GES 40211~40412

Technical Specification of GECOL

Pre-molded Straight Joint Kit for

XLPE Insulated Cable (11kV, 30kV, 66kV)

(Revision history)
- Issued on: Jan. 01, 2007
- Amended on: Jan.01, 2013

General Electricity Company of Libya

 Contents

1 SCOPE AND SERVICE CONDITIONS.............................................................................................. 4

1.1 SCOPE .................................................................................................................................................. 4

1.2 SERVICE CONDITIONS ........................................................................................................................... 4
1.2.1 Normal service conditions ......................................................................................................... 4
1.2.2 Unusual service conditions ........................................................................................................ 4

2 NORMATIVE REFERENCES ............................................................................................................. 4

3 DEFINITIONS ....................................................................................................................................... 5

3.1 STRAIGHT JOINT ................................................................................................................................... 5

3.2 EXTRUDED ........................................................................................................................................... 5
3.3 PREMOLDED ......................................................................................................................................... 5

4 KINDS AND RATINGS......................................................................................................................... 5

4.1 KINDS .................................................................................................................................................. 5

4.2 RATING ................................................................................................................................................ 6
4.2.1 Voltage and frequency................................................................................................................ 6
4.2.2 Current and temperature ........................................................................................................... 6
4.2.3 Earthing ..................................................................................................................................... 6
4.2.4 Dimensions of cables ................................................................................................................. 6

5 REQUIREMENTS ................................................................................................................................. 7

5.1 GENERAL REQUIREMENTS .................................................................................................................... 7

5.2 KIT COMPONENTS ................................................................................................................................ 8
5.3 REQUIRED CHARACTERISTICS .............................................................................................................. 8
5.3.1 Temperature ............................................................................................................................... 8
5.3.2 Joint housing ............................................................................................................................. 8
5.3.3 Conductor connector ................................................................................................................. 8
5.3.4 Screen rebuilding metallic material for tape screened cable ..................................................... 9
5.3.5 Mechanical screen connector for wire screened cable .............................................................. 9
5.3.6 Armor restoration component .................................................................................................... 9
5.3.7 Rejaketing tube .......................................................................................................................... 9
5.3.8 Special tools and equipment required for jointing work ............................................................ 9
5.4 ELECTRICAL REQUIREMENTS ............................................................................................................... 9
5.4.1 AC withstand voltage ................................................................................................................. 9
5.4.2 DC withstand voltage .............................................................................................................. 10

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 5.4.3 Partial discharge voltage......................................................................................................... 10
5.4.4 Impulse voltage withstand ....................................................................................................... 10
5.4.5 Thermal cycling characteristics ............................................................................................... 11
5.4.6 Thermal short circuit current withstand of screen connector ................................................... 11
5.4.7 Thermal short circuit current withstand of conductor connector ............................................ 12
5.4.8 Dynamic short circuit current withstand ................................................................................. 12

6 TESTS ................................................................................................................................................... 12

6.1 TYPE TESTS ........................................................................................................................................ 12

6.2 ROUTINE TESTS .................................................................................................................................. 12
6.3 ACCEPTANCE TESTS ........................................................................................................................... 12

7 MARKING ........................................................................................................................................... 12

8 PACKING AND DELIVERY .............................................................................................................. 13

9 DOCUMENT AND CERTIFICATE .................................................................................................. 13

9.1 INFORMATION TO BE PROVIDED WITH THE BID .................................................................................. 14

9.2 DOCUMENTS TO BE APPROVED BY GECOL ........................................................................................ 14
9.3 DOCUMENTATION ............................................................................................................................... 14

10 WARRANTY ........................................................................................................................................ 15

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 GES (Technical Specification of GECOL)

Pre-molded Straight Joint Kit for XLPE Insulated Cable

(11kV, 30kV, 66kV)

1 Scope and service conditions

1.1 Scope
The specification covers the pre-molded polymeric straight cable joint kits for armored/
non-armored, single/three core(s) stranded conductor, extruded dielectric shielded, XLPE
insulated cables rated in preferred voltage of 11kV, 30kV and 66kV on distribution system
in Libya.

1.2 Service conditions

1.2.1 Normal service conditions

Cable joints shall be suitable for use under the following service conditions:
(a) In air, including expose to direct sunlight
(b) Directly buried in earth
(c) Intermittently or continuously submerged in water at a depth not exceeding 7m
(d) Environmental temperatures within the range of –10°C to +50°C
(e) Installed in cable conduits or underground chambers or tunnels or vaults

1.2.2 Unusual service conditions

Condition other than those listed in ‎1.2.1 for cable joints are considered to be unusual.
The manufacturer should discuss with GECOL for the unusual service conditions.

2 Normative references
The cable joints shall confirm to the latest edition of following international standards:
(a) IEC 60228: Conductors of insulated cables
(b) IEC 60502: Power cables with extruded insulation and their accessories for rated
voltage from 1kV (Um=1.2kV) up to 30kV (Um=36kV)
(c) IEC 60502-2: Power cables with extruded insulation and their accessories for rated
voltages from 1kV up to 30kV, Part 2 : Cables for rated voltage from 6kV up to 30kV
(d) IEC 60502-4: Test requirements on accessories for cables with rated voltage from 1kV
(Um=1.2kV) up to 30kV (Um=36kV)
(e) IEC 60840: Power cables with extruded insulation and their accessories for rated
voltages above 30 kV (Um = 36 kV) up to 150 kV (Um = 170 kV) - Test methods and
requirements

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 (f) IEC 61442: Electric cables – Test methods for accessories for power cables with rated
voltage from 6kV (Um=7.2kV) up to 30kV *Um=36kV)
(g) IEEE Std 404: Extruded and laminated dielectric shielded cable joints rated 2,500V to
500,000V

3 Definitions

3.1 Straight joint

Accessory making a connection between two cables to form a continuous circuit

3.2 Extruded
A joint in which both cables are insulated with extruded dielectric materials rated 2.5kV
to 500kV.

3.3 Premolded
A joint that is factory molded in the shape that it will take when installed. Installation is
performed by sliding the joint over the cable.

4 Kinds and ratings

4.1 Kinds
Kinds of the joint are determined by kinds of cables to be applied as listed in Table 1 of
this specification.
Table 1 – Kinds of straight joints
Specification Nominal No. of Cross Sectional
Armor Screen
No. Voltage (kV) Core(s) Area (mm2)
4021118 240
Al Wire Cu Tape
4021120 400
1
4021218 240
Non Cu Tape
4021220 11 400
4023116 150
4023117 3 Steel Tape Cu Tape 185
4023118 240

Specification Nominal No. of Cross Sectional

Armor Screen
No. Voltage (kV) Core(s) Area (mm2)

5/17 Amended on Jan. 2013

 4031120 400
Al Wire Cu Wire
4031122 630
1
4031220 400
30 Non Cu Wire
4031222 630
4033116 150
3 Steel Tape Cu Tape
4033118 240
4041120 400
4041121 Al Wire Cu Wire 500
4041122 630
66 1
4041220 400
4041221 Non Cu Wire 500
4041222 630

4.2 Rating
The normal rating specified shall be the continuous rating under the worst temperature
and geographical conditions encountered in Libya.

4.2.1 Voltage and frequency

(a) The nominal system phase to phase voltage shall be 11kV, 30kV and 66kV.
(b) The system highest voltage for equipment shall be 17.5kV, 36kV, 72.5kV respectively.
(c) The voltage rating of joints shall be 8.7/15kV, 18/30kV and 36/66kV respectively.
(d) The system frequency shall be 50Hz.

4.2.2 Current and temperature

The current and temperature ratings of the cable joint shall be equal to or greater than
those of the cable for which it is designed as verified in GES 17200~17401.

4.2.3 Earthing
11kV system is effectively earthed system and no earthing on the line. 30kV system is
low resistance earthed system and no earthing on the line. 66kV system is effectively
earthed system and no earthing on the line.

4.2.4 Dimensions of cables

The joints shall comply with the cable dimensions listed in Table 2 of this specification.

Table 2 - Dimensions of cables

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 Rated No. of Cross Sectional Approx. Diameter (mm)
Armor Screen 2
Voltage Core(s) Area (mm ) Conductor Insulation Overall

240 18 29 43
Al Wire Cu Tape
400 23 34 49
1
240 18 29 36
Non Cu Tape
8.7/15kV 400 23 34 43
150 14 25 70
Steel
3 Cu Tape 185 16 27 74
Tape
240 18 29 80
400 23 40 59
Al Wire Cu Wire
630 31 48 66
1
400 23 40 54
18/30kV Non Cu Wire
630 31 48 60

Steel 150 14 32 93
3 Cu Tape
Tape 240 18 36 104
400 23 48 70
Al Wire Cu Wire 500 26 51 74
630 31 52 77
36/66kV 1
400 23 48 59
Non Cu Wire 500 26 51 62
630 31 52 66

5 Requirements

5.1 General requirements

Joints shall be factory engineered kits and shall be the product of one manufacturer.
Joints shall be fully shielded, suitable for use on 11kV, 30kV and 66kV distribution
systems of Libya. The joint kit and its material shall be appropriate for each cable size and
applicable voltage.
The joints shall be easily adapted to accommodate XLPE cables. The joints shall be
capable of tolerating any variance in the manufactured dimension of the cable such as oval,
out of round, sectored or oversize cable cores.
The joint kit shall contain all necessary components for stress relief, conductor

7/17 Amended on Jan. 2013

connection, and reinstatement of cable insulation and sealing.
The entire joint shall be suitable for continuous operation under water. The joint shall be
capable of immediate energizing at once after installation of all components.
The pre-molded straight joints shall meet the requirements of the latest edition of IEC
60502-4, IEC 60840 and related international standards.

5.2 Kit components

The joints kit shall contain all necessary components to reinstate the cable insulation,
metallic shielding, armor, over sheath of each core, etc.
The straight joint kits shall include following components:
(a) Joint housing(s)
(b) Shear off Connector(s) suitable for both copper and aluminum conductors.
(c) Screen rebuilding metallic material(s) for tape screened cables
(d) Mechanical screen connector(s) for wire screened cables
(e) Armor restoration component(s) for armored cables
(f) Rejaketing tube(s)
(g) Sufficient lubricants, cleaning material and cleaning cloth
(h) Installation instruction
(i) Component list
(j) All other items necessary to complete the joint

5.3 Required characteristics

5.3.1 Temperature
The joints and its components shall have equal or greater temperature endurance ability
than the insulation material of conductors to be jointed.

5.3.2 Joint housing

The joint housing shall be of one piece type and shall be of reasonable size to
accommodate cables easily. The housing shall be capable of proper sealing, sufficient
strength, robustness and impact resistance. Joint housing shall be able to smooth the
electrical field over the connector and cable screen ends. Heat transfer sleeve could be
applied, if necessary.

5.3.3 Conductor connector

The conductors connector(s) shall be Shear off type suitable for both copper and
aluminum conductors, and have good conductivity and mechanical strength. The material
shall not make galvanic corrosion with conductors.

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5.3.4 Screen rebuilding metallic material for tape screened cable
Screen rebuilding metallic material shall ensure the correct screen connection across the
joint area and make electrical contact for tape screened cables with the outer screen of the
joint. The screen rebuilding material shall be copper.

5.3.5 Mechanical screen connector for wire screened cable

Mechanical screen connector cable shall ensure the correct screen connection across the
joint area and make electrical contact for wire screened cables with the outer screen of the
joint. The material of screen rebuilding connector shall copper.

5.3.6 Armor restoration component

Quick installable armor restoration component shall be provided for armored cables. The
material of armor restoration component shall not make galvanic corrosion with armor of
cables.

5.3.7 Rejaketing tube

The rejaketing tube shall provide mechanical impact and chemical resistance as
expected from cable over sheaths. The entire joint shall be environmentally sealed with a
heat activated tube which shall be adhesive and capable of prevention the ingress of
external moisture and contamination.

5.3.8 Special tools and equipment required for jointing work

The joint shall require the fewest special tools or equipment for jointing work. But if any
special tool and equipment is needed for the jointing work, full details shall be included in
the offer as separate items and with individual prices.

5.4 Electrical requirements

5.4.1 AC withstand voltage

The joints shall withstand following test voltage without breakdown or flashover for the
time specified in Table 3 of this specification.

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 Table 3 - AC withstand voltage and duration

Rated voltage of joint AC test voltage

Duration
(kV) (kV rms, dry)
8.7/15 39 5 min
18/30 81 5 min
36/66 90 15 min

5.4.2 DC withstand voltage

The joints shall withstand following test voltage without breakdown or flashover for the
time specified in Table 4 of this specification.
Table 4 – DC withstand voltage and duration
Rated voltage of joint DC test voltage
Duration
(kV) (kV, dry)
8.7/15 35 15 min
18/30 72 15 min
36/66 144 15 min

5.4.3 Partial discharge voltage

Minimum partial discharge voltage of the joints shall greater than following Table 5 of
this specification. The joints shall be tested at 5K to 10K above maximum cable conductor
temperature in normal operation and at ambient temperature.
Table 5 - Minimum partial discharge voltage
Rated voltage of joint Test voltage level Partial discharge limit
(kV) (kV rms) (pC)
8.7/15 15 10
18/30 30 10
36/66 54 5

5.4.4 Impulse voltage withstand

The joints shall withstand 10 positive and 10 negative full wave impulses with a
magnitude equal to the value specified in Table 6 of this specification under 5K to 10K
above maximum cable conductor temperature in normal operation and ambient
temperature.

10/17 Amended on Jan. 2013

 Table 6 - Impulse voltage withstand level

Rated voltage of joint Impulse withstand voltage level

(kV) (kV peak)

8.7/15 95
18/30 170
36/66 325

5.4.5 Thermal cycling characteristics

The joints shall withstand AC test voltage specified in Table 7 of this specification
without breakdown or flashover during 30 times (8.7/15kV and 18/30kV joint) or 20 times
(36/66kV joint) of heating and cooling cycles in the air and in the water. Thermal cycle is
specified in Clause 9 of IEC 61442 and Clause 12.3.6 of IEC 60840.
Table 7 - AC withstand voltage

Rated voltage of joint AC test voltage

(kV) (kV rms, dry)
8.7/15 23
18/30 45
36/66 72

5.4.6 Thermal short circuit current withstand of screen connector

The screen connector of joints shall withstand short time, short circuit currents. The
magnitude and duration shall comply with Table 8 of this specification. The joints shall be
tested at 5K to 10K above maximum cable conductor temperature in normal operation and
ambient temperature. The short-circuit test shall not cause any deterioration of the joints
ability.
Table 8 – Short circuit current and duration
Cross sectional area of Short circuit current
Duration
conductor (mm2) (kA)
150 21.5 1 sec.
185 26.5 1 sec.
240 34.3 1 sec.
400 57.2 1 sec.
500 71.5 1 sec.
630 90.0 1 sec.

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5.4.7 Thermal short circuit current withstand of conductor connector
The conductor connector of joints shall withstand short time, short circuit currents. Test
method is specified in Clause 11 of IEC 61442. The short-circuit test shall not cause any
deterioration of the joints ability.

5.4.8 Dynamic short circuit current withstand

The joints shall withstand dynamic short circuit currents. Test method is specified in
Clause 12 of IEC 61442. The short-circuit test shall not cause any deterioration of the
joints ability.

6 Tests

6.1 Type tests

Tenderer shall include with their offers type test certificates including test carried out in
accordance with the IEC 60502-4, IEC 60840 and IEC 61442, which are issued by an
approved internationally acknowledged reputable independent testing laboratory.
(a) AC withstand voltage test (IEC 61442 Clause 4, IEC 60840 Clause 12.3.7)
(b) DC withstand voltage test (IEC 61442 Clause 5)
(c) Impulse withstand voltage test (IEC 61442 Clause 6, IEC 60840 Clause 12.3.7)
(d) Partial discharge voltage level test (IEC 61442 Clause 7, IEC 60840 Clause 12.3.4)
(e) Thermal cycling test (IEC 61442 Clause 9, IEC 60840 Clause 12.3.6)
(f) Thermal short circuit test (IEC 61442 Clause 10, 11)
(g) Dynamic short circuit test (IEC 61442 Clause 12)

6.2 Routine tests

Following routine tests shall be applied 100% of production.
(a) Partial discharge voltage level test (IEC 61442 Clause 7, IEC 60840 Clause 12.3.4)
(b) AC withstand voltage test (IEC 61442 Clause 4, , IEC 60840 Clause 12.3.7)

6.3 Acceptance tests

Cable joint kits are to be checked for compliance with this specification and with the
ordering quantity. GECOL reserves the rights to ask for several kinds of type tests to
confirm the quality of the joints in the presence of GECOL representatives.

7 Marking
The joints shall be permanently and legibly identified with the following information
items.
(a) Manufacturer’s identification
(b) Model identification
(c) Part identification

12/17 Amended on Jan. 2013

 (d) Date of manufacture (month and year)
(e) “Use before” (if applicable)
(f) Maximum phase-to-phase voltage ratings
(g) Applicable cable type, cross sectional area of conductor and insulation diameter range

8 Packing and Delivery

Each joint kit shall be in a separate corrugated cardboard box and every 100 kits shall be
contained in a wood box. Each joint kit shall have a list of materials indicating quantities
and instruction sheet.
The supplier shall provide packing of the joints as is required to prevent their damage or
deterioration during transit to their final destination and long period of storage, as indicated
in the contract. The packing shall be sufficient to withstand, without limitation, rough
handling during transit and exposure to extreme temperatures, salt and precipitation during
transit and storage.
(a) The supplier shall prepare the kit and its components for shipment to protect it from
damage during shipment and subsequent storage.
(b) All joints and their components shall be shipped from the factory to the specified site.
(c) Each shipment shall include a detailed packing list identifying all items by part
number, including hardware.
(d) All material shall be carefully loaded for protection during shipment.
(e) All materials shall be arranged to allow safe unloading at the site.
(f) There shall be handling instruction to minimize damage.

The outer packing must be clearly marked on at least four (4) sides as follows;
(a) Name of the procuring department
(b) Name of the supplier
(c) Contract description and number
(d) Final destination
(e) Gross weight
(f) Any special lifting instructions
(g) Any special handling instructions
(h) Any relevant pollution or environment classifications

9 Document and Certificate

The joints and all associated materials quoted by the supplier shall be approved by
GECOL. The quantity of documents and certificates submitted shall be not less than three
copies. The joints shall conform to the latest edition of IEC 60502-4, IEC 60840 and
relevant international standards including Clause 2 of this specification. The design and
construction of joint shall be subjected to the approval of GECOL.

13/17 Amended on Jan. 2013

9.1 Information to be provided with the BID
Technical descriptions, data sheets, catalogues and other information shall be submitted
with the BID and those which are submitted shall be sufficient to enable GECOL to
evaluate thoroughly the proposal as to its compliance with the requirements of this
specification.
The minimum requirement is as follows:
(a) Detailed summary of difference with this specification
(b) Technical Data Sheet duly filled in and signed (Annex A)
(c) Material safety data certificates of all chemical materials used for manufacturing
(d) Detailed drawing including outer figures of all components with dimension and inner
structure in A3 or A4 size
(e) Detailed handling, installation and maintenance manual & schedule for good operation
(f) Component list and numbers
(g) Electrical field diagram and calculations
(h) Brochures and catalogues containing outline dimensions, main electrical and
mechanical data, etc.
(i) Applicable design specification and standards in English language
(j) Test certificates approved by international institute in accordance with Table 5 of IEC
60502-4 and/or Annex C of IEC 60840
(k) Quality control system and relevant certificate

9.2 Documents to be approved by GECOL

The supplier shall furnish all relevant technical information, drawings etc. to GECOL
for approval prior to the start of manufacture. Offers without Technical Data Sheet
completely filled in will be rejected.
(a) Vendor(s) details/ Reference list
(b) Technical Data Sheet
(c) Tests schedule and procedures
(d) Transportation schedule and storage conditions
(e) Drawings of materials (All drawings shall be in A3 or A4 size with title block
approved by GECOL)

9.3 Documentation
All documents supplied under this specification shall be documented to the extent that
the end user can easily understand its theory of operation, performance, installation and
maintenance for the product. All documents shall be submitted being filed in order to
approve of GECOL and reorder later.
Language in all documents and drawings shall be written in English and dimensions
shall be used in metric SI-units.

14/17 Amended on Jan. 2013

10 Warranty
The supplier shall provide a full three-year limited warranty on all equipment supplied.
The warranty shall cover all parts and all costs, which are directly attributable to the
supplier. Warranty coverage shall begin on the date that the equipment is received.

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Appendix A
Technical Data Sheet

No. Description Particulars

1 Manufacturer’s name
2 Applicable standards
3 Identification No. (Model No.)
4 Applicable cable type
5 Applicable cross sectional area of conductor (mm2)
6 Applicable diameter of insulation (mm)
7 Applicable diameter of oversheath (mm)
8 Rating current (A)
9 No. of core(s)
10 Type of joint
11 Voltage rating phase to ground (kV rms)
12 Voltage rating phase to phase (kV rms)
13 Normal operation temperature (°C)
14 Emergency operation temperature (°C)
15 Dimension
a) Diameter (mm)
b) Length (mm)
16 AC withstand voltage test
a) Minute(s)
b) Voltage level (kV rms)
17 DC withstand voltage test
a) Minute(s)
b) Voltage level (kV avg)
18 Minimum partial discharge voltage level (kV rms, pC)
a) at above normal operation temperature
b) at ambient temperature
19 Impulse withstand voltage test (kV peak)

Signature :

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 Technical Data Sheet

No. Description Particulars

20 Thermal cycle test (kV rms)

a) In air
b) In water
21 Thermal short circuit test of screen
a) Short circuit current (kA)
b) Short circuit duration (Sec.)
22 Thermal short circuit test of conductor
a) Short circuit current (kA)
b) Short circuit temperature (Sec.)
23 Dynamic short circuit test
a) Short circuit current (kA)
b) Short circuit duration (Sec.)
24 Packing method
25 Joint kit components
26 Special tools and equipment for jointing work

Signature :
Designation :
Name of Tenderer :

Date :

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