UKV, TRIPLEX, CROSS-UNKED POLYETHYLENE (XLPE) INSULATED UNDERGROUND CABLE

TNB
DISTRIBUTION
Pengurus Besar, Kejuruteraan
No. 3, Jalan 51A/223,
46710 Petaling Jaya.
Tel: 03-7552121 Faks:
7572895,7563746

TECHNICAL SPECIFICATION

11KV, TRIPLEX, CROSS-UNKED POLYETHYLENE

(XLPE) INSULATED UNDERGROUND CABLE

Prepared by Ir. Tan Chow Heang

Manager - Cable

Ir. Moh Shew Chong

Senior Manager - Overhead lines & Cables

Approved by Technical Committee, TNB Distribution Sdn Bhd

Date 29 th June 2000

Page 1 of 13
Created by Tan Chow Heang
C: \SPEC\Specdata \01203 .doc
 11KV, TRIPLEX, CROSS-LINKED POLYETHYLENE (XLPE) INSULATED UNDERGROUND CABLE

1 .0 Introduction
This specification covers the design, construction, tests and drumming of llkV cross-
linked polyethylene (XLPE) insulated, PE sheathed, Triplex underground aluminium
conductor power cables.

The cable shall be suitable for use in the Tropical Zone, with an ambient ground
temperature of approximately 25 degrees Centigrade with heavy rainfall and high
underground water table.

2. 0 Electrical System
The cable shall be designed for continuous operation under the following conditions:-
(a) Rated Frequency - 50Hz, 3 phase
(b) Nominal Voltage - llkV (rms)
(c) Maximum voltage - 12kV (rms)
(d) Impulse withstand level - 75kV peak
(e) Maximum continuous conductor operating temperature - 90° C
(f) 3 Phase Symmetrical Fault Level - 350MVA

3.0 Design
3 .1 Standards
This specification shall make reference to the following standards unless otherwise
stated.
i. IEC 60502-2 (1997): Power cables with extruded insulation and their
accessories for rated voltages from 6kV up to 30kV. And all other standards
that it refers to.
ii. B.S.2627: Wrought Aluminium for Electrical Purposes
Page 2 of 13
Created by Tan Chow Heang
C: \SPEC\Specdata \01203 .doc
 11KV, TRIPLEX, CROSS-LINKED POLYETHYLENE (XLPE) INSULATED UNDERGROUND CABLE

3.2 Conductor
The conductor shall be of plain aluminium manufactured to H68 condition in accordance
with B.S 2627. The conductor shall be of circular stranded compacted type and its cross-
sectional area shall comply with IEC 60502-2 (1997).

The nominal cross-sectional area of the conductor required are:-

1. 95mm 2
2. 150mm2
3. 240mm 2

3.3 Conductor Screen

The conductor screen shall consist of a layer of extruded thermosetting semi--conducting
material (non-metallic in nature) applied over the conductor and shall be free of
protrusion or intrusion visible without the use of magnifying glass. The minimum thickness
of screen at any point shall not be less than 0.5mm.

3.4 Insulation
The insulation shall be of cross-linked polyethylene (XLPE) and shall be applied by
extrusion over the conductor screen and comply with the requirements of IEC 60502-2
(1997).

The insulation shall be free from void and impurities not larger than 100 microns in size.

3.5 Insulation Screen

The insulation screen shall consist of a layer of thermosetting semi-conducting material
(non-metallic in nature) extruded over the cable insulation. It shall be free from
Page 3 of 13
Created by Tan Chow Heang
C: \SPEC\Specdata\01203 .doc
 11KV, TRIPLEX, CROSS-LINKED POLYETHYLENE (XLPE) INSULATED UNDERGROUND CABLE

protrusion or intrusion visible without the use of magnifying glass. The minimum thickness
of screen at any point shall not be less than 0.5mm. The screen shall be strippable without
the need of special tool(s) or application of heat.

The conductor screen, insulation and insulation screen shall be triple extruded,

3. 6 Metallic Screen
A metallic screen shall be applied directly over the semi-conducting layer. The metallic

screen shall comprise of 2 layers of plain annealed copper tape, of nominal thickness not
less than 0.1 mm each of 30mm in width, helically applied over the insulation screen. Each
layer of copper tape shall have an overlap of not less than 15%.
Joints between successive tapes shall be brazed.

3. 7 Separator
A separating layer in the form of a non-hygroscopic, foamed polypropylene tape(s),
of minimum thickness not less than 0.2 mm, shall be applied over the metallic
screen layer.

3. 8 Outer Sheath
The outer sheath shall be extruded over the layer of foamed polypropylene separator

tape. It shall be of black colour, UV resistant, PE type ST7 with termite repellant
compound approved for use in Malaysia.

The outer sheath thickness shall be designed in accordance to the requirement as

stipulated in IEC 60502-2 (1997). but shall not be less 2.3 mm nominal.

3. 9 Stranding
Three single core cables shall be stranded (twisted) with a long lay with respect to
Page 4 of 13
Created by Tan Chow Heang
C: \SPEC\Specdata \01203 .doc
 UKV, TRIPLEX, CROSS-LINKED POLYETHYLENE (XLPE) INSULATED UNDERGROUND CABLE

each other.

The direction of lay shall be right-handed. The pitch shall be such that the cores
are held firmly to each other.

4.0 Core & Cable Identification

The cores shall be indelibly marked by means of colour tapes, i.e. Red, Yellow & Blue, laid
along the copper tape screen and also marked on the outer sheath of the finished cable
core with Numerical figure 1,2 & 3 at an interval of not more then 150mm corresponding
to Red, Yellow & Blue phase.

The following identification shall be indelibly marked on the outer sheath of the Red
phase finished cable core at intervals of not more than one (1) meter.
The acronym "TNB"
Conductor Cross-sectional Area
Manufacturers Name
Voltage Rating
Month and Year of manufacture
the running length of cable

5.0 Sealing and Drumming

Both ends of each finished state cable length shall be effectively sealed against ingress
of moisture, dirt and other vermin. The end projecting from the drum shall be adequately
protected against mechanical damage during handling and transit.

Each drum shall bear the following information printed on one flange, which includes
Cable Type
Voltage Rating

Page 5 of 13
Created by Tan Chow Heang
C: \SPEC\Specdata \01203 .doc
 11KV, TRIPLEX, CROSS-LINKED POLYETHYLENE (XLPE) INSULATED UNDERGROUND CABLE

- Length (m)
Conductor Size (Sq. mm)
- Net Weight (kg)
Gross Weight (kg)
- The Words 'TNB'
Manufacturers Nome
Contract Number
Drum Number

The direction of roll shall be conspicuously indicated by an arrow.

The preferred drum length shall be as follow:-

1. 95mm2 500 meters
2. 150 mm2 500 meters
3. 240mm2 500 meters

6.0 Inspection and Testing

6.1 General Requirements
It is the responsibility of the manufacturer to ensure that the cable is inspected and
tested at all stages of manufacturing in accordance to requirements as stipulated in this
specification.

The approval or passing of any such tests and inspections shall not prejudice the right of
the TNB to reject the cable if it does not comply with this specification when installed or
if it does not give complete satisfaction in service. This condition shall apply only if the
causes of the above-mentioned situations are due to any deficiency or wrong action on the
part of the manufacturer towards the fulfillment of the requirements of this

Page 6 of l.3
Created by Tan Chow Heang
C \SPEC\Specdata \01203 .doc
 11KV, TRIPLEX, CROSS-LINKED POLYETHYLENE (XLPE) INSULATED UNDERGROUND CABLE

specification.

The manufacturer shall allow the representative of TNB or its appointed Quality Agents
access to all production facilities necessary for the manufacture of this cable, at all
reasonable times. The manufacturer is responsible to maintain all Quality and Test
records for a minimum period of Five (5) years. TNB and/or its appointed agent reserved
the right to inspect these records as and when deems necessary.

During such inspection, any corrective actions necessary shall be complied with within the
scope of this specification.

The tests shall be carried out in accordance to the standards as stipulated in subsection
3.1 and any additional requirements as stated in the specification.

6.2 Type Test

The cable shall have passed the type tests in accordance with IEC 60502-2 (1997)

In the event that modifications to the design of the cable are made which in the opinion
of TNB that it will affect the performance of the cable, the relevant type tests shall be
repeated at the expense of the manufacturer.

6.3 Routine Tests

Routine tests shall be carried out by the manufacturer on all cables in the finished state
or, where appropriate, during the manufacturing processes in accordance to IEC 60502-2
(1997).
i. Measurement of resistance of conductor
ii. Partial discharge test
Page 7 of 13
Created by Tan Chow Heang
C, \SPEC\Specdata \01203 .doc
 11KV, TRIPLEX, CROSS-LINKED POLYETHYLENE (XLPE) INSULATED UNDERGROUND CABLE

iii. High voltage test

6.4 Sample Tests

Sample Tests in accordance with IEC 60502-2 (1997) shall be carried out by the
manufacturer. These tests are to be made by the manufacturer on samples or components
taken from a completed cable and at an interval of every lOkM length of cable
manufactured. It shall be carried out at the commencement of a contract before any
acceptance testing can be done.

Any test included under this category can be waived if the manufacturer has carried out
as part of the routine tests.

6.5 Acceptance Test

For each contract, a schedule for the implementation of acceptance testing shall be
agreed between the manufacturer and TNB in order that acceptance testing may be
carried out on a regular basis. Acceptance test shall be carry out at every Two (2) month
interval beginning with the first delivery of the contract.

The representative of TNB shall randomly select the drums of cable to be tested on 10%
of all drums in a lot which shall be made up of cables from a number of production
batches.

All routine and other test results carried out by manufacturer shall be made available for
inspection during acceptance testing. On the passing of the tests, security labels shall be
affixed to each drum in the lot in order to signify approval at factory.

The acceptance tests to be carried out by the manufacturer and witnessed by a

Page 8 of 13
Created by Tan Chow Heang
C, \SPEC\Specdata \01203 .doc
 11KV, TRIPLEX, CROSS-LINKED POLYETHYLENE (XLPE) INSULATED UNDERGROUND CABLE

representative of TNB shall consist of all the tests listed under routine tests. The check
on the length of cable per drum shall be done periodically at the discretion of TNB.

If any sample foils in any of the tests, two further samples shall be taken from the same
batch and submitted to the same test or tests in which the original sample foiled. If both
additional samples pass the tests, all the cables in the batch from which they were taken
shall be regarded as complying with the requirements of this standard. If either of the
additional samples foils, the batch from which they were taken shall be regarded as
foiling to comply.

6. 7 Quality Control
The manufacturer shall set up and implement a good quality management system. This
system shall be inspected/audited by TNB appointed Quality Audit Agent before the
commencement of any new contract and subsequently at agreed regular interval to
ascertain the proper implementation of the quality management system.

6. 8 Instruments and Calibration

All measuring and recording instruments and testing equipment to be used in assessing the
quality of the cables and its components at all stages of manufacturing shall be calibrated
at recognized calibration laboratory approved by TNB at the expense of the
manufacturer. Manufacturing of cable shall not commence or shall not be continued if the
manufacturer defaults on this requirement.

7.0 Technical Data

The tenderer shall forward technical data pertaining to the design and construction of
the cable, in the format as shown in Appendix A attached, together with the tender
submission.

Page 9 of 13
Created by Tan Chow Heang
C: \SPEC\S pecdata \01203 .doc
 11KV, TRIPLEX, CROSS-IJNKED POLYETHYLENE (XLPE) INSULATED UNDERGROUND CABLE

TECHNICAL DATA

Ref Description Unit Particular

1. Voltage (Uo/U) kV

2. Number of Cores

3. Conductor
- Material
- Cross sectional area mm 2
- Number of strands
- Conductor shape
- Nominal diameter mm

4. Conductor Screen
- Material
- Nominal thickness mm
- Method of application

5. Insulation
- Material
- Nominal thickness mm
- Method of application

6. Insulation Screen
- Material
- Nominal thickness mm
- Method of application
- Diameter over insulation screen mm

7. Metallic Screen
- Material
- Thickness mm

8. Binder Tape
- Material
- Nominal thickness mm

Page 10 of 13
Created by Tan Chow Heang
C, \SPEC\S pee data \01203 .doc
 11KV, TRIPLEX, CROSS-UNKED POLYETHYLENE (XLPE) INSULATED UNDERGROUND CABLE

TECHNICAL DATA

Ref Description Unit Particular

9. Inner Sheath
- Material
- Minimum thickness mm
- Overall diameter over inner sheath

10. Outer Sheath

- Material
- Nominal thickness mm
- Overall diameter over outer sheath mm

11. Anti- Termite

- Material

12. Completed Cable

- Approx. overall diameter mm
- Approx. weight per kilometer kg
- Approx. cable length per drum m

13. Cable Drums

- Material
- Approx. flange diameter mm
- Approx. outer width mm

14. Condition Upon Which Current

Carrying Capacities are Based
- Soil thermal resistivity K-m/w
- Ground temperature deg.C
- Ambient air temperature deg.C
- Burial depth mm
- Type of duct material
- Type of earth bonding
- Load factor
- Number of circuits

Page 11 of 13
Created by Tan Chow Heang
C, \SPEC\Specdata \01203 .doc
 11KV, TRIPLEX, CROSS-LINKED POLYETHYLENE (XLPE) INSULATED UNDERGROUND CABLE

TECHNICAL DATA

Ref Description Unit Particular

15. Minimum Radius of Bend
- Laid direct in ground mm
- Laid in duct mm
- Laid in air mm

16. Min. internal diameter of duct mm

17. Max. DC Resistance of Conductor at 25 Ohm/km

deg. C

18. Max. Conductor Temperature

- Laid direct in ground deg.C
- drawn into ducts deg.C
- Laid in air deg.C

19. Min. Insulation Resistance per Km of

Cable MOhm
- At 25 deg. C

20. Star Reactance at 50Hz Ohm/km

21. Max. Capacitance uf/km

22. Equivalent Star Capacitance uf/km

23. Max. Charging current per Cable at Nom. A/km

Volt

24. Impedance's at 25 deg. C

- Positive sequence impedance R + jX Ohm/km
- Negative sequence impedance R + jX Ohm/km
- Zero sequence impedance R + jXo Ohm/km

Page 12 of 13
Created by Tan Chow Heang
C: \SPEC\Specdata \01203 .doc
 11KV, TRIPLEX, CROSS-LINKED POLYETHYLENE (XLPE) INSULATED UNDERGROUND CABLE

TECHNICAL DATA

Ref Description Unit Particular

25. Max. Current Carrying Capacity Based on
Condition Specified (See Ref: 14)
- Cable laying formation - Trefoil for
lC cable
- Laid in ground Amp
- Drawn into duct Amp
- Laid in air Amp

26. Conductor Short Time Current Rating

- Initial temperature Deg.C
- Max. conductor short time deg.C
temperature
- For 1 second kA
- For 3 second kA

27. Copper Tape Earth Fault Current Rating

- Initial temperature Deg.C
- Max. conductor fault temperature Deg.C
- Continuous current carrying capacity Amp
- For 1 second kA
- For 3 second kA

28. Max. Volt Drop at Max Conductor Temp.

- For 1 - phase circuits mV/A.m
- For 3 - phase circuits mVIA.m

Page 13 of 13
Created by Tan Chow Heang
C, \SPEC\Specdata \01203 .doc