SECTION 16124 MEDIUM VOLTAGE CABLES

PART 1 GENERAL 1.1 SECTION INCLUDES A. Medium Voltage (MV) Cables and Accessories rated up to 8700/15000 Volts including, but not limited to, the following: 1. 2. 3. 4. 5. 1.2 Multi Core MV cables. Single Core MV cables. Earth cable. Splices and terminations. Cable markers, support and ties.

REFERENCES A. B. C. SASO IEC 60228 IEC 60502 Saudi Arabian Standards Organization Conductors for Insulated Cables. Extruded Solid Dielectric Insulated Cables for Rated Voltages from 1 kV up to 30 kV. Thermoplastic Insulated Cable and Wire, O to 35 kV

D. 1.3

IPCEA S61-402

SUBMITTALS A. B. Comply with Section 01300. Submit samples of each type of cable proposed and, if requested by the Engineer, other accessories. 1. Subject certificate of origin for each cable lot, termination kits and all other accessories stating the origin, date of manufacture, composition, standards to which it complies and test certificate.

C.

For all types and sizes of cables, submit the following Manufacturers details: 1. 2. 3. 4. 5. 6. 7. Dimensions Weight Construction Current rating and derating factors Method of installation Maximum conductor operating temperature Volt drop/amp/meter

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8. 9. 10. 11. D.

Impedance: Separate resistance and reactance values of single and multicore cables Resistance of armoring in ohms/1000 m length of cable Characteristic curves for short circuit rating Minimum bending radius

Submit factory/shop test results showing test voltages, duration of tests and polarization indices for each routine test, in accordance with the requirements of IEC Standards. Submit the results of type tests when required by the Engineer. Submit cable termination diagrams and jointing details. 1. Submit shop and construction drawings for approval, including but not limited to the following: a. Exact routing layouts with necessary sections that show coordination between various trades. Details of cable support and details of cable connections and termination.

E.

b.

2.

At project handing over stage submit as-built drawings (record drawings) for the cable installation showing exact and final routes/locations of cable, duct banks, manholes in accordance with the requirements of division 1 specification.

1.4

QUALITY ASSURANCE A. Manufacturers: Firms regularly engaged in manufacture of MV cables and accessories of the types, sizes and ratings required, whose products have been in satisfactory use in similar service for not less than 10 years. Preference shall be given to local manufacturers and agents/suppliers. Installer: Firms regularly engaged and qualified with at least 5 years of successful installation experience on projects with electrical installation work similar to that required for the project. Cables shall generally be Manufacturer's standard construction and materials. Where this contradicts any part of the Specifications, the Contractor shall state so, at the time of tender. All MV cables and accessories furnished under these Specifications shall conform to applicable standards of the Electricity Supply Authority (SEC), SASO and IEC.

B.

C.

D.

1.5

DELIVERY, STORAGE AND HANDLING A. B. End of cables shall be sealed to prevent ingress of moisture. All cables shall be transported on drums with solid timber battens for protection of cables over the circumferences of the drums. Drums shall not be transported on their sides. Each cable drum shall be provided with appropriate weatherproof metallic label indicating project name, order no., type, size and length of the cable delivered.

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C.

Care shall be taken during transit to avoid damage to cable and drums. Before acceptance on site, cable drums and cables shall be inspected for: 1. 2. 3. Damage. Compliance with Specifications. Quantity.

D.

All MV Cables and accessories shall be stored in factory installed coverings in a clean, dry indoor space which provides protection against the weather and direct exposure to the sun light. As far as possible, each distribution cable shall be supplied in one continuous length without any joint. Where the required run length of any individual cable exceeds the maximum/standard length of a cable drum, as Manufactured in the factory, the cables shall be jointed with prior approval of the Engineer using an approved cable joint. Cables shall be handled with care and every effort made to avoid damage to the cable, to other services and to building fabric. Recommendations or instructions available from the cable manufacturers concerning the installation of cables shall be taken into account. Any damage shall be reported immediately to the Engineer. Cable drums shall be unloaded carefully by means of either a crane or ramp and impact with the ground shall be avoided. They shall be supported on axles and axle stands while the cable is being pulled; twisting and abrasion of the cable serving or over sheath shall be avoided.

E.

F.

G.

1.6

WARRANTY A. Submit written guarantee signed by the contractor and manufacturer for the period of one year from the date of substantial completion. The guarantee shall cover the repair and replacement of defective materials and workmanship as directed by the Engineer.

PART 2 - PRODUCTS 2.1 GENERAL A. 3,800 volts circuit as referred to herein or shown elsewhere in the Contract Documents shall comprise three single-core cables or one three-core cable rated 8700/15000 volts, armored or unarmored with a separate single-core green/yellow insulated earth cable of the sizes shown on drawings and specified herein.

2.2

MULTICORE MV CABLES A. Provide 3 core, armored or unarmored (as per drawings) MV cable rated at 8700/15000 Volts, as shown on Drawings. The cables shall conform to the following minimum requirements: 1. Conductor: 2. Conductor Screen: Concentric circular copper, stranded to IEC 60228 class 2. Extruded semi-conducting thermosetting material, 0.3 mm minimum thickness.
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3. Insulation:

4. Insulation Shield:

5. Armor: 6. Outer Sheath:

7. Marking:

8. Outside Diameter: B.

Cross-linked thermosetting polyethylene (XLPE), minimum 4.5 mm thick rated 90 C to IEC 60502 and containing no carbon black. Manufacturer shall warranty that the insulation will not emit any toxic fumes in the event of a fire. Extruded semi-conducting thermosetting material and uncoated copper tape. Metal shield shall have a fault capability of 1,000 Amps rms symmetrical minimum for 1 second. Semi-conducting material shield shall be readily removable for termination. If shown on Drawing, the armor shall be of galvanized double steel tape armor over extruded PVC bedding. Extruded Red PVC Type ST2 to IEC 60502. Manufacturer shall warranty that the outer sheath will not emit any toxic fumes in the event of a fire. A durable marking shall be provided on the surface of the outer jacket (over sheath) at intervals not exceeding 610 mm. Marking shall include Manufacturer's name, insulating material, conductor size and voltage class. Cores shall be marked by red, yellow and blue tapes applied within the insulation screen. As per IEC 60502.

Coordinate the critical dimensions of the MV Cables to be within the allowable tolerances of the premolded splices and tapes. The short circuit ratings of all MV Cables shall be coordinated with associated MV switchgear and short circuit study/calculations.

C.

2.3

EARTH CABLE A. Provide separate earth cables in all medium voltage ring and radial circuits in accordance with applicable International Standards and the requirements given in Section 16452 - GROUNDING. The Size of earth cable for each MV cable or circuit shall be based upon short circuit calculations, but in any case not less than 95 mm2. In case the MV cable is armoured cable (steel or aluminium), armouring can be used as the earth cable.

B.

C.

2.4

SPLICES AND TERMINATIONS A. Cable splicing or jointing shall not be allowed in any circumstances, except where the required run length of any individual cable exceeds the maximum/standard length as Manufactured in the factory. Obtain Engineers written approval for any splice or joint, prior to ordering the cable. Splices and terminations for all MV Cables rated up to 8700/15000 Volts shall be furnished in kit form and shall conform to the recommendations of the cable Manufacturer. All material shall be furnished in factory sealed packages and shall not be opened until required for use.

B.

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C.

Splices for all MV Cables shall be pre-molded and rated for continuous duty and short circuit duty at the rating of the services to which they are connected. They shall be suitable for direct buried underground installation or mounted on cable trays/ladders as per the requirements on site. Termination shall be insulated using the materials specified and the procedures recommended by the Manufacturer of the kit being used. Splices for the earth shall be made exothermally or as per the recommendations of MV cable splice Manufacturer.

D.

E.

2.5

CABLE MARKERS, SUPPORTS AND CLEATS A. Cable markers and identification discs for all MV Cables shall be provided in accordance with the applicable codes and regulations. The supports for all MV Cables shall be approved galvanized cast steel clamps/ cleats with 10 mm hexagon headed zinc plated fixing bolts and studs. All MV Cables shall be tied on cable trays/ladders by non-releasing type cable cleats or any other approved clamps. The clamps for single core cables shall be of cast aluminium type or other equal and approved non-ferrous material.

B.

C.

D.

PART 3 - EXECUTION 3.1 INSPECTION A. Examine the areas and conditions under which the cables are to be installed and correct any unsatisfactory conditions detrimental to the proper and timely completion of the work. Do not proceed with the work until all unsatisfactory conditions have been corrected in a manner acceptable to the Engineer.

3.2

CABLE INSTALLATION A. General: Follow requirements of Specifications Section 16050 and details shown on drawings. No work shall commence until the Contractor has investigated the site satisfactorily, and ascertained that the area is free from drains or other underground services. The Contractor shall obtain approval of the routes for external cables with appropriate installation details on shop drawings prior to commencement of any excavation on site. Pull cables off drum mounted on cable jacks or a stationary cable trailer. Care shall be taken to protect the cable at all times during the installation process. Cable rollers shall be used to prevent undue friction below the cable and at all changes in direction. The Contractor shall comply with all other Manufacturer's instructions.

B.

C.

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D.

Pull cables into position using a conductor pull or a wire basket over the metallic insulation screen. When installing into a duct system via a manhole, utilize a feeding tube long enough to reach from the conduit entrance to the outside of the manhole. When installing into cable ducts, all multi-core cables shall be installed singly and continuous between the manholes. Splicing of cables between the manholes shall not be allowed in any case. For cables pulled into thrust boring or cable ducts exceeding 10 m length, use cable stockings for hauling. Precautions shall be taken to ensure that strain is taken on the cable cores as well as on the sheath. The pulling tension of the cable shall not exceed the maximum tension recommended by the Cable Manufacturer. Utilize both manual and power types puling mechanisms on site as required with the rated capacity (in Newtons) clearly marked on the mechanism. A dynamometer shall be used to show the tension on the cable during all pulls and the indicator shall be constantly watched. If any excessive strain develops, the pulling operation shall be stopped at once and the difficulty determined and corrected. The dynamometer shall have a maximum tension indicator to show the maximum tension developed during a pull. The cable play-out reel shall be equipped with a suitable brake and shall be constantly manned during all pulls. Under no circumstances shall cable be pulled using equipment not monitored by a dynamometer. The use of motor vehicles in pulling cable is prohibited. Any cable so pulled shall be removed and replaced. To avoid insulation damage from excessive sidewall pressure at bends in raceway runs, the pulling tension in the cable in Kg as it leaves the bend shall not exceed 500 times the radius of the bend in meters. Support cables at all times without excessive sag. Cables shall be located in such a way as to minimize interference with other cables to be installed. Provide adequate length of cables in manholes to avoid distorting pressures on the cables at conduit bushings. Provide cable protection such as a layer of light rubber belting, friction tape or similar material where required before permanently fixing the cables in place. Exercise extreme care to prevent tension during bending of MV Cables. The permanent radius of cable bend at any location after installation shall not be lesser than the cable manufacturers recommendations. Seal cable ends during pulling and immediately after cutting if splices or terminations are not to be made immediately. Arc proof all MV cables in manholes and building entrances. Arc proofing in a manhole shall be extended in one helically wound half lapped layer from one duct end along the cable to the other duct end. Secure arc proofing in position with glass tape randomly wrapped to the instructions of the arc proofing tape Manufacturer.

E.

F.

G.

H.

I.

J.

K.

L.

M.

N.

O.

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P.

Provide moisture seal in conduit/building transition after all MV Cables are installed. A special caulking compound of a putty-like consistency shall be used, which shall be workable with the hands at temperatures as low as 1.7 oC, and shall not slump up to a temperature of 149 oC or less. It shall not be hardened materially when exposed to air. Install earth cable and its associated MV cable(s) in same conduit or together with the MV cable(s) when they are direct buried. Ground earth cable in every manhole. Shields and armour of MV cables shall be earthed at both ends. Install cable markers and identification discs in accordance with the applicable codes and regulation and locate them so that they are readily visible when cable is permanently fixed in position.

Q.

R.

3.3

SPLICING AND TERMINATIONS A. Splicing and terminations of all MV cables shall be carried out by the personnel certified by Saudi Electric Company (SEC). Utilize appropriate crimping tools for splicing and terminations of all MV Cables, with guides to position the connectors or lugs in the tool correctly. The connectors, lugs and associated dies shall be of correct type and size suitable for the MV cable under splicing or terminations. Crimping tools shall be designed with steps to prevent over crimping and shall be of a type which have provision to prevent the tool from opening until the crimp action is completed. Crimping tools shall be an approved product by the connector Manufacturer. Comply with Manufacturer's recommendations and instructions for splicing and terminations of MV cables, provided these do not contradict with the applicable standards. Contractor shall submit to the Engineer any contradictions found prior to work commencements. Splices shall not be made to utilize short lengths of cable. When cables are being installed into a duct system with manholes, the splices shall only be provided within the manholes and no splice shall be allowed outside the manholes. Keep work areas dry, dust free and ventilated during splicing and terminating MV cables. Before making final splice or termination of MV cables, ensure conductor phasing is correct. Where the shape and configuration of terminal fittings make workmanlike insulation of the bare connection impractical, the contours of the connection shall be smoothed by filling voids and moldings over irregular surface with electrical putty before application of the recommended thickness of insulating material. Follow the detailed splicing and termination requirements and procedure, as applicable for MV cables splicing and terminations, given in Section 16126.

B.

C.

D.

E.

F.

G.

H.

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3.4

FIELD QUALITY CONTROL A. After completion of the installation of all MV cables, test each conductor for phasing, continuity and insulation resistance. Carry out a high voltage DC insulation test between each conductor and earth at 2 times the phase to earth working voltage for 15 minutes. Full tests shall be carried out only once. Where preliminary tests are required on sections of cable prior to terminating or jointing they shall be carried out at reduced time and voltage. Test procedures shall be in accordance with the appropriate IEC standard. All MV cables shall be tested when splicing and terminations are fully prepared and completed except for final connections of cable tails onto equipment. In addition to above, carry out any test(s) required to comply with the procedures of Saudi Electric Company (SEC) for power connection requirements, and any other test required by the Engineer.

B.

C.

END OF SECTION

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