least 6 meters. The fence shall not be connected to this earth ring.

Each gantry shall be connected to the earth ring at both ends by means of 400 and 300 & 95
sq.mm copper conductor for 400, 300, 132 kV respectively. The gantry shall be similarly
interconnected. All the lightning arrestors shall be bonded for earth connections and
connected to earth-ring from both the sides. Similarly, all cable boxes and coupling
condensers shall be bonded together and connected to the earth-ring from both ends.

Full details of earthing system showing earthing layout, size and type of each earth
connection shall be submitted for approval. All the joints shall be tinned.

The tenderer shall note that, if it is necessary, the length of each earth electrode shall be
increased and / or the number of electrodes shall be increased so that the earth resistance of
the earth system will not exceed one ohm and will also prevent the levels of touch and step
voltage exceeding the limits recommended in VDE 014/LSEE std. 8--1976. The tenderer
shall confirm provision of this while quoting the lump sum price for this item and no extra
payment will be granted for any reason arising from the site conditions.
Drawings of earthing of gantry structures and termination equipment such as surge diverters,
cable boxes etc. The proposed method of routing the overhead earthing steel wire between the
pinnacles of the gantry and then between these pinnacles and the terminal tower and also
between this terminal tower and the second to be submitted for approval.

8.1(b) Earthing of Auxiliary Structures and Equipment for 33 and 11 KV Lines:

The platforms shall be provided with 4 sets of earthing devices, which shall be included in the
tender price.
Single surge diverters cable boxes and isolators...etc., each shall be provided with one set of
earthing device, and each earthing device shall be included in the unit rates and connected to
the earth ring and will also prevent the levels of touch and step potentials exceeding the limits
recommended in VDE 0141/IEEE Std. 80-1976.
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8.2 Loading and Factors of Safety:

i) Based on maximum loading conditions likely
to occur during erection and normal operating conditions : 2.5
ii) Maximum simultaneous working loading as
modified by one broken wire conditions : 1.5
iii) Factor of safety against over-turning : 2.5
iv) Stranded conductors subject to maximum
wind load at a temperature -6 oC : 2.5
These factors of safety are based on ultimate strength of conductors and elastic limit for other
items.

8.3 Insulator Attachments:

The structures shall be complete with the insulator attachments for the strain insulators.

8.4 Galvanizing:
Specification for galvanizing included under part IV shall apply for these structures also.

8.5 Foundations:
The specifications for foundations under part IV shall apply to the foundations required for
the structures and equipment included for the sub-stations.

8.6 Surge Arrestors (Surge Diverters):

Zinc oxide type (gapless type) shall be offered provided it fully complies with latest
recommendations of IEC No 60099-4. Full details shall be subject to MEW approval.
The equipment offered shall be suitable for operation under system condition specified and
shall have sufficient capacity to discharge the system charging current. The surge arrestors
shall be complete with the auxiliary supporting structures. Surge detectors and counters and
each one connected with separate earthing device set and connected to the earth ring as
specified.
Surge arresters shall be equipped with (integrated station condition monitoring) ISCM
systems which shall provide necessary data as leakage current measurement and display,
surge current impulse metering and display, 3rd harmonic analysis of leakage current with
P P

compensation for network-dependent harmonics, temperature correction, and indication by

means of LEDs in the colors of traffic lights.
Such system shall be equipped with wireless communication for evaluating long-term
measurements, counter history (i.e time and date of surge), and energy summation
20 kA heavy duty surge diverters for 400,300, 132 kV and 10 kA heavy duty surge diverters
for 33 and 11 KV lines shall be supplied.
The surge arrestors shall fulfill the following requirements:-
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1. Rated voltage kV 400 275 132 33 11

2. Max. System voltage kV RMS 420 300 145 36 12
3. Impulse withstand voltage 1.2/50/uf 1425 1050 650 200 95
4. Min. creep age distance mm 21000/15000 15000/10900 6600/4800 1300 580
8.7 Tests:

8.7.1 Type tests (design tests)

- Insulation withstand tests on the arrester housing
- Residual voltage tests
- Long-duration current impulse withstand test
- Operating duty tests
- Tests of arrester disconnections / fault indicators
- Short-circuit tests
- Internal partial discharge tests
- Test of the bending moment
- Environmental tests
- Seal leak rate test
- Radio interference voltage (RIV) test

8.7.2 Routine tests and acceptance tests

- Routine tests

The minimum requirement for routine tests to be made by the manufacturer shall be as follows:-

a) Measurement of reference voltage (Uref).

The measured values shall be within a range specified by the manufacturer;

b) Residual voltage test.

This test is compulsory for arresters with rated voltage above 1 kV.
The test may be performed either on complete arresters, assembled arrester units or on a
sample comprising one or several resistor elements. The manufacturer shall specify a suitable
lightning impulse current in the range between 0,01 and 2 times the nominal current at which
the residual voltage is measured. If not directly measured, the residual voltage of the complete
arrester is taken as the sum of the residual voltages of the resistor elements or the individual
arrester units. The residual voltage for the complete arrester shall not be higher than the value
specified by the manufacturer.

c) Internal partial discharge test.

This test shall be performed on each arrester unit. The test sample may be shielded against
external partial discharges.
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The power-frequency voltage shall be increased to the rated voltage of the sample, held for 2s
to 10s, and then decreased to 1,05 times the continuous operating voltage of the sample. At
that voltage, the partial discharge level shall be measured according to IEC60270.
The measured value for the internal partial discharge shall not exceed 10 pC.
Alternatively, the manufacturer may carry out the partial discharge measurement at the rated
voltage or at a higher value without reducing the test voltage afterwards.

d) For arrester units with sealed housing, a leakage check shall be made on each unit by any
sensitive method adopted by the manufacturer.

e) Current distribution test for multi-column arrester. This test shall be carried out on all
groups of parallel resistors. A group of parallel resistors means a part of the assembly where
no intermediate electrical connection between the columns is used. The manufacturer shall
specify a suitable impulse current in the range 0,01 to 1 times the nominal discharge current
at which the current through each column shall be measured.
The highest current value shall not be higher than an upper limit specified by the
manufacturer. The current impulse shall have a virtual front time of not less than 7 s and the
half-value time may have any value.

NOTE 2 If the rated voltage of the groups of parallel resistors used in the design is too high
compared to available test facilities, the rated voltage of the group of parallel resistors used in
this test can be reduced by introducing intermediate electrical connections between the
columns, thereby establishing several artificial groups of parallel resistors. Each such
artificial group will then pass the current distribution test specified.

8.7.3 Acceptance tests

Standard acceptance tests

When the purchaser specifies acceptance tests in the purchase agreement, the following tests
shall be made on the nearest lower whole number to the cube root of the number of arresters
to be supplied.

a) Measurement of power-frequency voltage on the complete arrester at the reference

current measured at the bottom of the arrester. The measured value shall be within a range
specified by the manufacturer. For multi-unit arresters, the value may deviate from the
reference voltage of the arrester.
b) Lightning impulse residual voltage on the complete arrester or arrester unit (see 8.3), at
nominal discharge current if possible or at a current value chosen according to 8.3. In this
case, the virtual time to half-value on the tail is less important and need not be complied with.
The residual voltage of a complete arrester is taken as the sum of the residual voltages of the
individual arrester units. The residual voltage for the complete arrester shall not be higher
than a value specified by the manufacturer.
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c) Internal partial discharge test

The test shall be performed on the complete arrester or the arrester units. The test sample may
be shielded against external partial discharges.
The power-frequency voltage shall be increased to the rated voltage of the sample, held for 2s
to 10s, and then decreased to 1,05 times the continuous operating voltage of the sample. At
that voltage, the partial discharge level shall be measured according to IEC 60270. The
measured value for the internal partial discharge shall not exceed 10 pC.
Any alteration in the number of test samples or type of test shall be subjected to MEW
approval.

8.8 33kV Cable Sealing Ends:

Cable end sealing bushings shall be outdoor type suitable for 300 sq.mm copper
conductor.1/core XLPE insulated cable. The cable bushing shall be complete with brass (or
non-ferrous) wiping glands, plumbing into the lead sheath, non-ferrous cable lugs, bolts and
nuts. Jumper connectors and earth bonding clamps for fastening the cables along the tower
members at not more than 90 cms spacing between such clamps shall be provided. The
leakage distance shall not be less than 1300mm.

8.9 33 and 11 KV Isolators:

Isolator units shall be outdoor type and shall be horizontal mounted. The isolators shall be
double break rotating post insulator type. The creepage distance of the supporting insulators
should be adequate for operation under heavy atmospheric pollution's in Kuwait and shall be
not less than 1300 mm.

33 kV and 11 kV three phase isolators shall have a guaranteed continuous current rating of
not less than 400 Amps under Kuwait worse climatic conditions.
Isolators shall be designed for live and off-load operation and they shall be suitable for
switching transformer magnetizing currents and line charging current. The isolators shall be
capable of withstanding system short circuit current for 3 seconds i.e. 17.5 kA and 26 kA
three phase symmetrical faults for 33 kV and 11 kV isolators respectively.

The contacts of the isolators shall be of copper material (silver faced or base copper) and
carry their rated loads without overheating or welding and the design shall be such that they
do not call for more frequent maintenance than once in two years. All isolators units shall
include necessary supporting structures. The operating mechanism shall be of robust
construction suitable for manual operation and capable of being locked in 'ON' and 'OFF'
positions. Full technical specification of the isolators shall be submitted with the offer.
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PART IX
ACCEPTANCE TESTS
Test at Site:

The Contractor shall carry out the site test detailed below at no extra cost and before
handing-over, any section of the work.
The Contractor shall provide necessary apparatus and instruments to carry out these
tests. All such tests shall be carried out in the presence of and to the satisfaction of the
Engineer.

9.1 Tower Footing Resistance:

The footing resistance of each individual tower shall be measured in an approved

manner before the earth conductors are erected.

9.2 Continuity Test:

The complete overhead line shall be tested, before connection to cable end sealing
bushings and surge diverters, for continuity of each phase conductor.

9.3 High Voltage Tests:

The overhead lines shall be tested with a D.C. voltage applied between each phase and
earth by means of a D.C. high voltage testing unit and without cleaning of the
insulators. Tenderers shall state leakage current expected for such tests, for the
different sections of lines and taking into consideration the atmospheric conditions
given in clause No. 3.2. The Contractor shall supply the necessary apparatus,
instruments and the D.C. high voltage testing unit including those required for
carrying out this test and should be shown in the schedules.

The test voltage shall be applied for fifteen minutes for 400, 300 and 132 KV
Overhead Lines and five minutes for 33 and 11 kV overhead lines and shall be as
follows:-
Line Voltage D.C. Test Voltage to Earth
400 KV 325 KV
300 KV 245 KV
132 KV 108 KV
33 KV 27 KV
11 KV 9 KV
The electric power necessary for the tests at site shall be arranged by the contrator.
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The Contractor shall satisfy himself that all connections are good before switching on
the power and shall be responsible for and make good any damage that may arise
because of faulty connections.

9.3.1 The above test shall be repeated after six months from the date of taking over and
without any cleaning of insulators.

9.3.2 All D.C. measuring apparatus, instruments including D.C. high voltage testing unit
(see clause 8.3) will be subject to checking and calibration by MEW before starting
the high voltage D.C. current test, catalogues and details to be submitted with the
offer. Full details and catalogues of the proposed high voltage D.C. testing equipment
shall be submitted for approval before shipping the test equipment.