TECHNICAL DEPARTMENT

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 TECHNICAL DEPARTMENT

COMPLIANCE STATEMENT

SPECIFICATION NO. EP-MS-P4/S3-050 Issue:2 01/05/2013

1.0 SCOPE
The design, manufacture, testing,supply,delivery and performance requirements of multi-core,
XLPE insulated cables for use on Standard Pilot Wire Protection Schemes and
Telecommunication Purposes.
The cables will generally be laid in the ground, in a suitable backfill material, or in open trenches
in substations.
2.0 REFERENCES:

The cables shall be in conformity with IEC 60502 Part 1, and subsequent amendments, except as
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may be otherwise stated, and of the following generic types.

3.0 GENERAL

The details given in this specification are based on international standards and KAHRAMAA QICC COMPLY
requirements in general and for the guideline to the manufacturers. The parameters given
herewith are minimum requirements, however, manufacturer shall confirm in all aspects to
supply of best design, high quality and good workmanship towards the manufacturing the
material for the safe and accurate installation and continuous smooth operation throughout
the life of the material stipulated herein.
KAHRAMAA reserve the right to reject any material if found not as per International standards
mentioned hereto and KAHRAMAA requirements.
Manufacturer may offer any better product up and above the specified one herein, however,
KAHRAMAA reserves the right to accept or not.
All cables covered under this Specification should be designed for continuous operation life for
not less than 30 years under the climatic conditions specified herein.
4.0 ENVIRONMENTAL CONDITIONS QICC COMPLY

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4.1 Climatic Conditions

Altitude : Low laying, generally close to sea level, no point exceeding 100meters above sea level.
Maximum air temperature: 50 oC(46 oC typical).
Minimum air temperature: 0 oC(10 oC typical).
Mean Maximum summer air temperature: 45 oC typical.
Mean Maximum exposed
Sunlight temperature: 75 oC. QICC COMPLY
Solar Radiation - Peak: 1030/W/sq.m.
Humidity: 100% humidity is common throughout the year,
and may occur at temperatures in excess of 30 °C
Rainfall : Very low on average.
General Atmospheric Condition: may be described as a hot atmosphere containing
very fine, highly penetrating dust particles.
Ground temperature at
one meter depth in summer: 35°C, and never falls to 0°C.
General Ground Conditions: Very dry, limestone type, with typical thermal
conductivity 2.0 to 4.0°C m/W.
Very wet, high salt content, very corrosive.
5.0 Cable Ratings:
5.1 Rated Votage Uo/U/Um 0.6/1.0/1.12kV QICC COMPLY
6.0 CABLES CONSTRUCTION-DETAILS
6.1 Conductors:
Stranded, annealed copper conductor, circular in shape in accordance with IEC 60228. QICC COMPLY
6.2 Standard Sizes:
The nominal size shall be (4c x 4mm² + 4 x 2c x 1.5mm²) 4 core 4 mm² (cores shall be laid up
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together) and 4x2 core 1.5mm². (cores shall be laid up in four sets of twisted pairs)
6.3 Core Insulation:
Extruded solid dielectric: Designation XLPE (IEC 60502) Highest rated temperature 90°C (IEC
60502) Insulation thickness, as appropriate to applied voltage, (IEC 60502).
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The process of extrusion shall have the facility at the point of extrusion to monitor and control the
thickness of the insulation and the concentricity of the cable. The cable core should be dry cured.
6.4) Core Identification:
Core Identification shall be by numbers printed on the cores insulation. The numbers shall be in
clear contrast to the color of the core insulation.
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The four cores shall have the colors RED, YELLOW, BLUE & BLACK.
The four pairs of 1.5mm² cable shall be at the discretion of the manufacturer subject to following.

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i) The colors shall have clear contrast.

ii) Each twisted pair shall have the same color combination throughout all manufactured length,
i.e. color A & color B shall be twisted together, as shall color C and color D in all manufacturing QICC COMPLY
length.
iii) The colors should be permanent and guaranteed for entire service life of cable.
6.5 Inner Covering and Fillers:
The inner covering shall be extruded. The material to be used shall be for the operating
temperature and design temperature conditions and of a thickness in accordance with IEC
60502 and compatible with insulating material. The material should be fire retardant and
comprises of anti aging components. The cores shall be laid up with non hygroscopic fillers and QICC COMPLY
bound with a closed helix of polymer tape of material appropriate to the cable temperature.
There should not be any gap between cores and maintain the perfect round shape of overall
cable.
6.6 Armor:
The armor shall comprise a single layer of galvanized steel wire of diameter appropriate to IEC
60502. The armour shall be embedded in, and covered by a material suitable to prevent the flow
of water transversely and longitudinally. The material shall be chemically inactive with the
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components with which it is in contact, both with and without the presence of water. It shall also
remain substantially solid at the working temperature of the adjoining components.

6.7 Oversheath:
PVC extruded directly over the armor and water inhibitor (water blocking tape). The material
should be fire retardant, UV resistance, anti aging components and high resistant to soil. It shall
be type ST2 in accordance with IEC 60502 and IEC 60332-1. Thickness shall be in compliance
with the above standard. The over sheath shall be colored in BLACK, and shall be embossed with
the legend:
- KAHRAMAA
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- CABLE RATING
- CABLE SIZE AND NUMBER OF CORES
- STANDARD NO.
- YEAR OF MANUFACTURE
- NAME OF MANUFACTURER AND COUNTRY OF ORIGIN
- RUNNING SERIAL (AT INTERVAL OF 1 METER)

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7.0 TESTS:
This relates to type tests and tests to be carried out during or after manufacture of the
specified Cables. Routine, type and special tests shall be carried out in accordance with latest
version of International standards IEC 60502-2, IEC 60228 & BSI BS EN 60811 and shall be
repeated if KM considers necessary for a particular project or supply order.
Copy of type test reports issued from reputed independent laboratories need to be submitted.
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The following tests shall be carried out on each manufactured length of cable, or sample length
as instructed by KAHRA MAA.
Manufacturer has to submit test plan and schedule for Kahramaa approvals.
Kahramaa has the right to witness any test with no obligation to Kahramaa.

A. Routine Tests:
Routine tests are to be carried out each and every drum manufactured. One set of routine test
reports of each drum shall be fixed with the drum in a strong water-proof envelope. Another set
to be submitted along with drums serial numbers and details as mentioned in clause 8.0 prior to
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delivery. The following routine tests are to be carried out.
1. Electrical Resistance of Conductors.
2. Voltage Test.
B. Sample Tests:
Sample tests are to be carried out on 10 % drums of each lot. Samples to be taken from both
sides of the entire length of the drum. One set of sample test reports of shall be submitted to IEC 60811-1-1 was
KAHRAMAA for review and approval. Another set to be submitted along with drums serial replaced with
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numbers and details as mentioned in IEC 60811-202,
clause 8.0 prior to delivery. The following sample tests are to be carried out.One set of sample test IEC 60811-203
report(wherever applicable) shall be fixed with the drum along with routine test report.
1. Conductor Examination.
2. Check of Dimensions as per IEC 60811-1-1
3. Hot Set Test.
C. Type Test:
Manufacturer shall carry out type tests to IEC 60502 on the cable with same exact
characteristics and issue certificates confirming that the cable has conformed.
In general, following test to be carried out at International Reputed Independent Laboratory in QICC COMPLY
accordance with IEC 60502- Part -1 and IEC 60228.
Type Test - Electrical QICC COMPLY

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1. Insulation Resistance Measurement at ambient temperature.

2. Insulation resistance measurement at maximum temperature in normal operation QICC COMPLY
3. Voltage Test for 4 h.
Type Test - Non-Electrical
1. Measurement of thickness of insulation.
2. Measurement of thickness of non-metallic sheaths (including extruded separation, but
excluding inner covering).
Special bending test is
3. Test for determination the mechanical properties of insulation before and after ageing.
not required for this
4. Test for determination the mechanical properties of non-metallic sheaths before and after type of cables.As per
ageing. IEC 60502-1,Special
5. Additional ageing test on piece of completed cable. bending test shall be
6. Loss of mass test on PVC sheaths of type ST2. made on cables
7. Pressure test at high temperature on insulation and non-metallic sheaths. having collective
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8. Test on PVC insulation and sheaths at low temperature.
metallic tapes.
9. Test for resistance of PVC insulation and sheaths to cracking (heat shock test).
10. Hot set test for XLPE insulation.
11. Water absorption test on insulation.
12. Flame spread test on single cables.
13. Shrinkage test for XLPE insulation.
14. Special bending test
15. Examination of conductor per IEC 60228

8.0 CABLE DRUMS

The drums shall be stoutly constructed of wood and supported with steel tie bars and shall be
fully lagged and bonded. On each flange of each drum a steel plate with tubular steel insert
shall be fitted to accept a 100mm diameter spindle to be used during cable installation. The steel
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plate shall be a minimum of 400mm x 400mm x 5mm thick, welded to tubular insert. The plates
shall be fixed with 6 bolts through the flange.
All drums shall be printed and engraved with:
- Manufacturer's name with Country of Origin.
- Drum number/year & month of manufacture of cable
- Size ,number of cores and voltage of cable, including the designation
"Cross Linked Polyethylene (XLPE)".
- Length of cable on the drum with sequential number.
- “KAHRAMAA”.

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 TECHNICAL DEPARTMENT

- The Contract No.

- An Arrow with the wording “Roll On this way” to indicate the direction of rolling
The nominal length to be as stated in the schedule below:-

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- A tolerance of ± 5% on the length of cable per drum shall be allowed.

- As and when required for specific project, the drum length may varies to minimize the
number of joints
9.0 TESTING, INSPECTION & DELIVERY
9.1 Before commencing the production/manufacturing of 1st lot, against KM tenders, the
manufacturer is obliged to produce samples and inform Kahramaa for inspection and
acceptance through witnessing factory acceptance tests, and routine tests.
9.2 For every subsequent lot, the manufacturer is obliged to inform Kahramaa, at least 20
days before dispatch, and obtain clearance for dispatch. KM Engineers have the option
of inspecting & witnessing all factory acceptance tests, including routine tests, at
manufacturer’s factory premises for each lot.
9.3 Acceptance by KM Engineer(s)/Representative(s) of any Lot shall not relieve the manufacturer
from any of their responsibilities, guarantees, or from other obligations, to comply with product
requirements.
9.4 Type tests are to be carried out on Samples, essentially of same design and ratings, as QICC COMPLY
being offered. Manufacturer is obliged to provide details of test procedures being followed, to the
KM inspection team before commencing factory accepting tests.
Kahramaa has the right to witness any test with no obligation to Kahramaa.

9.5 Each Lot needs to be subjected to all routine and sample tests at factory before delivery.
Further, each drum may be subjected to inspection on receiving them at DOHA to verify its
healthiness and its conformity with the guaranteed design data.

9.6 All tests should be performed in accordance with the latest issue of relevant IEC standards
9.7 Three sets (copies) of routine and sample tests & FAT reports to be prepared. One set to be
attached with the drum, in a strong water-proof envelope. Second copy to be sent along with
delivery note. Third copy to be sent to the end-user department.

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9.8 FAT report shall include copy of ‘quality control report’ containing ‘list of check points’
verified/inspected at factory against each drum. Each delivery note shall include the details of
‘serial number’ and ‘month/year’ of production of each drum. QICC COMPLY
9.9 Both the manufacturing date (i.e. month/year) and shipment date should be marked on
each drum, and the time difference between these two dates should not be more than 6-months.

10.0 STORAGE AND HANDLING

All cables supplied to KAHRAMAA or other projects shall be stored and handled in accordance
with BS8512:2008.
10.1 Storage shall be in accordance with clause 5.1 through 5.5. This is clearly illustrated in
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the figures 1a, 1b & 1c of this standard.
10.2 Manual handling and lifting with the fork lifter or crane shall be in accordance with
clause 6 & 7 of the standard.
11.0 INFORMATION TO BE PROVIDED AT THE TIME OF TENDER
11.1 An illustrated drawing showing the cable cross section design, all components, dimensions
of each layer and data sheets.
11.2 A specific compliance (clause by clause up to sub clause level ), statement of
conformity with the specification, else details of non-conformity with justification.
11.3 Details of method of protection against water ingress at armour level.
11.4 Permissible fault ratings of the conductors and the armour. QICC COMPLY
11.5 Type Test Report from International recognized Independent Laboratory.
11.6 Complete product catalogue with all ratings, characteristics & recommended installation
procedure.
11.7 Supply record for GCC and other countries.
11.8 Routine and Sample tests plan.
11.9 Quality assurance and quality control protocol or manual.
12.0 GUARANTEE
Supplied material shall be guaranteed against any defect for 5 (five) years from the date of QICC COMPLY
delivery or 3 (three) years from the date of installation whichever comes first.
13.0 DEVIATIONS FROM THE TECHNICAL SPECIFICATION
The Bidders are required to attach a separate deviation list to their Technical Offer and include
it in the Technical Package if the offered equipments do not meet the requirements of any QICC COMPLY
clause of the Specification.

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Offers without any deviation list attached to the Technical Offer and included in the Technical
Package shall mean that the offer meets the requirements of the Specifications on all the
clauses.
Offers with deviations listed out shall mean that the offer meets the requirements of the
Specification on all the other clauses not included in the deviation list.

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