21kV 1000mm² XLPE Cable Specification
21kV 1000mm² XLPE Cable Specification
N-015-R01
1. General
2. Material Specification
3. Technical Schedule
This specification covers the design, manufacture, testing, supply, delivery and off-
loading of 21 kV XLPE, 1000mm2 Cu conductor, lead sheathed cable, which will be
used as spare parts to existing 21 kV circuits in the EWA Transmission network. The
details of the 21 kV system are detailed below in the specifications.
The offered 21 kV single core underground cables shall be designed for a service life of
not less than 40 years in the service condition and installation environment prevailing in
Bahrain. It shall also fully satisfy the safety, health and environmental requirements
enforced by the laws established in Bahrain and EWA requirements. The materials
supplied shall operate under the service conditions and network parameters specified
below.
EWA will use the supplied materials as a spare for the existing 21 kV circuits; hence, the
material should be approved and compatible with the existing 21 kV cable system and
have a valid type test report relevant to this specification. (See clause 1.9).
1.2 SERVICE CONDITIONS
Note 1: This voltage level applies to 21 kV connections between transformer tertiary windings
and reactors.
Note 2: Ends shall be suitably earthed with/without SVL as per approved configuration.
The products and systems supplied under this contract shall conform to the requirements of
this specification, the best-accepted international practice for the material of this type and
the stringent requirements imposed by the service conditions. In addition, the contractor
shall follow the IEC and ISO standards or approved equivalent standards and maintain a
documented quality control and quality assurance system to ensure these objectives.
The tenderer shall submit an outline statement of his quality control and quality assurance
policies and procedures with his tender documents. The contractor shall submit all quality
certification documents relating to the material supplied to EWA.
1.5 STANDARDS
Unless otherwise stated in this specification, the material shall be designed, manufactured,
and tested according to the latest applicable IEC publications. Where no IEC publication
has been issued to cover a particular subject, a recognized and approved international
standard shall be applied.
In any instance where the tenderer proposes using an alternative national publication,
standard, recommendation, or code of practice to those specified (excluding IEC
publications), then he shall submit an English- language copy of the proposed document,
together with a detailed comparative analysis of the requirements of the specified and
proposed documents with his tender. Acceptance of any proposed alternative document
shall be at the discretion of EWA.
If there is a conflict between this specification and any IEC publications or national
standards, this specification shall take precedence after confirmation with EWA.
EW.A.'s acceptance of any alternative publication, standard, recommendation, or code of
practice shall not relieve the contractor of his obligation to supply material capable of
meeting this specification's stated requirements.
1.6 DESIGN
The supplier shall be responsible for the material designs supplied under the contract.
The material shall be designed to operate satisfactorily, in accordance with this
specification, on the system specified and under the stated service conditions.
EWA's acceptance or approval of the design of the material or its components shall not
relieve the supplier of his obligation to supply material fully capable of meeting the
service requirements.
1.7 MATERIALS
The supplied material, either completed products or their constituent parts, shall be
suitable and quality to ensure that the cable system will operate satisfactorily, following
this specification and under the stated service conditions.
1.8 MANUFACTURE
The manufacturer or supplier shall perform adequate quality checks during the
manufacturing process to determine design and component material compliance with
established criteria.
The supplier shall immediately notify EWA about any deviations from the criteria or any
occurrences in the manufacturing process. If remedial action, repair, or reworking may
be appropriate, such action shall only proceed with the prior approval of EWA. Any
product that has been repaired, reworked, or has been the subject of remedial action
without prior approval may be liable to rejection notwithstanding the results of any tests
prescribed by this specification. Any consequent delay due to the provisions of this
clause shall be the supplier's sole responsibility and shall not relieve him of his
obligations regarding adherence to the delivery schedule.
1.9 ROUTINE & TYPE TESTS
The manufacturer shall conduct routine tests on the materials supplied according to the
relevant IEC or approved alternative international or national standards. In addition, a
third-party inspection agency from the proposed list provided in Annexure I shall
witness the testing. The third-party inspection cost shall be included in the material's unit
price.
The offered material should have a valid type test report relevant to this specification.
The tenderer shall submit details of the type tests carried out on the cable and
accessories of a similar design (tested system) for approval by EWA. Suppose no
satisfactory-type test reports on a cable and accessories of a similar design are available.
In that case, it will be necessary for the contractor to carry out type tests on the cable
system for these offered materials according to the relevant IEC or approved alternative
international or national standards at his own expense. EWA will advise the number of
visits and details of participants for the test witnessing in due course and must approve
the list of proposed tests that shall be carried out on the materials.
The supplier or manufacturer who intends to carry out the type tests at his own expense
to meet EWA specification requirements must mention that clearly in his offer.
The tender documents and specifications shall use the International System of Units (SI) as
the measurement system. The length shall be in meters, the temperature in degrees Celsius,
electrical energy in kWh, and the pressure in bars (absolute).
The manufacturer or supplier shall produce all documents, drawings, instructions, labels,
packing lists, and nameplates in English. However, EWA will state in the contract if there are
any requirements to use both Arabic and English.
The supplier shall provide EWA with a technical folder in soft and hard copies at the time of
delivery of the materials. The hard copy shall be A4 size, and the drawing can be larger than
A4. The soft copy shall be prepared in electronic format using software approved by EWA,
on CD or similar media.
The costs for providing the technical folders in soft and hard copies are deemed to be
inclusive in the offered rates, and no extra payment will be made.
The detailed requirements for the minimum contents are as given below:
❖ Introduction giving details and lists of materials supplied.
❖ A brief summary of the manufacturing process, including reports on
any specific problems encountered.
❖ The quality control problems (if any) and the steps taken to rectify them.
❖ Manufacturer’s specifications for materials employed in the manufacturing.
❖ Approved drawings of the supplied material.
❖ All reports for Factory Acceptance, routine, special/sample, and type tests carried
out for the supplied materials.
1.13 RESPONSIBILITIES
The supplier shall guarantee the materials against faulty design, raw materials,
manufacturing defects, and faults arising from the supply and delivery of these materials
for a period of three years from the date of receipt of the materials.
1.15.1. Packaging
Power cables shall be delivered on steel drums. The ends of all cables shall be durably
sealed before shipment to prevent moisture ingress and shall be firmly and properly
secured.
The inner flanges of steel drums shall have suitable protection to avoid any damage to the
cable and must be secured to avoid any loose cables during the installation.
All drums shall be lagged with steel battens or covered with other suitable approved
material to provide physical protection for the cables during shipment and Subsequent
storage and handling operations. This lagging shall also provide a suitable protection
against all climatic conditions prevailing on site.
A cable drums packing list shall be prepared and submitted includes the drums number
and length of the cables on the drum.
All packaging lists are to be checked by one of the approved inspection agencies from
the list provided in Annexure I, for which costs are deemed part of contract price and
should obtain approval from EWA prior to dispatch the items.
1.15.2. Marking on Packages
All cable drums shall be clearly and indelibly marked with the following
information:
(1) Employer's name
(2) Contract number
(3) Contractor's name
(4) Contractor's Agent in Bahrain and his address
(5) Gross and net weights
(6) Contents (type of accessory) and number of items
(7) Material national stock number (NSN)
The following additional marking, where applicable, should appear on the same
flange or label as the above information:
(1) Voltage, cable type, length, number of cores/pairs.
(2) The position of the cable nose.
(3) The direction for rolling drums shall be indicated by an arrow.
(4) The cable drum dimensions
In all cases, any necessary handling/storage instructions shall also be displayed.
If any material being supplied has a limited shelf life, all such material shall be clearly
identified, given the manufacture date, storage conditions, and shelf life expiry date.
These details are to be included in the packing list.
The material shall be delivered to CSD, EWA Bahrain or designated stores. A separate
cover sheet, duly completed, is required for each bill of lading or airway bill. On
completion of inspection of material following delivery, if any shortfall or damage or
material which has passed its expiry date is notified to the supplier by EWA, then the
supplier shall make good any such shortfall or damage in the material at his own
expense. This shall include, where appropriate and necessary, any air-freight charges
which may be incurred.
The supplier shall ensure that no government traffic regulations are broken during the
delivery process. The contractor shall make personnel and facilities available to EWA
for inspection of materials during the handover.
1.18 DOCUMENTATION
B. Drawings
C. Delivery period
- The delivery period should be mentioned in the offer.
D. Shipping Plan.
- Method of shipment.
- Port of arrival.
- Method of Transport and client store from the port.
- A valid type test report according to the specification requirements and relevant IEC
Publications or approved international standards.
- The technical schedules must be fully completed and returned as part of the tender
documents.
- The third-party inspection must be included in the offer to witness the factory
tests, check, approve the packing list, and submit the inspection report supported
with pictures prior to the material shipment.
- The supplier must guarantee the materials three years from the date of receipt of
the materials and should be stated clearly in the submitted offer
Any offer not complying with the mandatorily required submission will be
rejected.
The 21kV cable system design employs three single-phase, copper conductor, XLPE
insulated with lead (and copper wire) sheath cables, per circuit.
The cables shall generally be installed in underground uPVC pipe ducts encased in
concrete, or in reinforced concrete surface troughs (with covers), or cable trays in
basements surrounded by air.
Where cables are installed in ducts, the ducts shall be filled with a thermally stable
bentonite material. Cables installed in troughs will be laid on a bed of approved selected
thermal sand or sand/cement mix, and the trough shall be filled with the same material.
a. The conductor temperature shall not exceed 90oC at the specified continuous rating.
b. The cable shall be capable of an overload of 120% of maximum continuous
transformer rating for up to two hours following a prior loading of 80% and the
conductor temperature shall not exceed 105oC at this rating.
c. The rated short-circuit withstand current for cable and shall not be less than 25kA for
one second, and the conductor temperature shall not exceed 250 o C. The metallic
sheath of the cable is required to be able to carry the full short circuit current.
d. The impulse withstands level for cable shall be at least 125kV for the cable.
e. The anti-corrosion serving shall be coated with graphite and capable of withstanding a
DC voltage test of 10kV for five minutes after installation and an annual DC test of
5kV for five minutes.
f. A water barrier to limit longitudinal migration of water under the metallic sheath in the
event of damage to the sheath shall be provided.
g. The copper conductor shall incorporate a water blocking mechanism to prevent
longitudinal migration of water along the conductor.
A. Conductor
The conductor shall be 1000 Sqmm copper from the plain annealed copper wires in
accordance with IEC 60228.
The maximum allowable continuous conductor temperature shall not exceed 90oC.
The maximum allowable one-seconds short circuit conductor temperature shall not
exceed 250oC.
B. Conductor Screen
The conductor screen shall consist of semi-conducting thermosetting material compatible
with the insulation and the conductor. It shall have allowable operating temperatures
equal to or higher than those of the insulation. A non-hygroscopic semi-conducting tape
may be applied between the conductor and the extruded semiconducting material.
C. Insulation
The insulation shall consist of cross-linked polyethylene (XLPE) which shall be “dry-
cured”. The insulation shall be firmly and continuously bonded to the extruded conductor
screen.
D. Core Screen
The core screen shall consist of semi-conducting thermosetting material and shall be
continuously bonded to the insulation. It shall have allowable operating temperatures
equal or higher than those of the insulation. A semiconducting tape may be applied over
the extruded core screen.
F. Metallic sheath
Lead sheath applied over the semi conductive water Swellable tape.
The metallic sheath could be either lead alloy or combination of lead and copper wire to
withstand the required short circuit level (25KA /3sec)
G. Anti-corrosion Serving
The extruded anti-corrosion serving shall be of black high-density polyethylene better
(HDPE). It shall be capable of withstanding a DC voltage test of 10kV for five minutes
after installation and an annual DC test of 5kV for five minutes.
The serving shall have an overall graphite coating or, alternatively, an extruded outer
semi-conducting layer to enable the above tests to be carried out.
The embossed letter/figures shall be easily read and shall be raised approximately 0.5mm
and consist of upright block characters approximately 15% of cable diameter in size. The
space between one set of embossed characters and the next shall not exceed 150mm.
The The continuous rating of the 21kV circuit shall be 33 MVA per phase (910A ).
The rating shall be calculated in accordance with IEC 60287. The following parameters
shall be used in the calculation:
1.1.1. The technical schedules shall be fully completed and returned as part of the tender.
1.1.2. The technical schedules shall be interpreted and completed in accordance with these
instructions, the scope of work and the technical specification. The scope of work
and technical specification shall constitute the specification.
1.1.3. All pages of the schedules shall be marked on the front with the tenderer's stamp,
initialled and dated.
The technical schedules shall be fully completed and returned as part of the tender
Any deviation from the specification shall be individually listed and described in
schedule TS-C. General references to other parts of the tender are not acceptable in lieu
of this listing. Full details of the deviation shall be given elsewhere in the tender, and
references to such details shall be listed in the schedule.
2 Conductor:
3 Conductor Screen:
(a) Material SC
Compound
(b) Nominal Thickness mm
4 Insulation:
5 Core Screen:
(a) Material SC
Compound
(b) Thickness mm
Drum Length
13
(a) Normal length per drum m 600
(b) Maximum length per drum m
Drum weight
14
(a) Gross weight of normally loaded drum kg
(b) Gross weight of maximum loaded drum kg
9. Susceptance μohm/km
13. Losses:
(a) Conductor loss per phase at current
(i) in item 11 W/m
(ii) rated load W/m
(b) Dielectric loss per phase at Uo W/m
(c) Sheath loss per phase at current W/m
(d) Total loss per phase W/m
20C %
40C %
60C %
Maximum operating temperature +5C %
0.5 Uo %
1.0 Uo %
1.5 Uo %
2.0 Uo %
1,000 ohm m
100 ohm m
10 ohm m
13 Storage conditions
All deviations from the Specification shall be individually listed hereunder and referenced to
relevant sections and clauses of the Specification and to detailed description elsewhere in the
tender. If no deviations are to be listed, then the word "NIL” shall be entered.
SIGNED: ....................................................................
COMPANY: ..............................................................
CESI SGS
VIA R. Rubattino 54 1, place des Alpes
20134 Milano, Italia P.O. Box 2152 Geneva 1, Switzerland
Ph : 39 0221251 Ph : +41 22 739 9111
Fax : 39 0221255440 Fax : +4122 739 9886
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