48 TMSS 03 R0

PAGE NO.
2 OF 18 48TMSS03R0/KIA

48-TMSS-03, Rev. 0 TRANSMISSION MATERIALS STANDARD SPECIFICATION
Date of Approval: September 27, 2006

TABLE OF CONTENTS

1.0 SCOPE

2.0 CROSS REFERENCES

3.0 APPLICABLE CODES AND STANDARDS

4.0 DESIGN AND CONSTRUCTION REQUIREMENTS

4.1 General
4.2 Materials

5.0 FABRICATION AND MATERIAL

5.1 General
5.2 Enclosure
5.3 Pilot Wire Supervision Equipment
5.4 Pilot Wire Isolation Equipment
5.5 Neutralizing Transformer
5.6 Insulating Transformers
5.7 Surge Arresters
5.8 Surge Counters
5.9 Cable Gland Plate
5.10 Terminal Blocks & Wiring
5.11 Grounding
5.12 Labelling

6.0 TESTS

7.0 DATA SCHEDULE

PAGE NO. 3 OF 18 48TMSS03R0/KIA

1.0 SCOPE

This SEC Transmission Material Standard Specification (TMSS) specifies the minimum
technical requirements for design, engineering, manufacture, inspection, testing and
performance of Pilot Cable Termination Equipment, intended to be used in the system of the
transmission network of Saudi Electricity Company, Saudi Arabia.

i. Type-A (For Central Area)
ii. Type-B (For Eastern Area)

The termination box is intended to accommodate the pilot cable under SEC Specification
48-TMSS-01.

2.0 CROSS REFERENCES

This Material Standard Specification shall always be read in conjunction with SEC General
Specification No. 01-TMSS-01, titled "General Requirements for All Equipment/Materials",
which shall be considered as an integral part of this TMSS.

This TMSS shall also be read in conjunction with SEC Purchase Order or Contract
Schedules for project, as applicable.

3.0 APPLICABLE CODES AND STANDARDS

The latest revision/amendments of the following Codes and Standards shall be applicable for
the equipment/material covered in this TMSS. In case of conflict, the vendor/manufacturer
may propose equipment/material conforming to one group of Industry Codes and Standards
quoted hereunder without jeopardizing the requirements of this TMSS.

3.1 NEMA ICS-1 Industrial Control and Systems General Requirements

3.2 IEEE 487 Recommended Practice for the Protection of Wire-
LineCommunication Facilities Serving Electric PowerStations

3.3 IEC 60529 Degrees of Protection Provided by Enclosures

3.4 ISO 898/1 Mechanical Properties of Fasteners Made of Carbon Steel and
Alloy Steel


4.0 DESIGN AND CONSTRUCTION REQUIREMENTS

4.1 General

4.1.1 The pilot cable termination box shall meet or exceed the requirements of this
specification in all respects.

4.1.2 All items shall be enclosed in a compact enclosure with provision for natural
air-cooling.

4.1.3 Two main types of boxes are required, one with send end pilot supervision
and one with receive end pilot supervision.

4.1.4 The outdoor type termination box completes with all its fittings and
attachments shall be capable of withstanding the effects of direct solar
radiation and ambient conditions at its installed location.

4.2 Materials

3.2.1 Enclosure

For Type-A
The enclosure shall be made out of polyester reinforced with fiberglass and shall be
self-extinguishing.

For Type-B
The enclosure shall be made from 3 mm minimum thickness of steel sheet.

5.0 FABRICATION/MATERIAL

5.1 General

5.1.1 The termination box shall consist of an enclosure containing the following:
For Type-A
Pilot wire Supervision Equipment and Pilot wire Isolation Equipment.

For Type B
Neutralizing transformer, insulating transformers, surge arresters, surge
counters, terminal block, insulating plate, earthing terminals and cable ducts.

5.1.2 Circuit distribution shall be as required by the Design Engineer.


5.2 Enclosuers

For Type-A
a) The box shall be made out of polyester reinforced with fiberglass and shall be
self-extinguishing.

b) The box shall be fitted with four external brackets to facilitate wall mounting
of boxes side-by side if necessary.

c) The front of the box shall comprise a door which is hinged on the left. The
door shall be fitted with two closing handles which do not have any integral
key locking arrangement. A suitable bracket shall be fitted to the centre of the
right side of the door to allow locking with a padlock having a hasp diameter
of 6 mm with 25 mm clearance. The door shall be suitably sealed to prevent
the ingress of dust to class IP-54 of IEC 529.

d) The top and bottom of the box shall each have a suitable cut-out for mounting
a cable gland plate for the outgoing multicore cables and pilot cables
respectively. The gland plates will be made of mild steel and will not be
drilled to accept any cables. No cable glands will be provided, drilling and
fittings of glands to gland plates will be done on site.

e) When pilot box is associated with two cable feeders, the necessary equipment
shall be mounted to the left for one cable feeder and to the right for the other
cable-feeder. A barrier of insulating material not less than 100mm deep shall
be fixed in the centre to segregate the 2 sets of equipment.

f) The box and door shall be finished in shade RAL-7033 -Grey.

For Type-B
a) The enclosure shall be dust proof and waterproof type conforming to a degree
of protection of IP-54.

b) The enclosure shall be made from 3-mm minimum thickness of steel sheet.

c) All seams shall be continuously welded with no open holes or knockouts.

d) The box shall have two front doors. The front doors shall be hinged type and
individually furnished with a handle and built-in lock with master key. Rear
access door shall not be provided.

e) A transparent window shall be provided for each of the surge counters in the
front door to enable the reading of the counters from outside without opening
the door.

f) All boxes shall be fitted with removable lifting devices mounted at each end
and as near as possible to the balance line.


g) A print pocket for instruction manual and schematic drawings storage shall be
supplied on the rear of the front doors. The pocket shall be deep enough to
hold the manual and drawing in place. Necessary clearances to be provided
for the pocket from any live part of the equipment.

h) The box shall be provided with adequate ventilation at both sides of the
enclosure to permit natural circulation of air. The ventilation shall be
vermin-resistant. Appropriate air filter shall be provided.

i) Cable glands shall be provided for entry and exit of the pilot cable.

5.3 Pilot Wire Supervision Equipment

5.3.1 Pilot wire supervision equipment shall be installed in the box for either
send end or receive end functions. The equipment shall be fully compatible
with the pilot wire protection relays which shall be specified at the time of
ordering. The pilot supervision equipment shall detect open circuit, short-
circuit or crossed pilots and loss of supervision supply.

5.3.2 For send end pilot supervision, the required pilot injection transformer shall
be suitable for a 127V 60 Hz input and 30V output. The auxiliary relays
shall be suitable for operation from 50 V dc and 125V dc for which a dc/dc
converter is preferred. However, a suitable dropping resistor may be
acceptable.

5.4 Pilot Wire Isolation Equipment

5.4.1 For each pilot wire protection, a suitable pilot isolation transformer shall be
supplied and fitted in the send or receive end box if required in order to
achieve a 5kV insulation level between the pilot wires and the protection
equipment. The ratio of the transformer shall be as recommended by the pilot
wire protection manufacturer.

5.4.2 An additional suitable pilot wire isolation transformer shall be supplied and
fitted in the send end box in order to achieve a 5kV insulation level between
the pilot wires and the pilot wire supervision equipment as covered in Section
5.3 above.


The neutralizing transformer for the telephone lines shall have the following
characteristics:

5.5.1 The d.c. resistance per one line shall be less than 60 ohms.

5.5.2 The transmission loss shall be less than 1.0 dB for 16 Hz at 70 V d.c.
levels.


5.5.3 The dielectric strength shall be 15 kV a.c. for 3 seconds between line
and earth, and between line and terminal and 3 kV a.c. for 3 seconds
between two windings.

5.5.4 The insulation resistance shall be more than 2000 megohms between
each winding and earth after electrification with 500 V d.c.

5.6 Insulating Transformers

The insulating transformers shall be provided with a center tap on the line side. The
center tap will be connected to the remote ground through a surge arrester. The
insulating transformers for the pilot lines shall have the following characteristics:

5.6.1 Impedance for the signal at 100 Hz and 50 V out put shall be 600
ohms. Allowable tolerance is 20%.

5.6.2 The dielectric strength shall be 15 kV a.c. for 3 seconds, and to
withstand for 10 times, between line and earth, and between line and
terminal.

5.6.3 The insulation resistance shall be more than 1000 megohms between
line and earth and between line and terminal after electrification with
500 Vd.c.

5.6.4 The rated discharge current of the line side coil shall be 60 A for 3
seconds and 100 A for 1 second between both ends and center tap.

5.6.5 The 1:1 transformer ensures decoupling of site from indoor
installation in case of potential rise with reference to a distant earth.
Voltage withstand will be of 15 kV 60 Hz during 1 min between the
primary coil and screen connected to earth, between secondary coil
and screen connected to earth, and between primary and secondary
coils. The attenuation will not be more than 0.5 dB at 1000Hz.

5.7 Surge Arresters

5.7.1 Pilot wire lines and spare lines circuits shall be protected by ceramic
type surge arresters.

5.7.2 Two (2) ceramic type surge arresters on one end, and two (2)
hermetbotton type surge arresters on the other end shall protect each
telephone line circuit.

5.7.3 The d.c. Striking voltage for both arresters shall be 230 V with
tolerance of 15%.


5.7.4 The surge striking voltage shall be less than 1000 V at the rate of 1 kV
per microsecond.

5.7.5 The rated a.c. discharge current for 1 second shall be 100 A for the
ceramic type and 60 A for the hermetbotton type.

5.7.6 The rated surge discharge current shall be 20 kA at 8 x 20
microseconds for the ceramic type and 15 kA at 10 x 50 microseconds
for the hermetbotton type.

5.7.7 Failure mode of the arrester after life test shall be as follows: After
surge life test, d.c. breakdown of the arrester shall be a voltage value
within 30% of sample quantity of 80% from a test.

5.7.8 The insulation resistance shall be more than 2000 megohms at 100 V
d.c. for the ceramic type and 1000 megohms at 100 V d.c. for the
hornet button type.

5.7.9 Fuses
Fuses shall be "semaphore type" ,i.e. equipped with an indicator
showing clearly the Operating condition of the fuse:
. One position or color of the indicator when OK.
. Another position or color of the indicator when the fuse is blown.

5.7.10 Mechanical Presentation
Isolation transformers, surge arrestors and fuses shall be housed in
specific boxes or cabinets.

Boxes or cabinets shall be equipped with Two Nos. of isolation
transformers for two Protection triplets, surge arrestors and fuses for
54 pairs at both ends of the cable. "

Boxes or cabinets shall have a spare capacity equal to 25% of the
equipped capacity, Allowing easy connection of additional protection
components within this spare limit.

The Provision of 25% is to be offered only for space in the boxes or
cabinets, to accommodate extra-components in the future. Offer must
not include the extra components.

5.8 Surge Counters

5.8.1 Two (2) surge counters shall be provided to separately count ground
potential rise (GPR), occurring at the box installation site, and
longitudinal induced voltage (LIV), which attack the pilot cable box
experiences.

5.8.2 The surge counter case shall be made from steel sheet.



5.8.3 The dry batteries, which are housed inside the case, shall be
accessible for easy checking and replacement.

5.8.4 The counter input impedance shall be more than 300 kilo-ohms

5.8.5 Basic waveform shall be 10 microseconds square wave or 10 x 200
microseconds impulse wave.

5.8.6 Typical voltage operation range is shown below.

Position

GPR Surge
Counter (V)

LIV Surge
Counter (V)

1 100 30
2 200 60
3 400 100
4 600(700) 200
5 800(1000) 300
6 1000(1500) 400

5.8.7 The allowable input peak value shall be 2000 V for the GPR surge
counter and 600 V for the LIV surge counter.

5.8.8 Voltage tolerance shall be within 20%.

5.8.9 Minimum operation interval shall be after 3 seconds.

5.9 Cable Gland Plate

5.9.1 Two mild-steel cable gland plates shall be provided. These shall not
be drilled to accept cables unless specifically requested at the time of
order. All gland plates shall be of sufficient strength to prevent
distortion in use.

5.9.2 The top gland plate shall be of sufficient size to accommodate the
maximum number of multicore cable glands depending on the type of
box as follows: For pilot box with SEND END pilot supervision:
1 Cable gland for 7 core 2.5 mm
2
PVC/PVC/SWA/PVC cable for
protection. 2 Cable glands for 4 core 2.5 mm
2
PVC/PVC/SWA/PVC
cables for supplies.For pilot box with RECEIVE END pilot
supervision:1 Cable gland for 7 core 2.5 mm
2
PVC/PVC/SWA/PVC
cable for protection.In addition to the above, for each consumers
feeder which requires emergency tripping facilities, the top gland
plate shall also accommodate one cable gland for 4 core 2.5 mm
2

PVC/PVC/SWA/PVC 5kV insulated cable for the emergency tripping
push button or receive relay as appropriate.


5.9.3 The bottom gland plate shall be of sufficient size to accommodate one
cable gland for the 12 core 0.9 mm diameter PVC/PVC/SWA/PVC
5kV insulated pilot cable.

5.9.4 For a pilot box which is associated with two cable feeders, each gland
plate shall be of sufficient size to accommodate all the necessary
cables for both feeders in line with 5.9.2 and 5.9.3 above.

5.9.5 For a pilot box associated with a turnkey contract where all the cables
are accommodated in trunking requiring bottom entry, the requirement
for the top gland plate may be deleted. The bottom gland plate shall
then be suitable for all the cable entries with the pilot cables on the
right and the multicore cables on the left.

5.9.6 Adequate cable glands to suit the application shall be supplied as
loose equipment inside the box.

5.10 Terminal Blocks & Wiring

For Type-A

a) For each pilot wire protection, a vertically mounted group of 13
terminal blocks shall be provided which have a 5kV insulation level.
Each terminal block shall be fitted with an isolating plug link. A
shorting bar shall be fitted on the equipment side of the terminal blocks.

b) The group of 5kV terminals shall be mounted towards the bottom right
of the box and the lowest two terminal blocks shall be used for the pilot
wire protection pair. The 11 terminal blocks above shall be used for the
spare pairs of the pilot cable.

c) For each pilot wire protection a vertically-mounted group of 15 or 7
terminal blocks shall be provided for send end or receive end
supervision respectively. These terminal blocks shall be insulated to
2kV. The group of 2kV terminals shall be mounted towards the top left
of the box.

d) All terminals which are insulated to the 5kV or 2kV levels shall be
suitably shrouded.

e) All wiring which is directly connected to the pilot wires shall be
insulated to at least 5kV.

f) All other wiring shall be insulated to at least 2kV.


g) The 5kV insulated wiring shall be segregated from all other
wiring.

h) For send end pilot supervision, 8 of the 2kV terminals shall be
for AC and DC auxiliary supplies.

i) For send or receive end pilot supervision, 7 of the 2kV terminals shall
be for protection and alarm.

For Type-B
a) The terminal block shall be designed for 5-pair or less high insulation
terminal strip.

b) Insulation used for molding terminal strips shall be high insulating
grade material.

c) The terminals shall have soldering tag and terminal screw.

d) The soldering tag shall be provided with soldering plate with the other
ones nickel-plated.

e) Each terminal shall be identified with respect to its use by numbering
system as stated in the identification card in the print pocket at the rear
of the front doors.

f) The insulation resistance between the terminals of the terminal strip and
between line and earth shall be not less than 10,000 megohms when
tested with 500 V d.c.

g) The dielectric strength between the terminals shall be not less
than 5 kV a.c. at 60 Hz for 1 minute.

h) As mounted in the box, the dielectric strength between the terminals of
terminal block and earthing terminal of the cabinet shall be not less than
15 kV a.c. at 60 Hz for 1 minute.

i) The insulating plate, where the terminal blocks, surge arresters and
remote earthing terminal are mounted, shall be minimum of 10 mm
thickness and conforming that Insulating materials shall be non-
hygroscopic and resistant to tracking.

Also, the pilot cable will be terminated in suitable terminal blocks inside watertight
marshalling cabinets at each end in the tele-control room.

The pilot cable will be terminated in watertight marshalling cabinets having the
doors with hinged constroction&self.locking81TaIlgement, of hot dip galvanized as
to form an Extremely rigid structure having sufficient space for Seven Isolating
Transformers and



The marshalling cabinets will be suitable for wall mounting or for erection on
steelwork. They will be insect-proof and water-proof with degree of protection
IP55.Provision'Will be made for locking the doors of the marshalling cabinets in the
closed position.

The terminals blocks will have an insulated bridging plug, so as to allow a circuit to
be isolated. The plugs will be color coded and / or numbered according to the
appropriate cables connected therewith.
For pilot conductors, only approved compression lugs or washers will be used at the
terminals. All cable glands required for the terminals Will be supplied and installed.

The pilot cables will be sealed by compression-type armor gripping mechanical
glands. These glands will be provided with an earthing and PVC shroud.

5.11 Grounding

5.11.1 The main earth connection to the box shall be via an M10 brass earth
stud which protrudes through the base of the box. The earth stud shall be
supplied with washers and locking nuts etc., to permit an earth bond to be
made to the substation main earth.

5.11.2 All internal exposed metallic parts shall be effectively earthed to the
earth stud via a removable link which is mounted on a barrel insulator
rated at least 5kV. A small earthing strip shall facilitate multiple
connections.

5.11.3 Two wandering earth leads 6mm
2
multi-strand PVC cable colour green/
yellow shall be provided. Each shall be long enough to earth any pilot
cable core.

5.11.4 The cable gland plates shall be effectively earthed to the earthing strip by
35 mm2 copper connections with 5kV insulation.

5.11.5 Two (2)-earthing terminals shall be provided in the box. One earthing
terminal shall be for the station ground and the other earthing terminal
shall be for the remote ground. Station ground and remote ground are as
follows:

I. Station Ground :
Locations within and around the perimeter of the power
station, which has the same potential as the station,
ground mat or ground grid under normal and during
system fault conditions.


II. Remote Ground:
Physical locations away from the station ground where
the maximum expected ground potential rise under
system fault conditions is less than 300 V.

5.11.6 The remote earthing terminal shall be insulated from the box.

5.11.7 The earthing terminals shall be made of tin-plated copper.

5.12 Labelling

5.12.1 All labels shall be made out of laminated plastic which, unless
otherwise specified, shall be suitable for black letters on a white
background.

5.12.2 All labels shall be fixed to the appropriate surface using self-tapping;
screws and labels shall not be fixed to removable shrouds.

5.12.3 A label shall be fixed near the top of the door, which shall be at least
180mm x 50mm. The top line of text shall read 'PILOT WIRE
PROTECTION'. The second line of text shall read as appropriate:
PILOT ISOLATION SEND END BOX
or PILOT ISOLATION RECEIVE END BOX
or PILOT-ISOLATION SEND AND RECEIVE END BOX.

5.12.4 A label shall be fixed near the bottom of the door having red letters on
a white background and at least 190mm x 50mm. The text shall read:

CAUTION: CONNECTIONS SUBJECT TO HIGH VOLTAGES EARTH
PILOT CORES BEFORE HANDLING

5.12.5 On the centre of the door shall be fixed a label 150mm x 50mm. This
label shall be left blank so that it can be engraved by SEC after
erection on site to indicate the feeder number. In the case of a box for
two cable circuits, two labels as above shall be fixed on the door, one
on the left and one on the right.

5.12.6 Two further blank labels 75mm x 25mm shall be fixed to the internal
back plate, one on the left and one on the right, for engraving by SEC
following erection on site to indicate the feeder numbers. The location
of each label shall be chosen to maximize legibility and access,
having due regard to the layout of all the components on the back
plate and the necessary wiring.

5.12.7 Suitable labels shall be fixed adjacent to each group of terminal
blocks to identify their use.


5.12.8 Markers shall be permanently attached and made of material that will
not deform or deteriorate and capable of withstanding the maximum
service ambient temperatures.

5.12.9 The label shall be marked in English and Arabic with the following
information:

a. SEC Item Number
b. SEC Purchase Order Number
c. Reference to this SEC Specification
d. Termination Box for Pilot Cable, Pairs
e. Number of Pilot Lines
f. Number of Telephone Lines
g. Number of Spare Lines
h. Circuit Name
i. Manufacturer's Name
j. Manufacturer's Serial Number
k. Year of Manufacture
l. Gross Weight in kilogram

6.0 TESTS

All test results shall be provided for review and acceptance by SEC.

6.1 Type (Design) Tests

All design (type) tests prescribed in the relevant standards shall be performed on the
representative unit or on the first unit of every new design or rating to be supplied to
SEC. In lieu of the actual design (type) tests, certified test reports of design (type)
tests performed on an identical unit may be submitted to SEC for review and
approval during bidding stage.

6.2 Routine (Production) tests

6.2.1 Dielectric Strength Test: A test voltage of 15 kV at power frequency
of 60 Hz shall be applied to each type of protection device for 3
seconds as follows:

a. Protection Device for Telephone Line - The test voltage shall
be applied between remote ground terminal and station ground
terminal of the box.

b. Protection Device for Pilot Line - The test voltage shall be
applied between the line side terminals and the equipment side
terminals of the insulating transformer and between the line


side terminals of the transformer and the station ground

c. Protection Device for Spare Line - The test voltage shall be
applied between remote ground terminal and station ground

6.2.2 The following test voltage, discharge current and relaying signal shall
be applied simultaneously to the protection device for the pilot line
circuit to determine operation of relaying circuit during operation of
protection devices:

a. 15 kV a.c. for 3 seconds at 60 Hz between line side terminals
and equipment side terminals of the insulating transformer.

b. Discharge current of 50 A and 100 A with a suitable
voltage, between line side terminals and remote ground
terminal of the box. The test period for a discharge current of
50 A is 3 seconds while for a discharge current of 100 A is 1
second.

c. Square wave 100 Hz relaying signal of 50 V o-p.

6.2.3 The termination box shall be subjected to temperature rise test in
accordance with NEMA ICS 1.



7.0 DATA SCHEDULE

PILOT CABLE TERMINATION BOX

SEC Enquiry No. Date:

SEC Purchase Order
No.
Date:
or Contract No.

SEC PTS No./Project Title with J.O. No.

REFERENCE
SECTION NO. DESCRIPTION 'A' 'B' 'C'

5.0 FABRICATION

5.2 Enclosure

Degree of Protection IP 54


D.C. resistance per line () < 60

Transmission loss (dB) for
16 Hz, @ 70Vd.c. < 1.0

5.4 Insulating Transformer

Impedance () @ 100 Hz & 50 V Out Put *

Discharge current (between both ends and
center taps)

for 3 seconds (A) *
for 1 second (A) *

'A'- SEC SPECIFIED DATA/PARAMETER.
'B'- BIDDER/SUPPLIER/VENDOR/CONTRACTOR PROPOSED DATA/PARAMETERS.
'C'- REMARKS SUPPORTING THE PROPOSED DEVIATION IN COLUMN 'B'.
(*)- DATA/PARAMETER TO BE PROVIDED/PROPOSED BY THE BIDDER/SUPPLIER/
VENDOR/CONTRACTOR IN COLUMN 'B'.



7.0 DATA SCHEDULE


5.5 Surge Arresters

D.C. striking voltage (Vd.c) *
Surge striking voltage (V) *
AC Discharge current (A) *
Surge discharge current
8/20 s (kA)
10/50 s (kA)
D.C. Break down Voltage (V d.c)
(after life test) *

5.6 Surge Counters
Type GRP/LIV
Counters 2
Dry Batteries Yes/No
Input Impedance () > 300

ADDITIONAL TECHNICAL INFORMATION OR FEATURES TO BE FURNISHED BY
SEC:
A.

ADDITIONAL SUPPLEMENTARY DATA OR FEATURES PROPOSED BY
BIDDER/VENDOR/SUPPLIER/CONTRACTOR:
B.

OTHER PARTICULARS TO BE FILLED UP BY BIDDER/VENDOR/SUPPLIER/
CONTRACTOR:
B.



7.0 DATA SCHEDULE


Actual Manufacturer
of Equipment/Material
Vendor/Supplier/
Contractor

Name of the Company
Location and address

Name and Signature of
authorized
epresentative

and date

Official Seal/Stamp
of the Company &
Date

48 TMSS 03 R0

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