Specification for 11kV Heat Shrinkable Joints EP-MS-P4/S3-085

EP-MS-P4/S3-085

Specification for
11 kV Heat Shrinkable Joints

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Specification for 11kV Heat Shrinkable Joints EP-MS-P4/S3-085

Document Control
Department Document Type Document Title
EP-MS-P4/S3-085
Material
Specification for
EP Specification
11kV Heat Shrinkable Joints
Standards
Issue Approval
Prepared By Approved By

Consultant M/s. Ewbank Preece Limited

Head of Design & Development
Member of the Mott Mac Donald Group,UK

Signature: Signature:

Issue Record
Issue No. Date Reason for re-issuing Document

0.0 30.04.2003 First issue of Materials Specification Standards

1.0
2.0
3.0
4.0
5.0

Key Words : Specification for 11kV Heat Shrinkable Joints

Review Frequency : Every 3 years

When this document is approved for publishing on the intranet, a copy of its Document Control page should be sent to
the QA section who is custodian of KM quality management system.

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Specification for 11kV Heat Shrinkable Joints EP-MS-P4/S3-085

1.0 SCOPE

The design, manufacture, testing and quality requirements of 11KV straight joints and transition
joints to use in the 11KV Distribution system of Electricity Networks Affairs. These joints will be
used for XLPE and PILC cables.

2.0 REFERENCES

ESI Standard 09-13 Issue October 1981 or any other equivalent international standard, which will
satisfy the above standard and shall be subjected to the approval of KAHRA MAA. One copy of
the specification in English language to which the joints are manufactured and tested shall be
submitted with the offer.

3.0 GROUND CONDITION

Ground temperature at one metre depth in summer 35 degree C.

General ground condition:-

a) Very dry limestone type, including rock. Typical thermal resistivity 2.0 to 4.0C.m/W.

b) Very wet, high salt content, very corrosive.

Under certain condition the joint may be permanently submerged in water to a depth of
approximately 1 metre.

4.0 SYSTEM CONDITIONS

11kV system has three phase and earth.

Nominal Voltage : 11kV

Maximum Voltage : 12kV
Maximum Symmetrical fault level : 25kA
Limited earth fault current
through earthing transformer : 4.5 kA
Frequency : 50 Hz
Impulse : 75 kV

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Specification for 11kV Heat Shrinkable Joints EP-MS-P4/S3-085

5.0 TYPES OF CABLE

3 core paper insulated, sector shaped, stranded copper conductor, belted construction, lead
sheathed, single galvanised steel wire armour and PVC oversheath and according to BS 6480.

Cable sizes are 3c.300 sq.mm, 3c.185 sq.mm, 3c.95sq.mm and 3c.70sq.mm.

3 core XLPE insulated , round compacted stranded copper conductor, extruded semi-conducting
layer over XLPE insulation, copper wire screen with one copper tape binder, PVC inner sheath,
single galvanised steel wire armour and PVC over sheath.

Cable sizes are 3c.240sq.mm, 3c.185sq.mm and 3c.70sq.mm.

6.0 JOINT DESIGN

Joint types shall be classified according to the types of cable used, i.e.

Type A : XLPE to XLPE.

Type B : PILC to PILC.
Type C : XLPE to PILC.
In all types of joints the following applies:

The joint shall accommodate cross core jointing. Joint dimension should be such that after
removing inner sheath(or lead) of the cables each core should have a minimum length of 500mm
either side of the center of the joint or total 1000mm minimum if the center is shifted. Joints
galvanized steel case should have sufficient dia to accommodate three insulated cores and earthed
tinned copper braid.

7.0 CORE CONNECTORS

For all types of joints the core connectors shall be compression type copper ferrule as per BS
4579 Part 1:1988. For transition joints barrier type ferrule should be provided. Independent type
test certificate and drawing showing the dimension of ferrules should be attached along with the
sample. Ferrule size shall be as per the joint sizes ordered in the bill of quantity.

Compression tools comprising foot pump, a three metre length of hydraulic connecting tube,
compression head and imprint die set(round crimp) shall be provided. Indent type die set is not
acceptable. Number of compression tools required shall be as per bill of quantity ordered.

8.0 CORE INSULATION REINSTATEMENT

Depending on joint types insulation reinstatement over cores and connectors shall be of heat
shrink type using clear insulating tube , stress control tube, anti-track insulating tube, semi-
conducting tube, conductive breakout, void filling tape and insulating tape.

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Specification for 11kV Heat Shrinkable Joints EP-MS-P4/S3-085

All components shall be tested as per ESI standard 09-13 issue 1, October 1981.
All tubing components will comply with the requirement of lists 1 and 4 of the ESI standard.
All moulded components will comply with the requirements of lists 2 and 4 of the ESI standard.
All sealants(adhesives) will comply with the requirement of list 3 of the ESI Standard.

Tenderers must submit authenticated test certificate from independent testing station along with
the offer.

9.0 ARMOUR AND LEAD SHEATH BONDING

The joint shall be provided with a galvanized steel case and tinned copper braid which shall be a
continuation of conductive path of the armour wire and where appropriate the lead sheath across
the joint. Tinned copper braid shall be of sufficiently robust, at least the equal of the armour of
the largest size of cable to be used, in respect of conductivity and fault carrying capability. 11kV
system is highly interconnected, a fault within the joint may result in the specified level of earth
fault current from each side of the joint.

The joint kit shall incorporate means of adequately connecting of steel wire armour, the core
metallic screen and lead sheath to the tinned copper braid.

Core metallic shield over semi-conducting tube shall be connected to the metallic screen of the
cable or to the lead sheath by using tinned copper mesh.

A supporting ring and braided copper tape shall be used to ensure adequate contact to the armour
wire. Contact shall be achieved by the use of worm drive clips(2nos) Lead sheath bonding with
armour and earth braid shall be achieved by plumbing.

Galvanized steel case shall be in two halves with interlocks and shall be not less than 1mm thick.
Steel case shall be connected to the cable armour by using of worm drive clips, and where
appropriate shall be plumed to the lead sheath.

The joint kit shall be supplied with sufficient quantity of Grade D plumbing metal.

10.0 HEAT SHRINK SEALING SLEEVES.

The heat shrink thick wall sealing sleeves inner wall shall be pre-coated with sealant and which
will protect the joint against the moisture and corrosion. Diameter of the sleeve shall be suitable
to accommodate the galvanized steel case and length of the sleeve shall be such that it overlaps
the cable PVC sheath by a minimum of 150mm either side of the joint.

Tube and sealant shall comply with ESI standard mentioned elsewhere.

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Specification for 11kV Heat Shrinkable Joints EP-MS-P4/S3-085

11.0 GENERAL REQUIREMENTS OF INSTALLED JOINTS.

Electric stress control for cable insulation screen in joints shall be achieved by heat shrink tubing.
This tubing shall have defined electrical characteristic, volume resistivity and dielectric constant in
accordance with IEC-60093 and IEC-60250.

Complete external leakage insulation between the high voltage conductor and earth potential shall
be achieved by utilising heat shrinkable non-tracking tubing and semi-conducting breakout. No
filling medium shall be required.

These components shall be weather, ultra violet light and salt pollution resistant.

Electrical stress control using semi-conducting heat shrink tubing over the cores and by the
insertion of high di-electric strength insulating material into the crutch of the cable such that
electrical discharge activity does not occur in the joint after it has been energized at its rated
voltage.

Hermetic sealing of the interface between heat shrinkable materials and cable surfaces shall be
provided by use of track resistant hot melt adhesive which can accommodate the creep and
relaxation that may occur with recovered heat shrink materials.

This sealant shall be pre-coated inside the heat shrinkable components and activated by the heat
applied to shrink the components, which shall be in excess of 125 degree C.

Uniform adhesive flow from the adhered heat shrink component into the adjoining surfaces will be
used as an indicator that shrinking is complete.

All completed joints must have a certified symmetrical fault withstand rating and earth fault
withstand rating. The certificate shall be issued by an independent testing authority and the
method of test shall be defined.

Joints must be insensitive to cable manufacturers tolerances allowed under BS 6480-1997 and
IEC-60502.

12.0 IDENTIFICATION AND PACKAGING

For the purpose of identification, gloves shall be marked clearly and permanently in a prominent
position with suppliers name and reference number.

Electrical conducting components shall be marked Conducting clearly and permanently.

Components shall be supplied in a single package as a complete joint and shall be clearly marked
with suppliers name, reference number, batch references, voltage and cable size. Packaging shall
be designed to protect ingress of moisture and mechanical damage.

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Specification for 11kV Heat Shrinkable Joints EP-MS-P4/S3-085

Components supplied with adhesive coatings shall have means to prevent the coated surfaces
from adhering to each other.

Each joint kit shall be supplied with a complete set of jointing instructions in English and Arabic
with dimensioned drawings.

Tender must be accompanied with one set of jointing instruction including dimensioned drawing.
Tender will not be accepted without jointing instructions including drawings.

13.0 STORAGE

Components shall be capable of being stored without deterioration within the temperature range -
10 degree C to + 45 degree C.

Components or materials shall have no shelf life limitation and no special storage condition in
given temperature limits.

14.0 ELECTRICAL PERFORMANCE TEST

Joints of similar design shall have been previously tested in accordance with the following, and
sample type test certificate shall be provided at the time of tender.

Authenticated type test certificates shall be from independent testing station.

Impact test: Electricity council engineering recommendation C81.

A.C Voltage withstand - IEC 60060.
Partial discharge-IEC 60270.
Impulse voltage withstand- IEC 60060 & IEC 60230.
Load cycling- VDE-0278.
Thermal short circuit- VDE-0278.
D.C withstand voltage-IEC 60060.
Dynamic short circuit-VDE-0278.

The preferred test sequence shall be :

1. Impact.
2. A.C Voltage withstand.
3. Partial Discharge.
4. Impulse voltage withstand.
5. Load cycling.
6. Partial Discharge.
7. Thermal short circuit.
8. Load cycling.
9. Partial Discharge.
10. A.C Voltage withstand.

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Specification for 11kV Heat Shrinkable Joints EP-MS-P4/S3-085

11. Impulse Voltage withstand.

12. D.C Voltage withstand.
13. Dynamic short circuit.

15.0 QUALITY CONTROL

The manufacturer shall in possession of current certification providing compliance with ISO 9001.
The certification shall be from a recognized international body. A copy of certificate shall be
included with the tender and which shall incorporate following information.

The identity of the certifying authority.

The identity of the manufacturing unit to which the certification applies.
The type of equipment to which the certification applies.
The date of issue and time of validity.

16.0 SALES RECORD

The manufacturer shall provide a record of sales of the type of joints specified in G.C.C countries
and other countries with a minimum of 5 years of field experience. This shall be provided at time
of tender.

17.0 SUPPLY OF TECHNICAL INFORMATION, TEST CERTIFICATES AND

SAMPLES

Tenderers must submit full technical literature for the joints offered including component
dimensions.

Tenderers must submit full specification and sample of all joints.

Tender must be accompanied by authenticated test certificates of ferrules, material

test certificates and Electrical test certificates from an independent testing station demonstrating
compliance of this specification.

18.0 DEVIATIONS FROM THE TECHNICAL SPECIFICATION

The Tenderers 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.

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