3.0 11kV 3 CORE CABLE.

3.1 SCOPE
This Specification covers the design requirements of multi-core, XLPE insulated cables for use
on the Qatar 11kV Distribution System for underground installation in general and rarely to be
used for above ground.

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

3.3 CABLE CLASSIFICATION

Nominal system voltage, phase to phase: 11 kV
Um
12 kV
The cables shall be in conformity with IEC 60502 Part 2, and subsequent amendments, except as
may be otherwise stated in this standard. The general classification of cables is mentioned below.
3.3.1. 3 (three) cores of stranded compacted copper conductor circular in shape.
3.3.2. A semi-conducting shield extruded directly over each core, for the purpose of stress
control.
3.3.3. XLPE core insulation, circular in section and of a thickness appropriate to the intended
system voltage.
3.3.4. Each core insulation layer to be covered with an extruded semi-conducting XLPE
compound shield for the purpose of stress control. The compound shield shall be covered
with a metallic screen for the purpose of equalizing potential on the semi-conducting screen
and each core shall be capable of carrying full earth fault current. Copper binder tapes shall
be provided on individual screen.
3.3.5. The cores shall be laid up with metallic screens in contact with each other and
interstice solidly extruded and surrounded by an extruded inner covering and the interstice
at the centre of the all three laid up cores shall be filled with non hygroscopic
polypropylene fillers.
3.3.6. The whole shall be surrounded by armour of galvanised round steel wires two water
blocking tapes one each, over and under the armour layer.
The above requirement is supplemented by further requirements stated later in this
specification.

3.4 ENVIRONMENTAL CONDITIONS

The following is a description of the prevailing climatic conditions, and of the electrical
characteristics of the Distribution System.
3.4.1 Climatic Conditions
Altitude:... Low lying, generally close to sea level with no point
exceeding 100 meters above sea level.
Maximum air temperature... 50C (46C typical)
Minimum air temperature 0C (10C typical)
Mean maximum summer
Air temperature 45C typical.
Mean maximum exposed
Sunlight temperature 75C.
Solar radiation peak.. 1030/W/sq.m.
Humidity... 100% humidity is common throughout the year, and may
occur at temperatures in excess of 30C.
Rainfall. Very low on average.
General atmospheric conditions... May be described as a hot atmosphere containing very fine,
highly penetrating dust particles.
Ground temperature at
one meter depth in summer.. 35C, and never falls to 0C.
General Ground Conditions.. Very dry, limestone type, with typical thermal conductivity
2.0 to 4.0C m/W. Very wet, high salt content, very
corrosive.

3.4.2 System:
11kV system has three phase and an earth.
i)

Nominal Voltage 11kV

ii) Maximum Voltage. 12kV

iii) Maximum symmetrical
Fault level.. 31.5kA
iv) Limited earth fault current
through earthing transformer. 4.5kA
v) Frequency.. 50Hz
vi) Impulse... 75kV

3.5 SHORT CIRCUIT RATINGS:

Cable Size (mm2)

Short circuit rating for 1 second

(kA)

300

Not less than 31.5

3.6 CABLE CONSTRUCTION DETAILS

Extrusion Process of Conductor Screens, Insulation and Insulation Screen shall be Triple
Head Extrusion. Further details of Cable constructions are as detailed below:3.6.1 Conductors:
Plain, stranded, compacted copper conductor with 100 % conductivity, clean smooth
surface and free from any foreign particles, circular in shape in accordance with IEC 60228.
3.6.2 Conductor Screening:
Extruded semi-conducting compound firmly bound to the insulation which not to be
effected by bending, pulling or short circuit and shall adhere to conductor surface not into
the conductor.
3.6.3 Insulation:
Extruded solid dielectric: Designation XLPE -IEC 60502
Highest rated temperature 90oC - IEC 60502
Insulation thickness, as appropriate to applied voltage - IEC 60502.
The process of extrusion shall have the facility at the point of extrusion to monitor and
control the thickness of the insulation and the concentricity of the cable. The cable core
should be dry cured.
3.6.4 Insulation Screening:
A layer of extruded semi-conducting material of the generic type easy strip. This is of
a type in which the layer can be removed by hand peeling, after application of a simple
tool, if needed. This will leave the underlying XLPE insulation undisturbed. Where such
a tool is needed, for instance a knife with depth of cut limitation; this will be supplied
In quantities at a sample ratio of10% of the number of joints supplied. Each core shall be
overlaid with a metallic screen, where such is necessary to equalize potential along the semiconducting screen, to ensure correct stress control. Each such screen shall be capable of
supporting individually an earth fault current of 4500 amps. for 1 second. The screen will
take the form of copper wires with a copper binder tape. The total cross-sectional area of
the copper shall not be less than 105 mm2 on all three cores equally divided to each core
i.e. 35 mm2 on each core.
Suitable core identification, means shall be provided for core identification shall be
provided,either by color, or number. A suitably marked helical tape over each insulated
core willsuffice for this purpose.

3.6.5 Inner Covering and Fillers:

The inner covering shall be extruded. The interstice of the laid up cores shall be solidly
extruded. The material to be used shall be for the operating temperature and design
temperature conditions and of a thickness in accordance with IEC60502 and compatible
with insulating material. The material should be fire retardant, UV resistance and comprises
of anti aging components. The interstice at the centre of the all three laid up cores shall be
filled with non hygroscopic polypropylene fillers.
3.6.6 Armor:
This shall meet the screening requirements of IEC 60502. It will comprise of galvanised,
round steel wires, of thickness in conformity with IEC 60502, and laid with no discernible
gaps. The wire armour shall be closed. i.e. with a minimum gap between adjacent wires.
Galvanizing of the wires shall be in conformity with BS EN 10257. Two swallowable water
blocking tapes shall be provided one each, over and under the armour layer. These tapes shall
be capable of absorbing water and remain dry by forming into gel. The purpose of which is
to inhibit flow of water in the event of penetration of the over-sheath, or inflow from a
faulty joint. The material shall be chemically inactive with the components with which it is
in contact, both with and without the presence of water. It shall be solid at the working
temperature of the adjoining components.
3.6.7 Over sheath:
PVC extruded directly over the armour and water inhibitor (water blocking tape). The
material should be fire retardant, UV resistance, anti aging components and high resistant
to soil. It shall be type ST2 in accordance with IEC 60502 and IEC 60332-1. Thickness
shall be in compliance with the above standard. It shall be RED in colour, and embossed
with the following legends:
KAHRAMAA
11,000 V XLPE
CABLE SIZE & NUMBER OF CORES
STANDARD NO.
YEAR OF MANUFACTURE
NAME OF MANUFACTURER ALONG WITH COUNTRY OF ORIGIN
RUNNING SERIAL (at interval of 1 meter)

3.7 CABLE DRUMS

All cables shall be supplied on cable drums with a maximum diameter of 2.55m and a maximum
width of 1.28 m. No drums with cable shall weight more than 7.5 tones. In addition the lengths of
cables on the drums shall be in accordance with the Schedule of Quantities.
Cable drums shall be stoutly constructed of wood and supported with steel tie bars and shall be fully
lagged and bonded. On each flange of each drum a steel plate complete with Tubular Steel insert
shall be fitted to accept 1 x 4 inch (100mm) spindle to be used during cable installation. The steel
plate shall be a minimum of 400mm x 400mm x
5mm thick, welded to the tubular insert. The plates shall be fixed with 6 bolts through the flange.
All drums shall be painted and engraved with:
- Manufacturers Name and country of origin.
- Year of manufacture of cable
- Drum number
- Size, number of cores and voltage of the cable, including the term "Cross Linked Polyethylene
(XLPE)".

The length of cable in the drum with sequential starting & end number.
KAHRAMAA.
An Arrow with the wording Roll On this way to indicate the direction of rolling
The Contract No.

The nominal length to be as stated in the schedule below:

Cable Size
3c x 300 mm2
-

Lengths per Drum

250 meters

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

As and when required for specific project, the drum length may varies to
minimize the number of joints.

3.8 STORAGE AND HANDLING

All cables supplied to KAHRAMAA or other projects shall be stored and handled in accordance
with BS8512:2008. Manufacturer / supplier should confirm compliance to this standard.
- Storage shall be in accordance with clause 5.1 through 5.5. This is clearly illustrated in the figures
1a, 1b & 1c of this standard.
- Manual handling and lifting with the fork lifter or crane shall be in accordance
with clause 6 & 7 of the standard.

3.9 TESTS:
This relates to type tests and tests to be carried out during or after manufacture of the specified
cables. Routine, type and special tests shall be carried out in accordance with latest version of
International standards IEC 60502-2, IEC 60228 & BSI BS EN 60811 and shall be repeated if KM
considers necessary for a particular project or supply order. Copy of type test reports issued from
reputed independent laboratories need to be submitted.
The following tests shall be carried out on each manufactured length of cable, or sample length as
instructed by Kahramaa.
Manufacturer has to submit test plan and schedule for Kahramaa approvals. Kahramaa has the right
to witness any tests with no obligation to Kahramaa.
A. Routine Tests:
Routine tests are to be carried out each and every drum manufactured. One set of routine
test reports of each drum shall be fixed with the drum in a strong water-proof
envelope. Another set to be submitted with drums serial numbers and details as
mentioned in clause 7.0 prior to delivery. The following routine tests are to be carried out.
1.
2.
3.

Electrical resistance of conductor

Partial Discharge Test
Voltage Test.

B. Sample Tests:
Sample tests are to be carried out on 10 % drums of each lot. Samples to be taken from
both sides of the entire length of the drum. One set of sample test reports of shall be submitted to
KAHRAMAA for review and approval. Another set to be submitted with drums serial numbers
and details as mentioned in clause 7.0 prior to delivery. The following sample tests are to be
carried out.
1.
2.
3.

Conductor Examination.
Check of Dimensions as per IEC 60811-1-1
Hot Set Test.

C. Type Tests:
Manufacturer shall carry out type tests to IEC 60502 on the cable and issue certificates
confirming that the cable has conformed. In addition the manufacturer shall carry out tests
to prove that the metallic screens are capable of sustaining the specified earth fault current. The
design philosophy for achieving this shall also be explained. In general, following test to be
carried out at International Reputed Independent Laboratory in accordance with IEC
60502- Part -2 and IEC 60228.
Type Test Electrical
1. Bending Test.
2. Partial Discharge Test.
3. Measurement of Tan
4. Heating Cycle Test.
5. Impulse Test
6. Voltage Test for 4 h.
7. Resistivity of semi-conducting screen
Type Test Non-Electrical
1. Measurement of thickness of insulation.
2. Measurement of thickness of non-metallic screen (including extruded separation, but
excluding inner covering).
3. Test for determination the mechanical properties of insulation before and after ageing.
4. Test for determination the mechanical properties of non-metallic sheaths before and after
ageing.
5. Additional ageing test on piece of completed cable.
6. Loss of mass test on PVC sheaths of type ST2.
7. Pressure test at high temperature on insulation and non-metallic sheaths.

8. Test on PVC insulation and sheaths at low temperature.

9. Test for resistance of PVC insulation and sheaths to cracking (heat shock test).
10. Hot set test for XLPE insulation.
11. Water absorption test on insulation.
12. Flame spread test on single cables.
13. Shrinkage test for XLPE insulation.
14. Strip ability test for insulation screen
15. Water penetration test
16. Examination of conductor per IEC 60228.

3.10 TESTING, INSPECTION & DELIVERY.

3.10.1 Before commencing the production/manufacturing of 1st lot, against KM tenders, the
manufacturer is obliged to produce samples and inform Kahramaa for inspection and
acceptance through witnessing factory acceptance tests, and routine tests.
3.10.2 For every subsequent lot, the manufacturer is obliged to inform Kahramaa, at least 20
days before dispatch, and obtain clearance for dispatch. KM Engineers have the option of
inspecting & witnessing all factory acceptance tests, including routine tests, at manufacturers
factory premises for each lot.
3.10.3 Acceptance by KM Engineer(s)/Representative(s) of any Lot shall not relieve the
manufacturer from any of their responsibilities, guarantees, or from other obligations, to
comply with product requirements.
3.10.4 Type tests are to be carried out on Samples, essentially of same design and ratings, as
being offered. Manufacturer is obliged to provide details of test procedures being followed,
to the KM inspection team before commencing factory accepting tests. Kahramaa has the
right to witness any tests with no obligation to Kahramaa.
Each Lot needs to be subjected to all routine and sample tests at factory before delivery.
Further, each drum may be subjected to inspection on receiving them at DOHA to verify
its healthiness and its conformity with the guaranteed design data.
3.10.5 All tests should be performed in accordance with the latest issue of relevant IEC
standards.
3.10.6 Three sets (copies) of routine and sample tests & FAT reports to be prepared.
One set to be attached with the drum, in a strong water-proof envelope. Second copy to be
sent along with delivery note. Third copy to be sent to the end-user department.

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

3.11 INFORMATION TO BE PROVIDED AT THE TIME OF TENDER.

3.11.1 An illustrated drawing showing the cable cross section design, all components, dimensions
of each layer.
3.11.2 A specific compliance (clause by clause up to sub clause level), statement of conformity
with the specification, else details of non-conformity with justification.
3.11.3 Details of the method of protection against water ingress at armour level.
3.11.4 Permissible fault ratings of the conductors and the armour.
3.11.5 Type Test Report from International recognized Independent Laboratory.
3.11.6 Complete product catalogue with all ratings, characteristics & recommended installation
procedure.
3.11.7 Supply record for GCC and other countries.
3.11.8 Routine and Sample Test Plan.
3.11.9 Quality assurance and quality control protocol or manual.

3.12 GUARANTEE
Supplied material shall be guaranteed against any defect for 5 (five) years from the date of delivery
or 3 (three) years from the date of installation whichever comes first.

13.0 DEVIATIONS FROM THE TECHNICAL SPECIFICATION

The Bidders are required to attach a separate deviation list to their Technical Offer and include it in
the Technical Package if the offered equipments do not meet the requirements of any clause of the
Specification.
Offers without any deviation list attached to the Technical Offer and included in the Technical
Package shall mean that the offer meets the requirements of the Specifications on all the clauses.
Offers with deviations listed out shall mean that the offer meets the requirements of the
Specification on all the other clauses not included in the deviation list.