400 kV XLPE Cables and Accessories ig33 1,5.13.L.01-Rev 2 LIST OF CONTENT FOR 400kV XLPE CABLES AND ACCESSORIE: INDEX SECTION TITLE 1 SCOPE 2 APPLICABLE STANDARDS 2 Intemational Standards 22. ‘Alternative Standards 23. DEWA Internal Specifications 24, Applicable Regulations/Guidelines 25. Precedence of Standards 3. DESIGN AND CONSTRUCTION 3.1 General Design Considerations 32. Conductors 333. Conductor Sereen 3. Insulation 3. Insulation Screen (non-metallic) 36, Insulation Sereen (Metallic) 37, Water sealing 38. Over sheath 39, Embossing 3.10. ‘Overall Dimensions Bll ‘Technical Submittals 4 COMPONENTS AND ACCESSORIES 4 Technical Description 42. Joints 43, ‘Outdoor Terminations 4a, GIS Terminations and Transformer Terminations 45. Sheath Bonding and Earthing 46 Cable Supports 5. OPERATIONAL REQUIREMENT 31 Partial Discharge Monitoring System 5.1 ‘Off Line PD Monitoring System 512 On line VHF Partial Discharge Monitoring System 52 Distributed Temperature Sensing System 6. MAITENANCE REQUIREMENT. 61 Spares 2 ‘TYPE, ROUTINE AND SAMPLE TESTS nM Pre-Qualification Test of Cable System 12 ‘Type Test of Cable and Accessories 3 Routine and Sample Tests 73 Sample Tests 732 Routine Tests 8 COMMISSIONING REQUIREMENTS AND TESTS 81 Tests after Installation 9 TRAINING 10 PACKAGING AND SHIPPING 101 Cable Length 102, Sealing and Drumming. " RATING AND DATA SHEET Dubai Electricity & Water Authority 1 of 25 All Rights are reserved400 kV XLPE Cables and Accessories ig33 1,5.13.L.01-Rev 2 4s. Para (63) Para (64) Para (65) Para (66) Para (67) Para (68) 481 Para (69) Para (70) Para (71) shall be insulated from the GIS or transformer / reactor cable chamber. The non-conductive ‘metallic bodies of cable termination & GIS at interface point shall be provided with equalizing earth bonds or suitable surge arresters to neutralize the transient ground potentials. Oil Pipes associated with terminations shall be adequately insulated so that in the event of fault, no ‘damages shall occur to piping Sheath Bonding and Earthing ‘The conductors and sheaths of single core 400 KV cables shall be successively transposed at ‘each joint location to create cross bonded sheathing scheme for installation route lengths ‘exceeding two sections. For installation route lengths consisting of two or less than two sections suitable single point bonding shall be proposed. The proposed bonding system of the 100 KV cable sheath circuit as well as design of the related individual components shall be subject to the approval of DEWA. The | ‘proposed sheath bonding scheme shall ensure low sheath losses in the underground cables, Earthing at each joint location shall comprise a grid of tinned copper wires thermit welded’ unless otherwise approved by DEWA, to copper cladded earth rods and insulated copper earth ‘connections to the equipments. The size of copper earth connections shall be adequate, but not less than $00 sqmm, to carry the full-expected fault current for the cable system. Where necessary, additional earth rods shall be provided to obtain this value under all considerable circumstances. we metal sheath of the cables shall be connected to the earthing system using single core bonding leads at the sealing ends. Bonding Cables Bonding cables shall be coaxial & single core type as per required application. The coaxial jconcentric type shall be of stranded annealed copper conductors with XLPE insulation for inner core and PVC insulation for outer core, with a conductive outer layer/skin with interspersed water blocking layers. The single core type bonding cables shall be of PVC Insulated stranded annealed copper conductors with a conductive outer layeriskin over the insulation, For installations requiring protection against fire, bonding cables having outer ‘conductive layer’skin with fire retardant properties shall be preferred. ‘The coaxial bonding cable shall have low surge impedance not exceeding 30 ohm and the insulation between inner & outer conductors shall have dielectric strength matching with that of the joint sleeve sectionalizing insulator and insulation level between outer conductor & ground shall have half of this value in compliance with the requirements stipulated in IEC 62067. Additionally the bonding cable shall be capable of withstanding the test voltage of 25 kV DC with 1 min duration according to IEC 60229, The installation of sheath bonding leads between joints and various types of link boxes as well as ground continuity conductors shall be Dubai Electricity & Water Authority 12 0f 25 All Rights are reserved400 kV XLPE Cables and Accessories ig33 1,5.13.L.01-Rev 2 Para (72) Para (73) Para (74) Para (75) 46. Para (76) Para (77) Para (78) Para (79) according to IEEE 575 recommendations. Bonding system shall be capable of withstanding DC Voltage test after installation at 10 KV DC to carth for 1 minute and the subsequent maintenance tests of 5 kV DC to earth for 1 minute. ‘The link boxes shall be made of non-magnetic & anti-corrosive material preferably stainless steel of sufficient mechanical strength suitable for indoor, outdoor or buried type of installation, For above-ground installations in indoor or ‘outdoor environments, the proposed link boxes shall be of IP66 ingress protection. ‘The buried type link boxes shall be designed to IP68 made of stainless steel of grade SS304 with minimum thickness of 2.0mm with water proof sealing arrangement suitable for horizontal installation in shallow pits of depth not exceeding two meters & for installations in tunnels, Al the cross bonding link boxes shall be designed to withstand the impacts due to bursting apart of SVLs. All the proposed types of link boxes shall have undergone Internal “Arcing tests as per IEC 61641 as applicable. The terminal posts & links shall be suitable for the specified short circuit requirements and the links shall be made of tinned copper & arrangement of links shall be so designed that refixing of removed links in wrong position is not possible. For cross bonding boxes the links shall be covered with heat shrink sleeves. The contact resistance of the links shall be less than 10 Micro Ohms. ‘The links & terminating cables shall be identified for their phase and a permanent red “DANGER” signage and electrical connection diagram of the link box shall be provided fixed on the front covering of the link box. The label shall be durable for long-term use ‘without deformation or decolouration. Further circuit identification labels shall be provided as detailed in relevant specifications. Cables Supports ‘The Bidder/Contractor shall provide all necessary racks, ladders, trays and supporting steelwork ete, required for the installation of the cables & accessories as per project scope requirements. For the clamping of cables on supports/racks, suitably designed non-magnetic clamps with ‘weather resistant rubber based lining, must’ be used to meet the expansion/contraction siresses imposed in normal service & to contain the expected electro-dynamic impulse forces during short-circuits and same shall be suitable for expected life expectancy of the cable, ‘The spacing of cable-supporting steel work and clamping shall be in accordance with the test arrangement during short circuit tests and same shall take care of the expected thermo ‘mechanical requirements & _ provide the supporting calculations for suggested spacing & supports to the approval of DEWA, Wherever cables and accessories are installed and exposed to direct solar radiation, sun shields of approved material and design shall be applied and installed, Within the stations, ‘ross over footbridges over the cables routed through path /access ways shall be provided in ‘order to prevent personnel stepping over the cables. All iron parts such, as footbridges, cable- supporting, structures, fasteners ete. shall be corrosion protected according to BS EN ISO 1461 or as described in relevant specifications and shall be grounded as per specification 15.1.9.0.06 OPERATIONAL REQUIREMENTS ‘The cables and accessories of the system shall be designed for real time monitoring of temperature, PD for cables System including accessories. The general requirements of these monitoring systems are as given in following articles. However bidders/contractors shall furnish complete details of DTS & PDM systems being proposed by them for accomplishment of this objective, Dubai Electricity & Water Authority 13 0f 25 All Rights are reserved400 kV XLPE Cables and Accessories ig33 1,5.13.L.01-Rev 2 Para (80) Para (81) Para (82) Para (83) Para (84) Para (85) Para (86) 512 Para (87) Para (88) In addition to temperature & PD monitoring systems said above, forall the indoor & outdoor cable terminations whose heat dissipating dielectric medium is primarily Insulating oil, shall be provided with suitable oil conservators with visual oil level monitoring watch columns in addition to dial type oil level gauges, unless otherwise approved by DEWA, with facilities for hard wiring them to control centre & SCADA centre. The Offline PD monitoring shall comprise incorporation of Permanent PD sensors (HECT’s) for Cable terminations / joints as part of cable installation for the local PD monitoring. This shall be complete with iis own measuring unit (PD acquisition box) at an easily accessible location, The total arrangement shall facilitate PD checks during site HV commissioning tests of cable circuits and also to carry out periodical PD surveys of cable circuits while in service, (GRERAWE the proposed HFCT's shall be compatible with DEWAYS existing Portable analyzer of Mis “Tschimp” make to fciiate onsite PD measurement of ebles. It shal be of “Split core type! and provided MME Ue cable ak boxes making use of the earth bond cables, The Method of insllainftemoval of HECT should be simple to faite future Feplacements i any without disturbing the bonding cable, HFCT's shall be provided for individual monitoring ofeach phase ofthe cable cuit along with derivation box together with conection cables for really connecting the portable analyser. ‘The datasheet & the specifiaions for sli type sensor and the se insialaionerrangetent bes bo be submited for approval ‘These shall be provided for the cable joints as local ‘These shall be compatible with DEWA’s existing Portable analyser dC Mis ‘Techimp” ms to facilitate on-site PD measurement of cables. The embedded sensors shall be provided for individually monitoring each phase of the cable along with derivation box cabled together for readily connecting the portable analyser. The data sheet é& the specifications for the ‘embedded sensor and the site installation arrangement have to be submitted for approval. ‘monitoring facility LFCT Sensor with connecting cable to be provided for deriving syne. signal ‘and to be cabled to the derivation box. b)_ Site demonstration: The cable terminations & joints of the cable installation shall be demonstrated for local PD. monitoring along with DEWA Portable analyser during ‘on-site after laying HV cable PD tests’ A continuous VHF PD monitoring system shall be provided with automatic facility for the simultaneous PD detection & collection of data on each accessory viz. ‘joints’ & ‘terminations’ in the 400kV XLPE cable by distributed sensor systems adopting inductive (HECT) technique for this purpose, the HFCT PD sensors embedded with capacitive coupler at the joints and HFCT sensors at terminations in the cable circuit or suitable sensors shall be provided. ‘The PDM system is also intended for performing on-site PD measurements on new cable installation as part of site High Voltage AC withstand test (30 to 300 Hz variable frequency) aimed at finding assembling faults before breakdown, The data acquired from the sensors {installed at each accessory) through its local PD detection units shall be transmitted via Dubai Electricity & Water Authority 140f 25 All Rights are reserved400 kV XLPE Cables and Accessories ig33 1,5.13.L.01-Rev 2 ‘optical fibres to the ‘station PC’ at control room. The PC shall provide a historical record of the progress of PD sources and will identify the areas of maximum activity. The PDM system shall have a remote data collection facility, which will be used as an office database for providing reports on PD status. Para (89) ‘The scope shall include Engineering, manufacture, supply, installation, testing and commissioning of the partial discharge continuous monitoring system, with all necessary auxiliaries and accessories to make a complete system, including site demonstration of successful operation. In order to achieve highest sensitivity for on-site PD measurements on. long lengths of cables, the capacitive type embedded PD sensors shall be integrated in to the joints! terminations. Local and remote facilites shall be provided for the on-line equipment ‘with a dedicated telephone and modem communication link to enable remote interrogation with the system, Any items/accessories necessary to make the system fully functional for the ‘rouble free monitoring of complete cable installation is included in the scope of work. Para (90) ‘The bidder/supplier has to indicate the exact quantities of individual items of the proposed system as per the details given in table below. Tem ] Description Quantity @ | HIECT Sensors for termination and IFCT sensor with embedded capacitive coupler For joints b_| Detector wits /Node units | ¢ [Isolation transformers / Surge proteclors ¢_[ Power supply (UPS) | Point On Wave Units | f Power supply requirements (supply points) AC/DC = | PCs Pre loaded with all necessary Hardware & Software, The PCs will each have a Combo drive, retrievable disk drive of 120GB, modem & printer a. Atsubestation b._ALOftice remote facility) | Cables a. Doubly screened co-axial exble b. Fibre Optic cable ©, Communication eable 4__Power Supplies AC/DC RF Connectors, glands, redueers ce, to complete installation ‘Others like hardware filters ete (i Tsyne Unit I Para (91) ‘The PCs & all its accessories shall be installed in a panel type cabinet at the control room of the 400kV substation, The colour & shade of the cabinet shall match with the control panels, which will be decided during engineering stage. a) System requiremer Para (92) ‘The system shall be suitable for Partial Discharges (PD) measurements on cable systems and shall be provided with multiple channels for PD signals and one channel for synchronization (phase reference purpose). The system shall be equipped with required no. of embedded or "T sensors with split core for PD signals and no. 1, LECT or any suitable sensor for synchronization and phase reference shall be based on voltage measurement. The system shall be provided with a memory support where data of monitoring are stored. The system shall be a stand-alone system including on board data processing capabilities. The system shall be based on a large memory large bandwidth digitizer for acquisition purposes. It shall acquire the entire waveforms of a large number of detected signals, so that the system will be able to characterize pulses, improve signal to noise ratio and derive pulse feature for separation purpose. The system shall be able to provide the PRPD & (3D pattem representation of PD phenomena. The system shall be able to efficiently separate PD phenomena and noise on the basis of the pulse shape. The system shall allow different PD phenomena to be classified on the basis of their characteristic pulse shape and split in different clusters relevant to homogeneous PD sources, so that further analysis can be carried ‘out on each dataset separately. The system shall have an efficient noise rejection capability Dubai Electricity & Water Authority 15 0f 25 All Rights are reserved400 kV XLPE Cables and Accessories ig33 1,5.13.L.01-Rev 2 without adding of any hardware filters or disturbance suppression devices, which may limit the significance of the acquired data. The system shall be able to provide distributions of ‘quantities related to pulse shape (pulse features) for classification purpose, such as equivalent time length, equivalent bandwidth. The system shall be able to provide quantities related to phase, amplitude and time between discharge distributions. The system shall be equipped with a fibre optic decoupling system between the HV/MV side and the operator for his ‘complete safety. Para (93) The sensitivity requirement of detector units shall be specified. The sensitivity level of individual detector units/couplers shall be adjustable depending on the site background noise level. The Overall sensitivity of PD detection system shall be specified. Capacity of each detector unit to be specified, to ensure accommodation of maximum possible number of PD sensor signals. Para (94) PDM System shall be provided with a user security for accessing the system with a log on and password entry procedure. The user levels shall be defined as Master User and other users for the modification of system, update, and entry of parameters or manual operation. b) Software: Para (95) ‘The system shall have a software module for acquisition phase and this shall include an automatic identification tool to recognize the PD phenomena and ability to record different ‘quantities. It should be able to either record the entire waveform of each detected pulse or ‘execute a on board signal conditioning phase in order to provide phase, amplitude, time and pulse features of each signal. The system shall have a data archiving feature to provide ‘access to historical data and file storage with date and time stamp with sufficient storage facility for historical data for the lifetime of cables. PDM system should have the option of printing all trend plotsireports/POW patterns! displays, etc, It shall be possible to upgrade ‘update the system software throughout the lifetime of the system with ongoing development ‘& refinements in PD technology. Para (96) ‘The PC operating system shall be the latest version of MS Windows. It should be suitable for ‘continuous process application and should have been tested for the same. The hardware configuration of PC should be the latest available in the market preferably industrial type subject to DEWA / Engineer approval. For storing the historical PD database, sufficient storage facility in the form of hard disc and retrievable hard disk drive of ITB (latest available), as specified shall be available in the substation and remote access office PC. Auto restarts facility for PCs to be provided suitably for unmanned substation Para (97) ‘The PDM system should have the facility of automatic data transfer on Daily basis to Headquarters PC for regular updating of PD data. AC any time it shall be possible to view the latest substation data (real time), by manually dialling from office PC. Suitable office PC with required software, memory’ capacity (PD archived data) to be included. PDM system shall be provided with option of printing all trend plots / reports / POW patterns / displays, ete ©) Diagnostics: Para (98) ‘The advanced diagnostic & measurement feature shall be able to perform unsupervised clustering of the recorded data, in order to separate PD pulses into shape-homogencous classes & these shape-homogeneous classes should contain pulses relevant to a single type of source. Same shall be able to divide the original PRPD pattern in to. sub-patterns, each one relevant to a sub-class, then to only one discharge typology & the provided software should be capable to distinguish the different sources of the PD Patterns. The noise rejection requirements shall be achievable by analysing certain stochastic characteristics of sub- classes. The system shall have a Spectrum analyser option to analyse the frequency spectrum of the detected signal if required so that the acquisition bandwidth can be profiled to improve the signal to noise ratio, Para (99) In addition the system shall have built-in intelligent diagnostics software (expert system) in ‘order to automatically interpret various types of defects, The bidder shall make available typical point-on-wave pattems (based on various possible causes of PD activities) as library Dubai Electricity & Water Authority 16 0f 25 All Rights are reserved400 kV XLPE Cables and Accessories ig33 1,5.13.L.01-Rev 2 Para (100) Para (101) Para (102) Para (103) Para (104) Para (105) Para (106) (W) LVAC Supply. pictures in order to recognize source of PD activity. The same shall be integrated with the analysis software, which will enable the user to take decision on the suspected PD activity. ‘The bidder should suggest how the PD database could be utilized to plan maintenance ‘outagesirisk assessment of insulation/lifetime assessment of insulation (predicting long term degradation of insulation). 4d) Measurement Capability: There shall be two different modes of system operation viz. a dedicated Continuous PD Monitoring mode for the normal day today operation of the system & a dedicated HV commissioning test mode which is exclusively for PD monitoring during HV commissioning lest. The HV commissioning mode shall also operate as an independent feature. The ‘complete HV & PD data recorded during HV test shall be possible to be reviewed in replay ‘mode after the HV test. As the sensitivity of PD measurement strongly depends on signal-to-noise ratio, the filtering facility has to be provided in order to distinguish the real PD from internal and external noise such as radio, communication signal tc. This is mainly duc to severe noise interference normally encountered under on-site conditions. Site measurements have to be performed before installation of the PDM system in order to identify the various sources of extemal noise to incorporate the same in the filtering facility. This filtering shall preferably be through software such as digital signal processing involving filtering, averaging which substantially improves signal to noise ratio so as to make it possible to catch the first PD reflection even under noisy conditions. If hardware filtering is employed then adequate ‘measures have to be taken to avoid masking of other signals, which may lie in the same frequency range. ‘The PDM system should have the schemes incorporating PD sensor identification and location, The trend plot facility shall be available with the update period of hourly/daily/weekly’ monthly/yearly ‘The PDM system should have the facility of Real Time display, which will give an instant indication of PD activity coupler wise, with one-second-update period. The computer screen shall display the PD signals. Similar facility should be available with office PC (remote) for the real time viewing of data through modem and telephone link ‘The system shall have a Built-in self-checking facility, incorporated in the control system which will continuously verify the correct operation of the whole monitoring system with the simulated PD signal viz. checking of the sensitivity of individual detector units, response of PD sensors in addition to the checking of the system functioning, The periodicity of such self-check operation shall be specified. In case of system failure this shall trigger an alarm for communication to SCADA. In addition to stated self-check facility, the system shall be proposed with suitable arrangementidevices for externally checking the healthiness of PD sensors by simulation method. The simulators & cables used as part of site sensitivity tests are to be handed over to DEWA far future use. ©) Power Supplies: Power supply requirement (AC & DC if required) to be specified for the complete ‘monitoring system. However it shall be noted that the complete PDM System shall be normally powered from the station LVAC dedicated essential supply with a dedicated on-line UPS supply as a back up to ensure a safe & reliable running of monitoring and data acquisition system and to properly shutdown the PDM PCs during supply interruption, ‘The LVAC supply distribution shall be of radial type through a separate distribution cabinet & ‘each outlet from this board shall be protected against surges, overload & short-circuit. The PDM system should be able to block the noise from the LVAC source taken to power up the units. The power failure shall be monitored for overload & short-circuit. Dubai Electricity & Water Authority 17 0f 25 All Rights are reserved400 kV XLPE Cables and Accessories ig33 1,5.13.L.01-Rev 2 (ii) UPS Supply Para (107) Para (108) Para (109) Para (110) Para (111) Para (112) Para (113) Para (114) Para (115) A dedicated on-line UPS system shall also be provided as a back up during supply interruption, to ensure trouble-free & reliable running of the PDM System for a minimum of 15 minutes duration, Ratings of UPS shall be proposed for the approval of DEWA. The UPS shall have ‘enough capacity to initiate a ‘safe’ shut down of the PDM PC and the peripherals after this 15-minute period if normal supply fails to resume. The PDM PCs shall restart automatically ‘on resumption of normal supply. ‘The UPS shall not generate spikes during changeover of supply, UPS shall automatically give indication / alarm when it requires battery replacement. Potential Free Contacts shall be generated to signal these events. These contacts shall be wired out (o Annunciation / Monitoring systems, ) Alarms: The system shall be designed suitable for an unmanned stations and operates automatically ‘The system shall generate alarms, which is possible to be connected to SCADA if suspected partial discharge activity is noticed or the system itself is in failure, thereby eliminating the necessity of system access periodically by the user, with options to set and change warning & alarm settings. ‘The PDM system shall generate alarm when action is required, viz a) PD alarm (abnormal PD activity indicating a risk of failure) & b) PD system fail alarm to be connected to SCADA with the use of SCADA interface relay & these shall be demonstrated by wiring the ‘contacts, Critical Process and Status alarms of the PDM system shall be displayed at (a) SCADA Centre (6) SCMS (c) Remote Office Station, In addition to system related Alarms, there shall be provision for monitoring & annunciations for Power failure, UPS healthiness & UPS battery replacement requirements. 2) Calibration & Testin ‘The bidder/supplier has to propose after installation to confirm healthi submitted for approval of DEWA. the intended factory tests prior to shipping & site tests 38 of the system, The test procedures & formats shall be ‘The site tests shall include calibration & demonstration for frequency response of sensors to ‘meet the 10pe sensitivity requirement and further site tests for sensitivity verification of detection units shall be based on the results of these calibration tests bh) Warrantee Intervention: In case of any indication of suspected PD activity by the on line system, further investigation hhas to be carried out by the contractorisupplier for the PD defect identification and location during the warranty period. The contractor shall also arrange for periodical review of the PD data viz, weekly ‘monthly by PD specialist and the monthly PD activity shall be submitted to DEWA/ Engineer with their recommendation, Documentation: ‘The bidder shall provide during bid stage, a complete reference list of supplies made globally for the proposed on line PD monitoring system, which are in successful operation, along with ‘guaranteed technical particulars & data sheet for various components used in the system. The proposal for PD monitoring system along with design brief has to be submitted during ‘engineering stage for the Employer / Engineer approval. This shall include broadly the data sheets & frequency response characteristics of sensors, a schematic drawing showing the position of sensors & associated monitoring scheme, UPS rating, details of protection available for electronics against transient over voltages to be specified & electromagnetic ‘compatibility details Operation & Maintenance manual covering all aspects of operation, maintenance & trouble shooting of the proposed PDM system shall be provided in hard copies & digital formats prior to installation of the system, Dubai Electricity & Water Authority 18 0f 25 All Rights are reserved