2.8.1 mv type test result

TIC 1007-11

TYPE TEST CERTIFICATE OF COMPLETE TYPE TEST

OBJECT Three-core power cable

TYPE 3 x 240 / 35 mm2 CU / XLPE / STA / PVC 36 kV

Rated voltage, U0/U (Um) 18 / 30 (36) kV Conductor material Cu Conductor cross-section 3x240 mm2 Insulation material XLPE

MANUFACTURER Bahra Cables Company, Jeddah, Kingdom of Saudi Arabia

CLIENT Bahra Cables Company, Jeddah, Kingdom of Saudi Arabia

TESTED BY KEMA HIGH-VOLTAGE LABORATORY Arnhem, the Netherlands

DATE OF TESTS 4 November 2010 to 14 January 2011

The object, constructed in accordance with the description, drawings and photographs incorporated in this Certificate, has been subjected to the series of proving tests in accordance with

IEC 60502-2

This Type Test Certificate has been issued by KEMA following exclusively the STL Guides. The results are shown in the record of Proving Tests and the oscillograms attached hereto. The values obtained and the general performance are considered to comply with the above Standard and to justify the ratings assigned by the manufacturer as listed on page 4.

The Certificate applies only to the object tested. The responsibility for conformity of any object having the same designations with that tested rests with the Manufacturer. This Certificate consists of 35 pages in total. © Copyright: Only integral reproduction of this Certificate is permitted without written

permission from KEMA. Electronic copies in e.g. PDF-format or scanned version of this Certificate may be available and have the status “for information only”.

The sealed and bound version of the Certificate is the only valid version.

KEMA Nederland B.V.

S.A.M. Verhoeven Director Testing, Inspections & Certification The Netherlands

Arnhem, 16 February 2011

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TABLE OF CONTENTS

TABLE OF CONTENTS .......................................................................................................................... 2

1 Identification of the test object......................................................................................................4 1.1 Description of the test object........................................................................................................4 1.2 List of documents .........................................................................................................................6

2 General information......................................................................................................................7 2.1 The tests were witnessed by........................................................................................................7 2.2 The tests were carried out by.......................................................................................................7 2.3 Reference to other reports ...........................................................................................................7 2.4 Subcontracting .............................................................................................................................7 2.5 Purpose of the test .......................................................................................................................8 2.6 Measurement uncertainty.............................................................................................................8 2.7 Applicable standards....................................................................................................................8

3 Electrical type tests ......................................................................................................................9 3.1 General.........................................................................................................................................9 3.1.1 Tests at elevated conductor temperature ....................................................................................9 3.2 Bending test followed by a partial discharge test.......................................................................10 3.2.1 Bending test ...............................................................................................................................10 3.2.2 Partial discharge test..................................................................................................................11 3.3 Tan δ measurement ...................................................................................................................12 3.4 Heating cycle test followed by a partial discharge test ..............................................................13 3.4.1 Heating cycle test .......................................................................................................................13 3.4.2 Partial discharge test..................................................................................................................14 3.5 Impulse test followed by a voltage test ......................................................................................15 3.5.1 Impulse test ................................................................................................................................15 3.5.2 Voltage test ................................................................................................................................18 3.6 Voltage test for 4 hours ..............................................................................................................19 3.7 Resistivity of semi-conducting screens ......................................................................................20

4 Non-electrical type tests.............................................................................................................21 4.1 Measurement of thickness of insulation.....................................................................................21 4.2 Measurement of thickness of non-metallic sheaths ...................................................................21 4.3 Tests for determining the mechanical properties of the insulation before and after ageing ......22 4.4 Tests for determining the mechanical properties of non-metallic sheaths before and after

ageing.........................................................................................................................................23 4.5 Additional ageing test on pieces of completed cable .................................................................24 4.6 Loss of mass test on PVC sheaths of type ST2 .........................................................................25 4.7 Pressure test at high temperature on non-metallic sheaths ......................................................26 4.8 Test on oversheath at low temperatures....................................................................................27

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4.9 Test for resistance of oversheath to cracking (heat shock test) ................................................27 4.10 Hot set test for XLPE insulation .................................................................................................28 4.11 Water absorption test on insulation............................................................................................28 4.12 Flame spread test on single cables............................................................................................29 4.13 Shrinkage test for XLPE insulation.............................................................................................29 4.14 Strippability test for insulation screen.........................................................................................30

5 Verification of cable construction ...............................................................................................31

APPENDIX A MEASUREMENT UNCERTAINTIES......................................................................... 32

APPENDIX B MANUFACTURER’S DRAWING(S)/DATA SHEET .................................................. 33

APPENDIX C PHOTOGRAPHS OF THE TEST OBJECT............................................................... 35

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1 IDENTIFICATION OF THE TEST OBJECT 1.1 Description of the test object

Manufacturer Bahra Cables Company Type 3 x 240 / 35 mm2 CU / XLPE / STA / PVC 36 kV Year of manufacture 2010 Sampling procedure by the manufacturer Quantity submitted > 45 m Rated voltage, U0/U (Um) 18/30 (36) kV No. of cores (core identification) 3 (red, yellow, blue) Marking on the cable BAHRA CABLES CO. KSA 3X240/35 mm2

CU / XLPE / STA / PVC 18/30 KV ICE 60502-2 "Manufacturing Year" "Meter marking" Saudi Electricity Company - SEC

Conductor - material copper, soft - cross-section 240 mm2 - nominal diameter 19,52 mm - type circular compacted - maximum conductor temperature

in normal operation 90 °C

Conductor screen - material thermosetting semi-conducting PE - nominal thickness 0,8 mm - material designation LE 0598 - manufacturer Borealis Insulation - material XLPE - nominal thickness 8 mm - material designation LS 4201R - manufacturer Borealis Insulation screen - material thermosetting semi-conducting PE - strippable yes - nominal thickness 1,1 mm - material designation LE 0511 - manufacturer Borealis

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Metallic screen - material Copper wires and tape - cross-section 35 mm2 - number and nominal diameter of wires 34 x Ø 0,66 mm - nominal thickness and with of tape 0,1 x 15 mm (overlap of 200%) - nominal thickness 1,72 mm Binder/Filling material PP non-hydoscopic filler and binder tape Inner sheath - material MDPE, type ST7 - nominal thickness 2,3 mm - material designation ME 6052 - manufacturer Borealis Metallic armour - material galvanized steel tape - nominal dimensions 2 x 0,8 x 60 mm - manufacturer Al-Qahtani Oversheath - material PVC, type ST2 - nominal thickness 4,2 mm - nominal overall diameter of cable 100 mm - material designation NAPICO ST2BK - manufacturer NAPICO - colour black - graphite coating applied no Longitudinally watertightness - along insulation screen not claimed - along the conductor not claimed Fire retardant (IEC 60332-1-2) yes Manufacturing details - type of extrusion CCV line, triple extrusion - manufacturer ot the extrusion line Maillefer Extrusion Oy - curing means CV-tube - along the conductor circulating nitrogen / pressurized water

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1.2 List of documents The manufacturer has guaranteed that the object submitted for tests has been manufactured in accordance with the following document. KEMA has verified that this document adequately represents the object tested. The following document is included in this Certificate:

drawing no./ document no.

revision date title

25090107 1 12 May 2010 MV Cable, 36 KV, Copper Conductor 240 sqmm, 3 cores, XLPE insulation, Steel Tape Armoured, PVC sheathed IEC 60502-2 and SEC 11-SDMS-03

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2 GENERAL INFORMATION 2.1 The tests were witnessed by The tests were not witnessed. 2.2 The tests were carried out by Name Company

Mr Th.H.P. Ariaans KEMA Nederland B.V., Mr J. Stankovic Arnhem, the Netherlands 2.3 Reference to other reports Report no. Tests described

TIC 1326-11 Additional test according client specifications based on AIEC CS8, ICEA S-97-682

2.4 Subcontracting The following tests were subcontracted to DEKRA:

- measurement of resistivity of semi conducting screens in accordance with clause 18.1.9 of IEC 60502-2

- non-electrical type tests in accordance with clause 19 of IEC 60502-2 with exception of water penetration test

- verification of cable construction in accordance with clauses 5-14 of IEC 60502-2.

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2.5 Purpose of the test Purpose of the test was to verify whether the material complies with the specified requirements. 2.6 Measurement uncertainty A table with measurement uncertainties is enclosed in appendix A. Unless otherwise indicated in the report, the measurement uncertainties of the results presented are as indicated in this table. 2.7 Applicable standards When reference is made to a standard and the date of issue is not stated, this applies to the latest issue, including amendments, which have been officially published prior to the date of the tests.

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3 ELECTRICAL TYPE TESTS 3.1 General 3.1.1 Tests at elevated conductor temperature For the tests with the cable at elevated temperature, induced conductor current was used for heating and a reference loop for temperature control of the conductor was installed. The reference cable was cut from the total cable length submitted by the client intended for the type test. This reference loop was installed close to the main loop in order to create the same environmental conditions as for the test loop. The heating currents in both the reference loop and the test loop were kept equal at all times, thus the conductor temperature of the reference loop is representative for the conductor temperature of the test loop. All three phases of both the reference loop and the test loop carried the same level three-phase current. Annex A, method 1 of IEC 60840 was used as a guide.

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3.2 Bending test followed by a partial discharge test 3.2.1 Bending test Standard and date Standard IEC 60502-2, clause 18.1.3 Test date 4 November 2010 Environmental conditions Ambient temperature 12 °C Temperature of test object 10 °C Characteristic test data Bending diameter: Three core cable (“others”) 15(d + D) ±5%

measured outer diameter of cable D (mm)

measured diameter of cable conductor d (mm)

required bending diameter Dr

(mm)

diameter of test cylinder Dt

(mm) 102,7 18,7 1730 ≤ Dr ≤ 1912 1800 Procedure The test sample shall be bent around a test cylinder at ambient temperature for at least one complete turn. It shall then be unwound and repeated, except that the sample shall be bent in the reverse direction without axial rotation. This cycle of operation shall be carried out three times. Observation The test was carried out successfully.

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3.2.2 Partial discharge test Standard and date Standard IEC 60502-2, clause 18.1.4 Test date 23 December 2010 Environmental conditions Ambient temperature 19 °C Temperature of test object 19 °C Characteristic test data Circuit direct Calibration 5 pC Noise 2 pC Sensitivity 4 pC Required sensitivity ≤ 5 pC Bandwidth 60-160 kHz Test frequency 50 Hz Coupling capacitor 2600 pF core voltage applied, 50 Hz duration partial discharge level

... x U0 (kV) (s) (pC)

1 2 36 10 - 1 1,73 31,1 - not detectable 2 2 36 10 - 2 1,73 31,1 - not detectable 3 2 36 10 - 3 1,73 31,1 - not detectable

Requirement There shall be no detectable discharge exceeding the declared sensitivity from the test object at 1,73 U0. Result The test was passed.

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3.3 Tan δδδδ measurement

Standard and date Standard IEC 60502-2, clause 18.1.5 Test date 23 December 2010

Environmental conditions Ambient temperature 20 °C Characteristic test data Temperature of test object 97 °C Length of test object 18,55 m Standard capacitor 100,05 pF

core voltage applied, 50 Hz core capacitance1) tan δ (kV) (µF/km)

1, 2 and 3 5 0,210 2,3 x 10-4

1) For information only Requirement The measured value shall not be higher than 40 x 10-4. Result The test was passed.

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3.4 Heating cycle test followed by a partial discharge test 3.4.1 Heating cycle test

Standard and date Standard IEC 60502-2, clause 18.1.6 Test period 24 December 2010 until 5 January 2011 Environmental conditions Ambient temperature 20-22 °C

Characteristic test data Stabilized temperature 97 °C

no. of heating- cycles

required stable conductor temperature

heating current during stable condition

heating per cycle cooling per cycle

(°C)

(A)

total duration (h)

duration of conductor at stable temperature (h)

total duration (h)

20 95-100 approx. 580 5 2 12 Procedure The heating cycles duration shall be at least 8 hrs. The conductor temperature shall be maintained within the stated temperature limits for at least 2 h of each heating period. This shall be followed by at least 3 h of natural cooling in air to a conductor temperature within 10 K of the ambient temperature. Observation The test was carried out successfully.

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3.4.2 Partial discharge test Standard and date Standard IEC 60502-2, clause 18.1.4 Test date 5 January 2011 Environmental conditions Ambient temperature 20 °C Temperature of test object 21 °C Characteristic test data Circuit balanced Calibration 5 pC Noise < 2 pC Sensitivity < 4 pC Required sensitivity ≤ 5 pC Bandwidth 60-160 kHz Test frequency 50 Hz Coupling capacitor 2600 pF core voltage applied, 50 Hz duration partial discharge level ... x U0 (kV) (s) (pC) 1 2 36 10 - 1 1,73 31,1 - not detectable 2 2 36 10 - 2 1,73 31,1 - not detectable 3 2 36 10 - 3 1,73 31,1 - not detectable


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3.5 Impulse test followed by a voltage test 3.5.1 Impulse test Standard and date Standard IEC 60502-2, clause 18.1.7 Test date 6 January 2011 Environmental conditions Ambient temperature 20 °C Characteristic test data Temperature of test object 97 °C Specified test voltage 170 kV

Note The three cable cores were tested simultaneously. Requirement Each core of the cable shall withstand without failure 10 positive and 10 negative voltage impulses. Result The test was passed.

testing arrangement polarity voltage applied (% of test voltage)

no. of impulses

see figure

voltage applied to

earthed

conductors metallic positive 50 1 1 (waveshape) screens 65 1 2 80 1 2 100 10 3 and 4 conductors metallic negative 50 1 5 (waveshape) screens 65 1 6 80 1 6 100 10 7 and 8

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3.5.2 Voltage test Standard and date Standard IEC 60502-2, clause 18.1.7 Test date 7 January 2011 Environmental conditions Ambient temperature 20 °C Temperature of test object 20 °C

testing arrangement voltage applied, 50 Hz

duration

voltage applied to earth connected to xU0 (kV) (min) conductors metallic screens 3,5 63 15

Note The three cable cores were tested simultaneously. Requirement No breakdown of the insulation shall occur. Result The test was passed.

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3.6 Voltage test for 4 hours Standard and date Standard IEC 60502-2, clause 18.1.8 Test date 7 January 2011 Environmental conditions Ambient temperature 20 °C Temperature of test object 20 °C


duration

voltage applied to earth connected to xU0 (kV) (h) conductors metallic screens 4 72 4


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3.7 Resistivity of semi-conducting screens Standard and date Standard IEC 60502-2, clause 18.1.9 Test period 3 January until 12 January 2011 Characteristic test data Temperature during ageing 100 ± 2 °C Duration 7 days Resistivity measured at 90 °C

item unit requirement measured/determined red yellow blue conductor screen - without ageing Ωm ≤ 1000 0,5 0,3 0,4 - after ageing Ωm ≤ 1000 0,6 0,8 0,7 insulation screen - without ageing Ωm ≤ 500 1,7 0,7 1,2 - after ageing Ωm ≤ 500 2,2 1,1 2,0 Note The measurement of resistivity shall be at a temperature within ± 2 °C of the maximum conductor temperature in normal operation. Result The test was passed.

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4 NON-ELECTRICAL TYPE TESTS 4.1 Measurement of thickness of insulation Standard and date Standard IEC 60502-2, clause 19.1 Test date 3 January 2011

requirement specified measured/determined insulation thickness unit

red yellow blue - nominal mm - 8,0 - - - - average mm - - 8,1 8,1 8,0 - minimum (tmin) mm ≥ 7,1 - 7,79 7,92 7,73 - maximum (tmax) mm - - 8,53 8,49 8,16 - (tmax - tmin) / tmax ≤ 0,15 - 0,09 0,07 0,05 Result The test was passed. 4.2 Measurement of thickness of non-metallic sheaths Standard and date Standard IEC 60502-2, clause 19.2 Test date 3 January 2011 Inner sheath

thickness unit requirement specified measured/determined

- nominal mm ≥ 2,0 2,3 - - average mm - - 2,9 - minimum (tmin) mm - - 2,20 Oversheath


- nominal mm ≥ 1,8 4,2 - - average mm - - 4,2 - minimum (tmin) mm ≥ 3,16 - 3,57 Result The test was passed.

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4.3 Tests for determining the mechanical properties of the insulation before and after ageing

Standard and date Standard IEC 60502-2, clause 19.3 Test period 3 January until 14 January 2011 Characteristic test data Temperature during ageing 135 ± 3 °C Duration 7 days

item unit requirement measured/determined red yellow blue without ageing - tensile strength N/mm² ≥ 12,5 22,7 24,5 23,3 - elongation % ≥ 200 531 547 546 after ageing - tensile strength N/mm² - 26,3 25,6 25,3 - variation with samples without ageing % ± 25 max. 16 4 9 - elongation % - 582 588 591 - variation with samples without ageing % ± 25 max. 10 7 8 Result The test was passed.

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4.4 Tests for determining the mechanical properties of non-metallic sheaths before and after ageing

Standard and date Standard IEC 60502-2, clause 19.4 Test period 3 January until 14 January 2011 Characteristic test data Temperature during ageing 110 ± 2 °C Duration 10 days Inner sheath

item unit requirement measured/determined

without ageing - tensile strength N/mm² ≥ 12,5 31,2 - elongation % ≥ 300 843 after ageing - tensile strength N/mm² - 29,4 - variation with samples without ageing % - -6 - elongation % ≥ 300 825 - variation with samples without ageing % - -2 Characteristic test data Temperature during ageing 100 ± 2 °C Duration 7 days Oversheath


without ageing - tensile strength N/mm² ≥ 12,5 17,9 - elongation % ≥ 150 237 after ageing - tensile strength N/mm² ≥ 12,5 17,7 - variation with samples without ageing % ± 25 max. -1 - elongation % ≥ 150 238 - variation with samples without ageing % ± 25 max. 1 Result The test was passed.

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4.5 Additional ageing test on pieces of completed cable Standard and date Standard IEC 60502-2, clause 19.5 Test period 3 January until 14 January 2011 Characteristic test data Temperature during ageing 100 ± 2 °C Duration 7 days Insulation


red yellow blue - tensile strength N/mm² - 23,7 23,9 24,6 - variation with samples without ageing % ± 25 max. 4 -2 6 - elongation % - 547 549 553 - variation with samples without ageing % ± 25 max. 3 1 1 Inner sheath


- tensile strength N/mm² - 29,7 - variation with samples without ageing % - -5 - elongation % - 854 - variation with samples without ageing % - 1 Oversheath


- tensile strength N/mm² - 16,7 - variation with samples without ageing % ± 25 max. -7 - elongation % - 230 - variation with samples without ageing % ± 25 max. -3 Result The test was passed.

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4.6 Loss of mass test on PVC sheaths of type ST2 Standard and date Standard IEC 60502-2, clause 19.6 Test period 3 January until 12 January 2011 Characteristic test data Temperature during ageing 100 ± 2 °C Duration 7 days Oversheath


- loss of mass mg/cm2 ≤ 1,5 0,2 Result The test was passed.

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4.7 Pressure test at high temperature on non-metallic sheaths Standard and date Standard IEC 60502-2, clause 19.7 Test date 14 January 2011 Characteristic test data (inner sheath) Temperature 110 ± 2 °C Duration 6 h Load 15,9 N Inner sheath


- depth of indentation % ≤ 50 4 Characteristic test data (oversheath) Temperature 90 ± 2 °C Duration 6 h Load 20,2 N Oversheath


- depth of indentation % ≤ 50 16 Result The test was passed.

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4.8 Test on oversheath at low temperatures Standard and date Standard IEC 60502-2, clause 19.8 Test date 10 January and 11 January 2011 Characteristic test data (oversheath) Temperature -15 ± 2 °C Cooling time ≥ 16 h Mass of hammer 1500 g Oversheath


- elongation % ≥ 20 195 - cold impact test - no cracks no cracks Result The test was passed. 4.9 Test for resistance of oversheath to cracking (heat shock test) Standard and date Standard IEC 60502-2, clause 19.9 Test date 14 January 2011 Characteristic test data (oversheath) Temperature 150 ± 3 °C Duration 1 h Diameter of mandrel 10 mm Number of turns 2 Oversheath


- soundness - no cracks no cracks Result The test was passed.

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4.10 Hot set test for XLPE insulation Standard and date Standard IEC 60502-2, clause 19.11 Test date 12 January 2011

Characteristic test data Air temperature 200 ± 3 °C Time under load 15 min Mechanical stress 20 N/cm2

item unit requirement measured/determined red yellow blue - elongation under load % ≤ 175 90 90 90 - permanent elongation % ≤ 15 0 0 0 Result The test was passed. 4.11 Water absorption test on insulation Standard and date Standard IEC 60502-2, clause 19.13 Test period 20 December 2010 until 11 January 2011 Characteristic test data Temperature 85 ± 2 °C Duration 14 days


red yellow blue - variation of mass mg/cm2 ≤ 1 < 0,1 < 0,1 < 0,1 Result The test was passed.

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4.12 Flame spread test on single cables Standard and date Standard IEC 60502-2, clause 19.14 and IEC 60332-1-2 Test date 14 January 2011 Characteristic test data Duration 480 s

item unit requirement measured/determined - length free of charring mm > 50 275 - downward limit charred surface mm < 540 455 Result The test was passed. 4.13 Shrinkage test for XLPE insulation Standard and date Standard IEC 60502-2, clause 19.16 Test date 4 January 2011 Characteristic test data Temperature 130 ± 3 °C Duration 1 h


red yellow blue - shrinkage % ≤ 4 1 1 2 Result The test was passed.

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4.14 Strippability test for insulation screen

Standard and date Standard IEC 60502-2, clause 19.21 Test period 3 January until 12 January 2011


red yellow blue

- before ageing N 4 ≤ F ≤ 45 15 / 18 / 20 16 / 18 / 17 21 / 19 / 18 - after ageing N 4 ≤ F ≤ 45 22 / 24 / 21 19 / 20 / 18 21 / 18 / 19 Requirement (additional) The insulation surface shall not be damaged and no trace of the insulation screen shall remain on the insulation. Result The test was passed.

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5 VERIFICATION OF CABLE CONSTRUCTION Verification of cable construction was carried out in accordance with clauses 5-14 of IEC 60502-2. The results are presented below. item unit requirement specified measured/determined conductor - diameter of conductor mm 17,6 ≤ d ≤ 19,2 - 18,7 approx - number of wires ≥ 34 - 61 - diameter of wires mm - - 2,4 approx - resistance at 20°C

Ω/km

≤ 0,0754

-

red: 0,0752

yellow: 0,0751

blue: 0,0754

observed/determined markings BAHRA CABLE CO KSA 3X240/35 MM2

CU/XLPE/STA/PVC 18/30KV IEC 60502-2 2010 construction - conductor of copper wires - construction 1-6-12-18-24 - semi conducting conductor screen - XLPE insulation - semi conducting insulation screen - screen of copper wires 36 x Ø 0,7 mm approx. - copper tape open helix 15 x 0,1 mm approx. - PP filler - synthetic tape - inner sheath of PE type ST7 - armour of double steel galvanized tape 0,8mm thickness - oversheath of PVC type ST2 outer diameter of the cable, average (mm)

102,7 approx.

outer diameter of the core, average (mm)

core 1: core 2: core 3: 39,8 38,1 39,8

Result No significant deviations from the specified requirements were found.

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APPENDIX A MEASUREMENT UNCERTAINTIES The measurement uncertainties in the results presented are as specified below unless otherwise indicated.

measurement measurement uncertainty

dielectric tests and impulse current tests

peak value: ≤ 3% time parameters: ≤ 10%

capacitance measurement tan δ measurement

0,3% ± 0,5% ± 5x10-5

partial discharge measurement < 10 pC : 2 pC 10 - 100 pC : 5 pC > 100 pC : 20%

measurement of impedance AC resistance measurement

≤ 1%

measurement of losses ≤ 1%

measurement of insulation resistance ≤ 10% measurement of DC resistance 1 µΩ - 5 µΩ : 1%

5 µΩ - 10 µΩ : 0,5% 10 µΩ - 200 µΩ : 0,2%

radio interference test 2 dB

calibration of current transformers 2,2 x 10-4 Ii/Iu and 290 µrad

calibration of voltage transformers 1,6 x 10-4 Ui/Uu and 510 µrad

measurement of conductivity 5% measurement of temperature -50 °C - -40 °C : 3 K

-40 °C - 125 °C : 2 K 125 °C - 150 °C : 3 K

tensile test 1% sound level measurement type 1 meter as per IEC 651 and

ANSI S1.4.1971 measurement of voltage ratio 0,1%

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APPENDIX B MANUFACTURER’S DRAWING(S)/DATA SHEET 2 pages (including this page)


revision date title

25090107 1 12 May 2010 MV Cable, 36 KV , Copper Conductor 240 sqmm, 3 cores, XLPE insulation, Steel Tape Armoured, PVC sheathed IEC 60502-2 and SEC 11-SDMS-03

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APPENDIX C PHOTOGRAPHS OF THE TEST OBJECT

Photograph 1: Impression of test set-up.

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OBJECT Three-core power cable TYPE 3 x 240 / 35 mm2 CU / XLPE / STA / PVC 36 kV

REPORT OF PERFORMANCE TIC 1326-11

18/30 (36) kV 3x240 mm2




DATE OF TESTS 3 January 2011 to 18 March 2011

TEST PROGRAMME Additional tests according client specifications based on AIEC CS8 (2007), ICEA S-97-682 (2007)

SUMMARY AND CONCLUSION

All tests were passed.

This Report of Performance applies only to the object tested. The responsibility for conformity of any object having the same designations with that tested rests with the Manufacturer. This report consists of 17 pages in total.

© Copyright: Only integral reproduction of this Certificate is permitted without written permission from KEMA. Electronic copies in e.g. PDF-format or scanned version of this Certificate may be available and have the status “for information only”.


KEMA Nederland B.V.


Arnhem, 6 July 2011

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TABLE OF CONTENTS




3 Additional tests according to AEIC CS8.......................................................................................8 3.1 Measurement of extruded conductor shield thickness.................................................................8 3.2 Measurement of conductor shield contact surface protrusion .....................................................9 3.3 Measurement of insulation shield contact surface protrusion....................................................10 3.4 Measurement of insulation shield field strippability test .............................................................11

4 Additional tests according to ANSI/ICEA S-97-682 ...................................................................12 4.1 Measurement of wafer boil test for conductor and insulation shields ........................................12 4.2 High Voltage Time Test..............................................................................................................13




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1 IDENTIFICATION OF THE TEST OBJECT

1.1 Description of the test object

Manufacturer Bahra Cables Company, Saudi Arabia Type 3 x 240 / 35 mm2 CU / XLPE / STA / PVC 36 kV Year of manufacture 2010 Sampling procedure by the manufacturer Quantity submitted > 45 m Rated voltage, U0/U (Um) 18/30 (36) kV No. of cores (core identification) 3 (red, yellow, blue) Marking on the cable BAHRA CABLES CO. KSA 3X240/35 mm2

CU / XLPE / STA / PVC 18/30 KV ICE 60502-2 "Manufacturing Year" "Meter marking" Saudi Electricity Company - SEC

Conductor - material copper, soft - cross-section 240 mm2 - nominal diameter 19,52 mm - type circular compacted - maximum conductor temperature


Conductor screen - material thermosetting semi-conducting PE - nominal thickness 0,8 mm - material designation LE 0592 - manufacturer Borealis Insulation - material XLPE - nominal thickness 8 mm - material designation LS 4201R - manufacturer Borealis Insulation screen - material thermosetting semi-conducting PE - strippable yes - nominal thickness 1,1 mm - material designation LE 0511 - manufacturer Borealis

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Metallic screen - material copper wires and copper tape - cross-section 35 mm2 - number and nominal diameter of wires 34 x Ø 0,66 mm - nominal thickness and with of tape 0,1 x 15 mm (overlap of 200%) - nominal thickness 1,72 mm Binder/Filling material PP non-hydoscopic filler and binder tape Inner sheath - material MDPE, type ST7 - nominal thickness 2,3 mm - material designation ME 6052 - manufacturer Borealis Metallic armour - material galvanized steel tape - nominal dimensions 2 x 0,8 x 60 mm - manufacturer Al-Qahtani Oversheath - material PVC, type ST2 - nominal thickness 4,2 mm - nominal overall diameter of cable 100 mm - material designation NAPICO ST2BK - manufacturer NAPICO - colour black - graphite coating applied no Longitudinally watertightness - along insulation screen not claimed - along the conductor not claimed Fire retardant (IEC 60332-1-2) yes Manufacturing details - type of extrusion CCV line, triple extrusion - manufacturer ot the extrusion line Maillefer Extrusion Oy - curing means CV-tube - along the conductor circulating nitrogen / pressurized water

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1.2 List of documents The manufacturer has guaranteed that the object submitted for tests has been manufactured in accordance with the following document. KEMA has verified that this document adequately represents the object tested. The following document is included in this Report of Performance:


revision date title

25090107 1 12 May 2010 MV Cable, 36 KV, Copper Conductor 240 sqmm, 3 cores, XLPE insulation, Steel Tape Armoured, PVC sheathed IEC 60502-2 and SEC 11-SDMS-03

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2 GENERAL INFORMATION

2.1 The tests were witnessed by The tests were not witnessed.

2.2 The tests were carried out by Name Company

Mr John Mooren KEMA Nederland B.V., Mr Rober Menger Arnhem, the Netherlands

2.3 Reference to other reports Report no. Tests described

TIC 1007-11 Type test certificate of complete type test in accordance with IEC 60502-2


2.4 Subcontracting The following tests were subcontracted to DEKRA Certification B.V.:

- measurement of extruded conductor shield thickness in accordance with clause 3.1 of AEIC CS8 - measurement of conductor shield contact surface protrusion in accordance with

clause 3.2 of AEIC CS8 - measurement of insulation shield contact surface protrusion in accordance with

clause 5.2 of AEIC CS8 - measurement of insulation shield field strippability in accordance with clause 5.3 and 10.3 of

AEIC CS8 - measurement of wafer boil test for conductor and insulation shields in accordance with

clause 9.4.12 of ANSI/ICEA S-94-682.

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2.5 Purpose of the test Purpose of the test was to verify whether the material complies with the specified requirements.

2.6 Measurement uncertainty A table with measurement uncertainties is enclosed in appendix A. Unless otherwise indicated in the report, the measurement uncertainties of the results presented are as indicated in this table.

2.7 Applicable standards When reference is made to a standard and the date of issue is not stated, this applies to the latest issue, including amendments, which have been officially published prior to the date of the tests.

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3 ADDITIONAL TESTS ACCORDING TO AEIC CS8

3.1 Measurement of extruded conductor shield thickness

Standard and date Standard AEIC CS8 clause 3.1 Test date 3 January 2011

requirement specified measured/determined conductor shield thickness

unit

red yellow blue - nominal mm - 0,8 - - - - average mm - - 0,94 0,97 0,83 - minimum mm ≥ 0,41 - 0,84 0,90 0,93 - maximum mm - - 1,02 1,03 1,01 Result The test was passed.

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3.2 Measurement of conductor shield contact surface protrusion

Standard and date Standard AEIC CS8 clause 3.2 Test period 3 February 2011 until 4 February 2011

requirement measured/determined item unit

red yellow blue - protrusion into the insulation mm ≤ 0,076 0,000 0,000 0,000 - protrusion into the conductor shield mm ≤ 0,18 0,00 0,00 0,00 Result The test was passed.

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3.3 Measurement of insulation shield contact surface protrusion



red yellow blue - protrusion and irregularities into the

insulation mm ≤ 0,13 0,00 0,00 0,00

- protrusion and irregularities into the insulation shield

mm ≤ 0,18 0,00 0,00 0,00

Result The test was passed.

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3.4 Measurement of insulation shield field strippability test

Standard and date Standard AEIC CS8 clause 5.4 and 10.3 Test date 31 January 2011

requirement measured/determined item

red yellow blue - removability at -10 °C ± 3 °C removable without tearing or

leaving residual conductive material on the insulation surface.

no tearing or residue

- removability at 40 °C ± 3 °C removable without tearing or leaving residual conductive material on the insulation surface.



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4 ADDITIONAL TESTS ACCORDING TO ANSI/ICEA S-97-682

4.1 Measurement of wafer boil test for conductor and insulation shields

Standard and date Standard ANSI/ICEA S-97-682 clause 9.4.12 Test date 10 February 2011


red yellow blue - waferboil test for conductor

shield no dissolvement or cracking of the shield

no dissolvement or cracks

- waferboil test for insulation shield

no dissolvement or cracking of the shield



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4.2 High Voltage Time Test

Standard and date Standard Client instructions based ANSI/ICEA S-97-682 clause 10.1.3 Test period 2 March 2011 and 17-18 March 2011

Environmental conditions Ambient temperature 20 °C Temperature of test object 20 °C Characteristic test data Test frequency 50 Hz Nominal insulation thickness 8 mm Initial voltage (3,9 kV/mm) 31,2 kV Voltage step (1,6 kV/mm) 12,8 kV Time period per voltage step 5 min

test voltage time determined item kV s

- AC breakdown voltage (red) 248,8 40 termination failure - AC breakdown voltage (yellow) 274,4 1 termination failure - AC breakdown voltage (blue) 223,2 284 termination failure Note If an AC breakdown occurs outside the active cable length (termination failure) and the 43,3 kV/mm (346,4 kV) step has not been completed the sample shall be re-tested. The cables cores used for AC breakdown test where from new cable that was only type tested in the main test loop see chapter 2.3. Requirement The minimum qualification withstand value according table 10.1 for XLPE cables is 24,4 kV/mm and is 195,2 kV. Result The test was passed.

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0,3% ± 0,5% ± 5x10-5



≤ 1%



5 µΩ - 10 µΩ : 0,5% 10 µΩ - 200 µΩ : 0,2%



calibration of voltage transformers 1,6 x 10-4 Ui/Uu en 510 µrad


-40 °C - 125 °C : 2 K 125 °C - 150 °C : 3 K



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revision date title

25090107 1 12 May 2010 MV Cable, 36 KV , Copper Conductor 240 sqmm, 3 cores, XLPE insulation, Steel Tape Armoured, PVC sheathed IEC 60502-2 and SEC 11-SDMS-03

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APPENDIX C PHOTOGRAPHS OF THE TEST OBJECT 1 page (including this page)

Photograph 1: Impression of test set-up

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TIC 1012-11


OBJECT Single-core power cable

TYPE 1 x 630 / 35 mm2 – CU / XLPE / PVC – 36 kV

Rated voltage, U0/U (Um) 18/30 (36) kV Conductor material Cu Conductor cross-section 1x630 mm2 Insulation material XLPE




DATE OF TESTS 4 November 2010 to 25 February 2011


IEC 60502-2

This Type Test Certificate has been issued by KEMA following exclusively the STL Guides. The results are shown in the record of Proving Tests and the oscillograms attached hereto. The values obtained and the general performance are considered to comply with the above Standard and to justify the ratings assigned by the manufacturer as listed on page 4 and 5.




KEMA Nederland B.V.


Arnhem, 6 July 2011

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TABLE OF CONTENTS






ageing.........................................................................................................................................24 4.5 Additional ageing test on pieces of completed cable .................................................................25 4.6 Loss of mass test on PVC oversheath of type ST2 ....................................................................26 4.7 Pressure test at high temperature on non-metallic sheaths .....................................................27 4.8 Test on oversheath at low temperature .....................................................................................28

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4.9 Test for resistance of oversheath to cracking (heat shock test) ................................................29 4.10 Hot set test for XLPE insulation .................................................................................................30 4.11 Water absorption test on insulation............................................................................................31 4.12 Flame spread test on single cables............................................................................................32 4.13 Shrinkage test for XLPE insulation.............................................................................................33 4.14 Strippability test for insulation screen.........................................................................................34





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Manufacturer Bahra Cable Company, Saudi Arabia Type 1 x 630 / 35 mm2 – CU / XLPE / PVC – 36 kV Year of manufacture 2010 Sampling procedure by the manufacturer Quantity submitted > 45 m Rated voltage, U0/U (Um) 18/30 (36) kV No. of cores (core identification) 1 Marking on the cable BAHRA CABLES CO. KSA 1X630/35mm² CU/XLPE/

STA/PVC 18/30 IEC 60502-2 Manufacturing Year – Meter marked Saudi Electricity Company - SEC

Conductor - material copper / Soft annealed - cross-section 630 mm2 - nominal diameter 30,8 mm - type circular – compacted - maximum conductor temperature


Conductor screen - material thermosetting semi-conducting / bonded - nominal thickness 0,8 mm - material designation HFDA 0587 BK - manufacturer DOW Chemicals Insulation - material XLPE - nominal thickness 8 mm - material designation HFDB 4201 EC - manufacturer DOW Chemicals Insulation screen - material thermosetting semi-conducting - strippable yes - nominal thickness (minimum) 1,4 mm - material designation HFDA 0693 BK - manufacturer DOW Chemicals

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Metallic screen - material copper wire and copper tape - cross-section 41 wires of 1,05 mm - nominal thickness and width of tape 0,1 x 15 mm (open helix) - nominal diameter 52,6 mm Binder/Filling material Yes Oversheath

- material PVC, type ST2 - nominal thickness 2,7 mm - nominal overall diameter of cable 60 mm - manufacturer Napico (Saudi Arabia) - material designation Napico ST2BK - colour black - graphite coating applied no Manufacturing details - type of extrusion CCV line - manufacturer of extrusion line Maillefer Extrusion Oy - curing means CV-tube - cooling means Circulating Nitrogen / Pressurized water

Fire retardant (IEC 60332-1-2) yes

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revision date title

25010111 2 18 May 2010 Single core MV Cable, 36 KV, Copper Conductor 630 sqmm, XLPE insulation, Non Armoured, PVC sheathed cable to IEC 60502-2 and SEC 11-SDMS-03

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Mr John Mooren KEMA Nederland B.V., Mr Robert Menger Arnhem, the Netherlands Mr Joaquin Fernandez Mr Jovan Stankovic 2.3 Reference to other reports Report no. Tests described




- non-electrical type tests in accordance with clause 19 of IEC 60502-2 - verification of cable construction in accordance with clauses 5-14 of IEC 60502-2.

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3 ELECTRICAL TYPE TESTS 3.1 General 3.1.1 Tests at elevated conductor temperature For the tests with the cable at elevated temperature, induced conductor current was used for heating. Additionally a reference loop for temperature control of the conductor was installed. The reference cable was cut from the total cable length submitted by the client intended for the type test. This reference loop was installed close to the main loop in order to create the same environmental conditions as for the test loop. The heating currents in both the reference loop and the test loop were kept equal at all times, thus the conductor temperature of the reference loop is representative for the conductor temperature of the test loop. Annex A, method 1 of IEC 60840 was used as a guide.

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3.2 Bending test followed by a partial discharge test 3.2.1 Bending test Standard and date Standard IEC 60502-2, clause 18.1.3 Test date 4 November 2010 Environmental conditions Ambient temperature 12 °C Temperature of test object 10 °C Characteristic test data Bending diameter: Single-core cable (“others”) 20(d + D) ± 5% measured outer diameter of cable D (mm)



(mm)



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3.2.2 Partial discharge test Standard and date Standard IEC 60502-2, clause 18.1.4 Test date 1 February 2011 Environmental conditions Ambient temperature 19 °C Temperature of test object 19 °C Characteristic test data Circuit direct Calibration 5 pC Noise 2 pC Sensitivity 4 pC Required sensitivity ≤ 5 pC Bandwidth 20 - 118 kHz Test frequency 50 Hz Coupling capacitor 2600 pF core voltage applied, 50 Hz duration partial discharge level

... x U0 (kV) (s) (pC)

1 2 36 10 - 1 1,73 31,1 - not detectable


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Standard and date Standard IEC 60502-2, clause 18.1.5 Test date 2 February 2011

Environmental conditions Ambient temperature 20 °C Temperature of test object 97 °C Characteristic test data Length of test object 16 m Standard capacitor 100 pF

core voltage applied, 50 Hz core capacitance1) tan δ (kV) (µF/km) 1, 2 and 3 5 0,295 1,4 x 10-4

1) For information only Requirement The measured value shall not be higher than 40x10-4. Result The test was passed.

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Standard and date Standard IEC 60502-2, clause 18.1.6 Test period 3 – 11 February 2011 Environmental conditions Ambient temperature 20 – 22 °C Characteristic test data

Stabilized temperature 97 °C





(°C)

(A)

total duration (h)


total duration (h)

20 95-100 approx. 1520 5 2 3 Procedure The heating cycle shall be of at least 8 h duration. The conductor temperature shall be maintained within the stated temperature limits for at least 2 h of each heating period. This shall be followed by at least 3 h of natural cooling in air to a conductor temperature within 10 K of ambient temperature. Observation The test was carried out successfully.

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3.4.2 Partial discharge test Standard and date Standard IEC 60502-2, clause 18.1.4 Test date 11 February 2011 Environmental conditions Ambient temperature 20 °C Temperature of test object 20 °C Characteristic test data Circuit direct Calibration 5 pC Noise 2 pC Sensitivity 4 pC Required sensitivity ≤ 5 pC Bandwidth 50 - 150 kHz Test frequency 50 Hz Coupling capacitor 2600 pF

core voltage applied, 50 Hz duration partial discharge level ... x U0 (kV) (s) (pC) 1 2 36 10 - 1 1,73 31,1 - not detectable


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3.5 Impulse test followed by a voltage test 3.5.1 Impulse test Standard and date Standard IEC 60502-2, clause 18.1.7 Test date 14 February 2011 Environmental conditions Ambient temperature 20 °C Temperature of test object 97 °C Characteristic test data Specified test voltage 170 kV

Requirement Each core of the cable shall withstand without failure 10 positive and 10 negative voltage impulses. Result The test was passed.

testing arrangement polarity voltage applied (% of test voltage)

no. of impulses

see figure

voltage applied to

earthed

conductor metallic positive 50 1 1 (waveshape) screen 65 1 2 80 1 2 100 10 3 and 4 conductor metallic negative 50 1 5 (waveshape) screen 65 1 6 80 1 6 100 10 7 and 8

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3.5.2 Voltage test Standard and date Standard IEC 60502-2, clause 18.1.7 Test date 15 February 2011 Environmental conditions Ambient temperature 20 °C Temperature of test object 20 °C


duration

voltage applied to earth connected to xU0 (kV) (min) conductor metallic screen 3,5 63 15

Requirement No breakdown of the insulation shall occur. Result The test was passed.

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3.6 Voltage test for 4 hours Standard and date Standard IEC 60502-2, clause 18.1.8 Test date 15 February 2011 Environmental conditions Ambient temperature 20 °C Temperature of test object 20 °C


duration

voltage applied to earth connected to xU0 (kV) (h) conductor metallic screen 4 76 4

Requirement No breakdown of the insulation shall occur. Result The test was passed.

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3.7 Resistivity of semi-conducting screens Standard and date Standard IEC 60502-2, clause 18.1.9 Test period 4 February 2011 until 11 February 2011 Characteristic test data Temperature during ageing 100 ± 2 °C Duration 7 days Resistivity measured at 90 °C

item unit requirement measured/determined conductor screen - without ageing Ωm ≤ 1000 0,2 - after ageing Ωm ≤ 1000 0,5 insulation screen - without ageing Ωm ≤ 500 0,9 - after ageing Ωm ≤ 500 2,8 Note The measurement of resistivity shall be carried out at a temperature within ± 2 °C of the maximum conductor temperature in normal operation. Result The test was passed.

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4 NON-ELECTRICAL TYPE TESTS 4.1 Measurement of thickness of insulation Standard and date Standard IEC 60502-2, clause 19.1 Test date 3 February 2011 insulation thickness unit requirement specified measured/determined

- nominal mm - 8,0 - - average mm - - 8,3 - minimum (tmin) mm ≥ 7,10 - 8,11 - maximum (tmax) mm - - 8,50 - (tmax - tmin) / tmax ≤ 0,15 - 0,02 Result The test was passed.

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4.2 Measurement of thickness of non-metallic sheaths Standard and date Standard IEC 60502-2, clause 19.2 Test date 3 February 2011 Oversheath



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Standard and date Standard IEC 60502-2, clause 19.3 Test period 4 February 2011 until 15 February 2011 Characteristic test data Temperature during ageing 135 ± 3 °C Duration 7 days

item unit requirement measured/determined without ageing - tensile strength N/mm² ≥ 12,5 26,6 - elongation % ≥ 200 510 after ageing - tensile strength N/mm² - 27,8 - variation with samples without ageing % ± 25 max. 5 - elongation % - 537 - variation with samples without ageing % ± 25 max. 5 Result The test was passed.

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Standard and date Standard IEC 60502-2, clause 19.4 Test period 4 February 2011 until 15 February 2011 Characteristic test data Temperature during ageing 100 ± 2 °C Duration 7 days Oversheath


without ageing - tensile strength N/mm² ≥ 12,5 18,4 - elongation % ≥ 150 263 after ageing - tensile strength N/mm² ≥ 12,5 17,1 - variation with samples without ageing % ± 25 max. -7 - elongation % ≥ 150 261 - variation with samples without ageing % ± 25 max. -1 Result The test was passed.

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4.5 Additional ageing test on pieces of completed cable Standard and date Standard IEC 60502-2, clause 19.5 Test period 4 February 2011 until 15 February 2011 Characteristic test data Temperature during ageing 100 ± 2 °C Duration 7 days Insulation


- tensile strength N/mm² - 27,1 - variation with samples without ageing % ± 25 max. 2 - elongation % - 512 - variation with samples without ageing % ± 25 max. 1 Oversheath


- tensile strength N/mm² - 18,4 - variation with samples without ageing % ± 25 max. 0 - elongation % 258 - variation with samples without ageing % ± 25 max. -2 Result The test was passed.

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4.6 Loss of mass test on PVC oversheath of type ST2 Standard and date Standard IEC 60502-2, clause 19.6 Test period 4 February 2011 until 15 February 2011 Characteristic test data Temperature during ageing 100 ± 2 °C Duration 7 days Oversheath



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4.7 Pressure test at high temperature on non-metallic sheaths Standard and date Standard IEC 60502-2, clause 19.7 Test date 5 February 2011 Characteristic test data (oversheath) Temperature 90 ± 2 °C Duration 6 h Load 13,5 N Oversheath



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4.8 Test on oversheath at low temperature Standard and date Standard IEC 60502-2, clause 19.8 Test period 3 February 2011 until 4 February 2011 Characteristic test data (oversheath) Temperature -15 ± 2 °C Cooling time ≥ 16 h Mass of hammer 1250 g Oversheath


- elongation % ≥ 20 245 - cold impact test - no cracks no cracks Result The test was passed.

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4.9 Test for resistance of oversheath to cracking (heat shock test) Standard and date Standard IEC 60502-2, clause 19.9 Test date 7 February 2011 Characteristic test data (oversheath) Temperature 150 ± 3 °C Duration 1 h Diameter of mandrel 8 mm Number of turns 4 Oversheath

item unit requirement measured/determined - soundness - no cracks no cracks Result The test was passed.

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4.10 Hot set test for XLPE insulation Standard and date Standard IEC 60502-2, clause 19.11 Test date 4 February 2011


item unit requirement measured/determined - elongation under load % ≤ 175 90 - permanent elongation % ≤ 15 5 Result The test was passed.

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4.11 Water absorption test on insulation Standard and date Standard IEC 60502-2, clause 19.13 Test period 2 February 2011 until 25 February 2011 Characteristic test data Temperature 85 ± 2 °C Duration 14 days


- variation of mass mg/cm2 ≤ 1 < 0,1 Result The test was passed.

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4.12 Flame spread test on single cables Standard and date Standard IEC 60502-2, clause 19.14 and IEC 60332-1-2 Test date 7 February 2011 Characteristic test data Duration 240 s

item unit requirement measured/determined - length free of charring mm > 50 265 - downward limit charred surface mm < 540 450 Result The test was passed.

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4.13 Shrinkage test for XLPE insulation Standard and date Standard IEC 60502-2, clause 19.16 Test date 7 Febraury 2011 Characteristic test data Temperature 130 ± 3 °C Duration 1 h


- shrinkage % ≤ 4 3 Result The test was passed.

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Standard and date Standard IEC 60502-2, clause 19.21 Test period 7 February 2011 until 15 February 2011


- before ageing N 4 ≤ F ≤ 45 20 / 21 / 20 - after ageing N 4 ≤ F ≤ 45 22 / 24 / 25 Requirement (additional) The insulation surface shall not be damaged and no trace of the insulation screen shall remain on the insulation. Result The test was passed.

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5 VERIFICATION OF CABLE CONSTRUCTION Verification of cable construction was carried out in accordance with clauses 5-14 of IEC 60502-2. The results are presented below. item unit requirement specified measured/

determined conductor - diameter of conductor (d) mm 28,7 ≤ d ≤ 32,5 30,8 30,9 approx. - number of wires ≥ 53 - 61 - diameter of wires mm - - 3,5 approx. - resistance at 20°C Ω/km ≤ 0,0283 - 0,0281

observed/determined

markings BAHRA CABLES CO. KSA. 1x630/35MM2 CU/XLPE/PVC SCW 18/30kV IEC 60502-2 2010

construction - conductor of copper wires - construction 1-6-12-18-24 - semi conducting conductor screen - XLPE insulation - semi conducting insulation screen - screen of copper wires 41 x Ø 1,0 mm approx. - copper tape 0,1 x 15mm open helix - synthetic tape - oversheath of PVC type ST2 outer diameter of the cable, average (mm)

61,5 approx.


52,9 approx.

Result No deviations from the specified requirements were found.

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0,3% ± 0,5% ± 5x10-5



≤ 1%



5 µΩ - 10 µΩ : 0,5% 10 µΩ - 200 µΩ : 0,2%





-40 °C - 125 °C : 2 K 125 °C - 150 °C : 3 K



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revision date title

25010111 2 18 May 2010 Single core MV Cable, 36 KV, Copper Conductor 630 sqmm, XLPE insulation, Non Armoured, PVC sheathed cable to IEC 60502-2 and SEC 11-SDMS-03

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OBJECT Single-core power cable TYPE 1x 630 / 35 mm2 CU / XLPE / STA / PVC 36 kV


18/30 (36) kV 1x630 mm2





TEST PROGRAMME Additional tests according client specifications based on AIEC CS8 (2007), ICEA S-97-682 (2007)






KEMA Nederland B.V.


Arnhem, 6 July 2011

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TABLE OF CONTENTS





4 Additional test according to ANSI/ICEA S-97 ............................................................................12 4.1 High Voltage Time Test..............................................................................................................12




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Manufacturer Bahra Cable Company, Saudi Arabia Type 1 x 630 / 35 mm2 – CU / XLPE / PVC – 36 kV Year of manufacture 2010 Sampling procedure by the manufacturer Quantity submitted > 45 m Rated voltage, U0/U (Um) 18/30 (36) kV No. of cores (core identification) 1 Marking on the cable BAHRA CABLES CO. KSA 1X630/35mm² CU/XLPE/

STA/PVC 18/30 IEC 60502-2 Manufacturing Year – Meter marked Saudi Electricity Company - SEC

Conductor - material copper / Soft - cross-section 630 mm2 - nominal diameter 30,8 mm - type circular – compacted - maximum conductor temperature


Conductor screen - material thermosetting semi-conducting / bonded - nominal thickness 0,8 mm - material designation HFDA 0587 BK - manufacturer DOW Chemicals Insulation - material XLPE - nominal thickness 8 mm - material designation HFDB 4201 EC - manufacturer DOW Chemicals Insulation screen - material thermosetting semi-conducting - strippable yes - nominal thickness 1,4 mm - material designation HFDA 0693 BK - manufacturer DOW Chemicals

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Metallic screen - material copper wire and copper tape - cross-section 41 wires of 1,05 mm - nominal thickness and width of tape 0,1 x 15 mm (overlap of -200%) - nominal thickness/diameter 2,1 mm Binder/Filling material Yes Oversheath

- material PVC, type ST2 - nominal thickness 2,7 mm - nominal overall diameter of cable 60 mm - manufacturer Napico (Saudi Arabia) - material designation Napico ST2RD - colour black - graphite coating applied no Manufacturing details - type of extrusion CCV line - manufacturer of extrusion line Maillefer Extrusion Oy - curing means CV-tube - cooling means Circulating Nitrogen / Pressurized water


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revision date title

25010111 2 18 May 2010 Single core MV Cable, 36 KV , Copper Conductor 630 sqmm, XLPE insulation, Non Armoured, PVC sheathed cable to IEC 60502-2 and SEC 11-SDMS-03

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2.2 The tests were carried out by Name Company

Mr John Mooren KEMA Nederland B.V., Mr Robert Menger Arnhem, the Netherlands








AEIC CS8

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3 ADDITIONAL TESTS ACCORDING TO AEIC CS8 3.1 Measurement of extruded conductor shield thickness

Standard and date Standard AEIC CS8 clause 3.1 Test date 3 February 2011


unit

- nominal mm - 0,8 - - average mm - - 1,13 - minimum mm ≥ 0,61 - 1,01 - maximum mm - - 1,27 Result The test was passed.

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- protrusion into the insulation mm ≤ 0,076 0,000 - protrusion into the conductor shield mm ≤ 0,18 0,00 Result The test was passed.

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- protrusion and irregularities into the

insulation mm ≤ 0,13 0,00


mm ≤ 0,18 0,00


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Standard and date Standard AEIC CS8 clause 5.4 and 10.3 Test date 5 February 2011 2011


- removability at -10 °C ± 3 °C removable without tearing or






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4 ADDITIONAL TEST ACCORDING TO ANSI/ICEA S-97

4.1 High Voltage Time Test

Standard and date Standard Client instructions based ANSI/ICEA S-97-682 clause 10.1.3 Test date 18 March 2011

Environmental conditions Ambient temperature 20 °C Temperature of test object 20 °C Characteristic test data Test frequency 50 Hz Nominal insulation thickness 8 mm Initial voltage (3,9 kV/mm) 31,2 kV Voltage step (1,6 kV/mm) 12,8 kV Time period per voltage step 5 min

test voltage time determined item

kV s - AC breakdown voltage 236,0 19 termination failure Note If an AC breakdown occurs outside the active cable length (termination failure) and the 43,3 kV/mm (346,4 kV) step has not been completed the sample shall be re-tested. The cable core used for AC breakdown test where from new cable that was only type tested in the main test loop see chapter 2.3. Requirement The minimum qualification withstand value according table 10.1 for XLPE cables is 24,4 kV/mm and is 195,2 kV. Result The test was passed.

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0,3% ± 0,5% ± 5x10-5



≤ 1%



5 µΩ - 10 µΩ : 0,5% 10 µΩ - 200 µΩ : 0,2%





-40 °C - 125 °C : 2 K 125 °C - 150 °C : 3 K



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revision date title

25010111 2 18 May 2010 Single core MV Cable, 36 KV , Copper Conductor 630 sqmm, XLPE insulation, Non Armoured, PVC sheathed cable to IEC 60502-2 and SEC 11-SDMS-03

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Photograph 1: Impression of test set-up

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TIC 1013-11


OBJECT Three-core power cable

TYPE 3 x 300 / 35 mm2 AL / XLPE / STA / PVC

Rated voltage, U0/U (Um) 8,7/15 (17,5) kV Conductor material AL Conductor cross-section 3x300 mm2 Insulation material XLPE






IEC 60502-2

This Type Test Certificate has been issued by KEMA following exclusively the STL Guides. The results are shown in the record of Proving Tests and the oscillograms attached hereto. The values obtained and the general performance are considered to comply with the above Standard and to justify the ratings assigned by the manufacturer as listed on page 4 and 5.




KEMA Nederland B.V.


Arnhem, 4 May 2011

Ord

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o: 7

0022

144

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TABLE OF CONTENTS

TABLE OF CONTENTS .......................................................................................................................... 2 1.1 Description of the test object........................................................................................................4 1.2 List of documents .........................................................................................................................6




ageing.........................................................................................................................................24 4.5 Additional ageing test on pieces of completed cable .................................................................25 4.6 Loss of mass test on PVC oversheath of type ST2 ....................................................................26 4.7 Pressure test at high temperature on non-metallic sheaths .....................................................27 4.8 Test on oversheath at low temperature .....................................................................................28 4.9 Test for resistance of oversheath to cracking (heat shock test) ................................................29 4.10 Hot set test for XLPE insulation .................................................................................................30

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4.11 Water absorption test on insulation............................................................................................31 4.12 Flame spread test on single cables............................................................................................32 4.13 Shrinkage test for XLPE insulation.............................................................................................33 4.14 Strippability test for insulation screen.........................................................................................34





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1.1 Description of the test object

Manufacturer Bahra Cable Company, Saudi Arabia Type 3 x 300 / 35 mm2 AL/XLPE/STA/PVC 8,7/15 (17,5) kV Year of manufacture 2010 Sampling procedure by the manufacturer Quantity submitted > 45 m Rated voltage, U0/U (Um) 8,7/15 (17,5) kV No. of cores (core identification) 3 (red, yellow, blue) Marking on the cable BAHRA CABLES CO. KSA 3X300/35 mm² AL/XLPE

STA/PVC 8.7/15 IEC 60502-2 Manufacturing Year – Meter marked Saudi Electricity Company - SEC

Conductor - material aluminium / H12 - cross-section 300 mm2 - nominal diameter 20,7 mm - type circular – compacted - maximum conductor temperature


Conductor screen - material thermosetting semi-conducting / bonded - nominal thickness 0,8 mm - material designation LE 0592 - manufacturer Borealis Insulation - material XLPE - nominal thickness 4,5 mm - material designation LS 4201 R - manufacturer Borealis Insulation screen - material thermosetting semi-conducting - strippable yes - nominal thickness 1 mm - material designation LE 0511 - manufacturer Borealis

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Metallic screen - material copper wire and copper tape - cross-section 34 wires of 0,66 mm - nominal thickness and width of tape 0,1x15 mm (open helix with gap -200%) - nominal thickness/diameter 1,52 mm Binder/Filling material yes Inner sheath - material MDPE-ME 6052, type ST7 - nominal thickness 2,0 mm - manufacturer Borealis Metallic armour - material galvanized steel tape - nominal diameter / dimensions 2x 0,8 x 60 mm - manufacturer Al-Qahtani- Saudi Arabia Oversheath

- material PVC, type ST2 - nominal thickness 3,8 mm - nominal overall diameter of cable 90,5 mm - material supplier NAPICO – Saudi Arabia - colour red - graphite coating applied no Manufacturing details - type of extrusion CCV line - manufacturer of extrusion line Maillefer Extrusion Oy - curing means CV-tube - cooling means Circulating Nitrogen / Pressurized water


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revision date title

23210110 1 12 may 2010 MV Cable, 15 KV, Aluminium Conductor 300 sqmm, 3 cores, XLPE insulation, Steel Tape Armoured, PVC sheathed IEC 60502-2 and SEC 11-SDMS-03

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Mr John Mooren KEMA Nederland B.V., Mr Robert Menger Arnhem, the Netherlands Mr Joaquin Fernandez Mr Jovan Stankovic 2.3 Reference to other reports Report no. Tests described




- non-electrical type tests in accordance with clause 19 of IEC 60502-2 - verification of cable construction in accordance with clauses 5-14 of IEC 60502-2.

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3 ELECTRICAL TYPE TESTS 3.1 General 3.1.1 Tests at elevated conductor temperature For the tests with the cable at elevated temperature, induced conductor current was used for heating. Additionally a reference loop for temperature control of the conductor was installed. The reference cable was cut from the total cable length submitted by the client intended for the type test. This reference loop was installed close to the main loop in order to create the same environmental conditions as for the test loop. The heating currents in both the reference loop and the test loop were kept equal at all times, thus the conductor temperature of the reference loop is representative for the conductor temperature of the test loop. All three phases of both the reference loop and the test loop carried the same level three-phase current. Annex A, method 1 of IEC 60840 was used as a guide.

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3.2 Bending test followed by a partial discharge test 3.2.1 Bending test Standard and date Standard IEC 60502-2, clause 18.1.3 Test date 28 January 2011 Environmental conditions Ambient temperature 5 °C Temperature of test object 15 °C Characteristic test data Bending diameter: Three core cable (“others”) 15(d + D) ±5%

measured outer diameter of cable D (mm)



(mm)



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3.2.2 Partial discharge test Standard and date Standard IEC 60502-2, clause 18.1.4 Test date 14 February 2011 Environmental conditions Ambient temperature 20 °C Temperature of test object 20 °C Characteristic test data Circuit direct Calibration 5 pC Noise 2 pC Sensitivity 4 pC Required sensitivity ≤ 5 pC Bandwidth 50 - 150 kHz Test frequency 50 Hz Coupling capacitor 2600 pF core voltage applied, 50 Hz duration partial discharge level

... x U0 (kV) (s) (pC)

1 2 17,4 10 - 1 1,73 15 - not detectable 2 2 17,4 10 - 2 1,73 15 - not detectable 3 2 17,4 10 - 3 1,73 15 - not detectable


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Standard and date Standard IEC 60502-2, clause 18.1.5 Test date 16 February 2011

Environmental conditions Ambient temperature 20 °C Temperature of test object 97 °C Characteristic test data Length of test object 3x17,4 m Standard capacitor 100 pF

core voltage applied, 50 Hz core capacitance1) tan δ (kV) (µF/km) 1, 2 and 3 5 0,349 1,3 x 10-4

1) For information only Requirement The measured value shall not be higher than 40x10-4. Result The test was passed.

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Standard and date Standard IEC 60502-2, clause 18.1.6 Test period 17 – 25 February 2011 Environmental conditions Ambient temperature 19 - 21 °C

Characteristic test data Stabilized temperature 97 °C





(°C)

(A)

total duration (h)


total duration (h)

20 95-100 approx. 495 5 2 5 Procedure The heating cycles duration shall be at least 8 hrs. The conductor temperature shall be maintained within the stated temperature limits for at least 2 h of each heating period. This shall be followed by at least 3 h of natural cooling in air to a conductor temperature within 10 K of the ambient temperature. Observation The test was carried out successfully.

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3.4.2 Partial discharge test Standard and date Standard IEC 60502-2, clause 18.1.4 Test date 28 February 2011 Environmental conditions Ambient temperature 20 °C Temperature of test object 20 °C Characteristic test data Circuit direct Calibration 5 pC Noise 2 pC Sensitivity 4 pC Required sensitivity ≤ 5 pC Bandwidth 50 - 150 kHz Test frequency 50 Hz Coupling capacitor 2600 pF core voltage applied, 50 Hz duration partial discharge level ... x U0 (kV) (s) (pC) 1 2 17,4 10 - 1 1,73 15 - not detectable 2 2 17,4 10 - 2 1,73 15 - not detectable 3 2 17,4 10 - 3 1,73 15 - not detectable


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3.5 Impulse test followed by a voltage test 3.5.1 Impulse test Standard and date Standard IEC 60502-2, clause 18.1.7 Test date 28 February 2011 Environmental conditions Ambient temperature 20 °C Temperature of test object 97 °C Characteristic test data Specified test voltage 95 kV

Note The three cable cores were tested simultaneously. Requirement Each core of the cable shall withstand without failure 10 positive and 10 negative voltage impulses. Result The test was passed.

testing arrangement Polarity voltage applied (% of test voltage)

no. of impulses

see figure

voltage applied to

earthed

conductors metallic positive 50 1 1 (waveshape) screens 65 1 2 80 1 2 100 10 3 and 4 conductors metallic negative 50 1 5 (waveshape) screens 65 1 6 80 1 6 100 10 7 and 8

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3.5.2 Voltage test Standard and date Standard IEC 60502-2, clause 18.1.7 Test date 1 March 2011 Environmental conditions Ambient temperature 20 °C Temperature of test object 20 °C


duration

voltage applied to earth connected to xU0 (kV) (min) conductors metallic screens 3,5 30,5 15


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3.6 Voltage test for 4 hours Standard and date Standard IEC 60502-2, clause 18.1.8 Test date 1 March 2011 Environmental conditions Ambient temperature 20 °C Temperature of test object 20 °C


duration

voltage applied to earth connected to xU0 (kV) (h) conductors metallic screens 4 34,8 4


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3.7 Resistivity of semi-conducting screens Standard and date Standard IEC 60502-2, clause 18.1.9 Test period 7 February 2011 until 16 February 2011 Characteristic test data Temperature during ageing 100 ± 2 °C Duration 7 days Resistivity measured at 90 °C

item unit requirement measured/determined red yellow blue conductor screen - without ageing Ωm ≤ 1000 0,3 0,4 0,4 - after ageing Ωm ≤ 1000 0,5 0,5 0,5 insulation screen - without ageing Ωm ≤ 500 0,4 0,9 0,6 - after ageing Ωm ≤ 500 0,9 1,0 0,9 Note The measurement of resistivity shall be carried out at a temperature within ± 2 °C of the maximum conductor temperature in normal operation. Result The test was passed.

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4 NON-ELECTRICAL TYPE TESTS 4.1 Measurement of thickness of insulation Standard and date Standard IEC 60502-2, clause 19.1 Test date 3 February 2011

requirement specified measured/determined insulation thickness unit

red yellow blue - nominal mm - 4,5 - - - - average mm - - 4,6 4,6 4,5 - minimum (tmin) mm ≥ 3,95 - 4,29 4,41 4,22 - maximum (tmax) mm - - 4,76 4,91 4,94 - (tmax - tmin) / tmax ≤ 0,15 - 0,10 0,10 0,15 Result The test was passed.

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4.2 Measurement of thickness of non-metallic sheaths Standard and date Standard IEC 60502-2, clause 19.2 Test date 3 February 2011 Inner sheath


- nominal mm 1,8 2,0 - - average mm - - 2,8 - minimum (tmin) mm - - 2,41 Oversheath



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Standard and date Standard IEC 60502-2, clause 19.3 Test period 3 February 2011 until 14 February 2011 Characteristic test data Temperature during ageing 135 ± 3 °C Duration 7 days

item unit Requirement measured/determined red yellow blue without ageing - tensile strength N/mm² ≥ 12,5 24,3 28,3 28,0 - elongation % ≥ 200 529 572 590 after ageing - tensile strength N/mm² - 27,8 28,6 29,0 - variation with samples without ageing % ± 25 max. 14 1 4 - elongation % - 605 580 592 - variation with samples without ageing % ± 25 max. 14 1 1 Result The test was passed.

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Standard and date Standard IEC 60502-2, clause 19.4 Test period 3 February 2011 until 14 February 2011 Characteristic test data Temperature during ageing 110 ± 2 °C Duration 10 days Inner sheath

item unit Requirement measured/determined

without ageing - tensile strength N/mm² ≥ 12,5 31,1 - elongation % ≥ 300 862 after ageing - tensile strength N/mm² - 29,8 - variation with samples without ageing % - -4 - elongation % ≥ 300 809 - variation with samples without ageing % - -6 Characteristic test data Temperature during ageing 100 ± 2 °C Duration 7 days Oversheath


without ageing - tensile strength N/mm² ≥ 12,5 17,7 - elongation % ≥ 150 284 after ageing - tensile strength N/mm² ≥ 12,5 17,2 - variation with samples without ageing % ± 25 max. -3 - elongation % ≥ 150 257 - variation with samples without ageing % ± 25 max. -10 Result The test was passed.

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4.5 Additional ageing test on pieces of completed cable Standard and date Standard IEC 60502-2, clause 19.5 Test period 3 February 2011 until 14 February 2011 Characteristic test data Temperature during ageing 100 ± 2 °C Duration 7 days Insulation


red yellow blue - tensile strength N/mm² - 27,2 26,8 26,0 - variation with samples without ageing % ± 25 max. 12 -5 -7 - elongation % - 591 518 520 - variation with samples without ageing % ± 25 max. 12 -9 -12 Inner sheath


- tensile strength N/mm² - 30,2 - variation with samples without ageing % - -3 - elongation % - 863 - variation with samples without ageing % - 1 Oversheath


- tensile strength N/mm² - 17,4 - variation with samples without ageing % ± 25 max. -2 - elongation % 283 - variation with samples without ageing % ± 25 max. 1 Result The test was passed.

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4.6 Loss of mass test on PVC oversheath of type ST2 Standard and date Standard IEC 60502-2, clause 19.6 Test period 2 February 2011 until 11 February 2011 Characteristic test data Temperature during ageing 100 ± 2 °C Duration 7 days Oversheath



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4.7 Pressure test at high temperature on non-metallic sheaths Standard and date Standard IEC 60502-2, clause 19.7 Test date 5 February 2011 Characteristic test data (inner sheath) Temperature 110 ± 2 °C Duration 6 h Load 14,7 N Inner sheath


- depth of indentation % ≤ 50 7 Characteristic test data (oversheath) Temperature 90 ± 2 °C Duration 6 h Load 18,8 N Oversheath



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4.8 Test on oversheath at low temperature Standard and date Standard IEC 60502-2, clause 19.8 Test period 3 February 2011 until 4 February 2011 Characteristic test data (oversheath) Temperature -15 ± 2 °C Cooling time ≥ 16 h Mass of hammer 1500 g Oversheath


- elongation % ≥ 20 210 - cold impact test - no cracks no cracks Result The test was passed.

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4.9 Test for resistance of oversheath to cracking (heat shock test) Standard and date Standard IEC 60502-2, clause 19.9 Test date 7 February 2011 Characteristic test data (oversheath) Temperature 150 ± 3 °C Duration 1 h Diameter of mandrel 8 mm Number of turns 4 Oversheath

item unit requirement measured/determined - soundness - no cracks no cracks Result The test was passed.

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4.10 Hot set test for XLPE insulation Standard and date Standard IEC 60502-2, clause 19.11 Test date 4 February 2011


item unit requirement measured/determined Red yellow blue - elongation under load % ≤ 175 95 90 90 - permanent elongation % ≤ 15 5 5 5 Result The test was passed.

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4.11 Water absorption test on insulation Standard and date Standard IEC 60502-2, clause 19.13 Test period 1 February 2011 until 24 February 2011 Characteristic test data Temperature 85 ± 2 °C Duration 14 days


Red yellow blue - variation of mass mg/cm2 ≤ 1 < 0,1 < 0,1 < 0,1 Result The test was passed.

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4.12 Flame spread test on single cables Standard and date Standard IEC 60502-2, clause 19.14 and IEC 60332-1-2 Test date 7 February 2011 Characteristic test data Duration 480 s

item unit requirement measured/determined - length free of charring mm > 50 280 - downward limit charred surface mm < 540 445 Result The test was passed.

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4.13 Shrinkage test for XLPE insulation Standard and date Standard IEC 60502-2, clause 19.16 Test date 7 February 2011 Characteristic test data Temperature 130 ± 3 °C Duration 1 h


Red yellow blue - shrinkage % ≤ 4 3 3 3 Result The test was passed.

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Standard and date Standard IEC 60502-2, clause 19.21 Test period 4 February 2011 until 22 February 2011

Item unit requirement Measured/determined

Red yellow blue

- before ageing N 4 ≤ F ≤ 45 19 / 22 / 24 23 / 25 / 22 25 / 23 / 22 - after ageing N 4 ≤ F ≤ 45 13 / 11 / 13 12 / 14 / 14 12 / 14 / 15 Requirement (additional) The insulation surface shall not be damaged and no trace of the insulation screen shall remain on the insulation. Result The test was passed.

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5 VERIFICATION OF CABLE CONSTRUCTION Verification of cable construction was carried out in accordance with clauses 5-14 of IEC 60502-2. The results are presented below. item unit requirement specified measured/

determined conductor - diameter of conductor (d) mm 19,7 ≤ d ≤ 21,6 - 20,9 approx. - number of wires ≥ 30 - 37 - diameter of wires mm - - 3,3 approx. - resistance at 20°C Ω/km ≤ 0,1 - 0,0984

observed/determined

markings BAHRA CABLES KSA 3X300/35MM2 CU/XLPE/STA/PVC 8.7/15KV IEC 60502-2 2010

construction - conductor of aluminium wires - construction 1-6-12-18 - semi conducting conductor screen - XLPE insulation - semi conducting insulation screen - screen of copper wires 36 x Ø 0,7mm approx. - copper tape open helix 15 x 0,1mm approx. - PP filler - synthetic tape - inner sheath of PE type ST7 - armour of double steel galvanized tape 60x0,8mm

thickness - oversheath of PVC type ST2 outer diameter of the cable, average (mm)

91,8 approx.


red: yellow: blue: 34,4 34,6 34,3

Result No deviations from the specified requirements were found.

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0,3% ± 0,5% ± 5x10-5



≤ 1%



5 µΩ - 10 µΩ : 0,5% 10 µΩ - 200 µΩ : 0,2%





-40 °C - 125 °C : 2 K 125 °C - 150 °C : 3 K



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revision date title


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OBJECT Three-core power cable TYPE 3x 300 / 35 mm2 AL / XLPE / STA / PVC 15 kV


8,7/15 (17,5) kV 3x300 mm2




DATE OF TESTS 3 February 2011 to 14 February 2010

TEST PROGRAMME Additional test according client specifications based on AIEC CS8 (2007), ICEA S-97-682 (2007)






KEMA Nederland B.V.


Arnhem, 6 July 2011

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TABLE OF CONTENTS





4 Additional tests according to ANSI/ICEA S-97...........................................................................12 4.1 Measurement of wafer boil test for conductor and insulation shields ........................................12



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Manufacturer Bahra Cable Company, Saudi Arabia Type 3 x 300 / 35 mm2 AL/XLPE/STA/PVC 8,7/15 (17,5) kV Year of manufacture 2010 Sampling procedure by the manufacturer Quantity submitted > 45 m Rated voltage, U0/U (Um) 8,7/15 (17,5) kV No. of cores (core identification) 3 (red, yellow, blue) Marking on the cable BAHRA CABLES CO. KSA 3X300/35 mm² AL/XLPE

STA/PVC 8.7/15 IEC 60502-2 Manufacturing Year – Meter marked Saudi Electricity Company - SEC

Conductor - material aluminium / H12 - cross-section 300 mm2 - nominal diameter 20,7 mm - type circular – compacted - maximum conductor temperature


Conductor screen - material thermosetting semi-conducting / bonded - nominal thickness 0,8 mm - material designation LE 0592 - manufacturer Borealis Insulation - material XLPE - nominal thickness 4,5 mm - material designation LS 4201 R - manufacturer Borealis Insulation screen - material thermosetting semi-conducting - strippable yes - nominal thickness 1 mm - material designation LE 0511 - manufacturer Borealis

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Metallic screen - material copper wire and copper tape - cross-section 34 wires of 0,66 mm - nominal thickness and width of tape 0,1x15 mm (open helix with gap -200%) - nominal thickness/diameter 1,52 mm Binder/Filling material yes Inner sheath - material MDPE-ME 6052, type ST7 - nominal thickness 2,0 mm - manufacturer Borealis Metallic armour - material galvanized steel tape - nominal diameter / dimensions 2x 0,8 x 60 mm - manufacturer Al-Qahtani- Saudi Arabia Oversheath

- material PVC, type ST2 - nominal thickness 3,8 mm - nominal overall diameter of cable 90,5 mm - material supplier NAPICO – Saudi Arabia - colour red - graphite coating applied no Manufacturing details - type of extrusion CCV line - manufacturer of extrusion line Maillefer Extrusion Oy - curing means CV-tube - cooling means Circulating Nitrogen / Pressurized water


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1.2 List of documents The manufacturer has guaranteed that the object submitted for tests has been manufactured in accordance with the following document. KEMA has verified that this document adequately represents the object tested. The following document is included in this Report:


revision date title


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2.2 The tests were carried out by DEKRA Certification B.V.








AEIC CS8 - measurement of wafer boil test for conductor and insulation shields in accordance with

clause 9.4.12 of ANSI/ICEA S-94-682.

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3 ADDITIONAL TESTS ACCORDING TO AEIC CS8 3.1 Measurement of extruded conductor shield thickness

Standard and date Standard AEIC CS8 clause 3.1 Test date 3 February 2011


unit

red yellow blue - nominal mm - 0,8 - - - - average mm - - 1,03 1,03 1,09 - minimum mm ≥ 0,41 - 0,90 0,98 0,87 - maximum mm - - 1,17 1,06 1,32 Result The test was passed.

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red yellow blue - protrusion into the insulation mm ≤ 0,076 0,000 0,000 0,000 - protrusion into the conductor shield mm ≤ 0,18 0,00 0,00 0,00 Result The test was passed.

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Standard and date Standard AEIC CS8 clause 5.2 Test date 11 February 2011 until 14 February 2011


red yellow blue - protrusion and irregularities into the

insulation mm ≤ 0,13 0,00 0,00 0,00


mm ≤ 0,18 0,00 0,00 0,00


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Standard and date Standard AEIC CS8 clause 5.4 and 10.3 Test date 5 February 2011


red yellow blue - removability at -10 °C ± 3 °C removable without tearing or






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4 ADDITIONAL TESTS ACCORDING TO ANSI/ICEA S-97

4.1 Measurement of wafer boil test for conductor and insulation shields

Standard and date Standard ANSI/ICEA S-97-682 clause 9.4.12 Test date 14 February 2011

requirement measured/determined item red yellow blue

- waferboil test for conductor shield



- waferboil test for insulation shield




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0,3% ± 0,5% ± 5x10-5



≤ 1%



5 µΩ - 10 µΩ : 0,5% 10 µΩ - 200 µΩ : 0,2%





-40 °C - 125 °C : 2 K 125 °C - 150 °C : 3 K



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APPENDIX B MANUFACTURER’S DRAWING(S)/DATA SHEET 2 pages (including this page) drawing no./ document no.

revision date title


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Test report for the fire testing of a Bahra Cables Company ‘CU/XLPE/SWA/LS0H’ 15kV 3x300mm2 cable Prepared for: Bahra Cables Company PO Box 5989 Jeddah Saudi Arabia 21432 17 August 2011

Test report number 272246

0578

Test report for the fire testing of a Bahra Cables Company ‘CU/XLPE/SWA/LS0H’ 15kV 3x300mm2 cable

Test report number 272246 Commercial in confidence

© BRE Global Ltd 2011 Page 2 of 10

Prepared on behalf of BRE Global by

Name Ewan MacDonald

Position Consultant

Signature

Approved on behalf of BRE Global by

Name Dave Hoare

Position Senior Consultant

Date 17 August 2011

Signature

BRE Global Bucknalls Lane Watford Herts WD25 9XX T + 44 (0) 1923 664100 F + 44 (0) 1923 664994 E [email protected] www.breglobal.com

BRE Global is not UKAS accredited to make opinions and interpretation. Any opinions and interpretations included as part of this report are clearly marked as such.

This report may only be distributed in its entirety and in accordance with the terms and conditions of the contract. Test results relate only to the items tested. We have no responsibility for the design, materials, workmanship or performance of the product or items tested. This report does not constitute an approval, certification or endorsement of the product tested. This report is made on behalf of BRE Global. By receiving the report and action on it, the client accepts that no individual is personally liable in contract, tort or breach of statutory duty (including negligence). No third party has any right to rely on this report.

0578

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1 Introduction

The requirement of the work was to determine the performance of a cable when tested to the requirements of IEC 60332-3-22:2000+A1:2008 [1], IEC 60332-3-24:2000+A1:2008 [2], IEC 61034-2:2005 [3], IEC 60754-1:1994 [4] and IEC 60754-2:1997 [5].

The client for this work was Bahra Cables, Jeddah, Saudi Arabia 21432. The scope of this work is given in BRE Global Quotation Q4962a, dated 30 June 2011.




2 Details of sample received and tests carried out

The cable tested was a 100.6mm diameter, 3 core cable comprising 3 off stranded copper conductors each with a conductor screen, XLPE insulation and core screen, an overall extruded filler, inner sheath, galvanised steel wire armour and a LS0H outer sheath. The over sheath had the following printed marking:

‘8.7/15kV IEC 60502-2 BS 7835 FR-IEC60332-3.24 IEC61034 IEC 60754-1/2 BAHRA CABLES CO. KSA 3X300/35MM CU/XLPE/SWA/LS0H 2011’.

The client’s reference for the cable was ‘3x300 CU/XLPE/SWA/LS0H 15KV cable’.

The test specimen was supplied by the client and received on 15 July 2011. BRE Global was not involved in the sample selection process and therefore cannot comment upon the relationship between samples supplied for test and the product supplied to market.

The client requested that the following tests were undertaken:

1. IEC 60332-3-22:2000+A1:2008

2. IEC 60332-3-24:2000+A1:2008

3. IEC 61034-2:2005

4. IEC 60754-1:1994

5. IEC 60754-2:1997

The tests were conducted between 18 July 2011 and 17 August 2011. Prior to the tests being carried out, the samples were conditioned as required by the test standards.




3 Test results

3.1 IEC 60332-3-22:2000+A1:2008 & IEC 60332-3-24:2000+A1:2008 - Multiple cable flammability

3.1.1 Determination of cable quantity The non-metallic volume (NMV) of the cable, calculated as defined in IEC 60332-3:2000+A1:2008, was determined as 5.793 l/m.

3.1.2 Test results The test conditions, observations and results are given in Table 1 below.

Test IEC 60332-3-22 IEC 60332-34

NMV requirement (l/m) 7.0 1.5

Sample NMV (l/m) 5.793 5.793

Sample array 2 cables spaced by 20mm 2 cables spaced by 20mm*

Number of burners 1 1

Burner application time (min:sec) 40:00 20:00

Flame out time (min:sec) 40:54 20:20

Extent of Char (m) 0.66 0.65

* Minimum number of cables required by IEC 60332-3-24:2000+A1:2008




3.2 IEC 61034-2:2005 - Smoke emission

3.2.1 Test procedure IEC 61034-2:2005 defines that for a cable with a diameter greater than 40mm the test array shall contain a single cable.

3.2.2 Test results The normalised minimum light transmittance recorded during the test was 83.7% (normalized according to IEC 61034-2:2005 by multiplying by a factor of D/80 where D is the diameter in millimetres of the cable under test). A copy of the light transmission versus time graph is given in Figure 1.

0

20

40

60

80

100

0 400 800 1200 1600 2000 2400

Tran

smis

sion

(%)

Time (secs)

Figure 1 Light transmission against time – Bahra Cables Company ‘CU/XLPE/SWA/LS0H’ 15kV 3x300mm2

cable - Test 180711b




3.3 IEC 60754-1:1994 - Halogen acid gas emission

3.3.1 Test Procedure The client requested that the halogen acid gas emission was measured on the XLPE insulation (incorporating the semi conductive tape and compound), filler, inner sheath and LS0H outer sheath only.

3.3.2 Test Results The results for each component when tested in accordance with IEC 60754-1:1994 is summarised in Table 2 below.

Table 2 IEC 60754-1:1994 – Halogen acid gas emission

Component % HCl per gram of sample

XLPE Insulation <0.5

Filler <0.5

Inner sheath <0.5

LS0H Outer sheath <0.5




3.4 IEC 60754-2:1997 - pH and conductivity

3.4.1 Test Procedure The client requested that the pH and conductivity was measured on the XLPE insulation (incorporating the semi conductive tape and compound), filler, inner sheath and LS0H outer sheath only.

3.4.2 Test Results The result for each component when tested in accordance with IEC 60754-2:1997 is summarised in Table 3 below.

Table 3 IEC 60754-2:1997 – pH, conductivity and weighted values

Component Mass (%)

pH Conductivity (µS/mm)

Weighted pH

Weighted Conductivity

(µS/mm)

XLPE Insulation 21.3 6.06 0.351

6.28

0.46 Filler 44.2 7.47 0.737

Inner sheath 10.8 6.02 0.178

LS0H Outer sheath 23.7 6.03 0.167




4 Conclusions

The test standard recommended performance criteria or the client's performance requirements for each test are listed below:

1. IEC 60332-3:2000+A1:2008 Annex B: Requirement - Maximum extent of char <2.5m

2. IEC 61034-2:2005 Annex B: Requirement - Minimum light transmission >60%

3. IEC 60754-1:1994: No requirement given

4. IEC 60754-2:1997: Requirement - pH>4.5, conductivity <10µS/mm

The Bahra Cables Company ‘CU/XLPE/SWA/LS0H’ 15kV 3x300mm2 cable satisfied the recommended performance criteria given for IEC 60332-3-22:2000+A1:2008, IEC 60332-3-24:2000+A1:2008, IEC 61034-2:2005 and IEC 60754-2:1997. Moreover, when tested to IEC 60754-1:1994 the insulation, filler, inner sheath and outer sheath each yielded a halogen acid gas emission of <0.5%.


==============REPORT ENDS============= Test report number 272246 Commercial in confidence


5 References

1. IEC 60332-3-22:2000+A1:2008, ‘Tests on electric cables under fire conditions. Part 3-22: Tests for vertical flame spread of vertically mounted bunched wires or cables – Category A’, International Electrotechnical Commission, Geneva, 2008.

2. IEC 60332-3-24:2000+A1:2008, ‘Tests on electric cables under fire conditions. Part 3-24: Tests for vertical flame spread of vertically mounted bunched wires or cables – Category C’, International Electrotechnical Commission, Geneva, 2008.

3. IEC 61034-2:2005, ‘Measurement of smoke density of cables burning under defined conditions – Part 2: – Test procedure and requirements’, International Electrotechnical Commission, Geneva 2005.

4. IEC 60754-1:1994, ‘Test on gases evolved during combustion of material from cables. Part 1: Determination of the amount of halogen acid gases’, International Electrotechnical Commission, Geneva, Switzerland, 1994.

5. IEC 60754-2:1997, ‘Test on gases evolved during combustion of electric cables. Part 2: Determination of degree of acidity of gases evolved during the combustion of materials taken from electric cables by measuring pH and conductivity’, International Electrotechnical Commission, Geneva, 1997.

2.8.1 mv type test result

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