70670140-HVL 06-1353 2007-01-11

Tests on a 0,6/1 kV LV cable,

4x300 mm2, Al/XLPE/PVC
TEST REPORT

Report no. 70670140-HVL 06-1353

Client Egytech Cables - Elsewedy
PC. # 36A, South (A1), Industrial Region (A1)
10th Of Ramadan City
Egypt

Concerning tests
Date 18 October up to and including 22 November 2006
Place KEMA High-Voltage Laboratory, Arnhem, the Netherlands
Object 0,6/1 kV LV cable
2
Type 4x300 mm , Al/XLPE/PVC
Manufacturer Egytech Cables - Elsewedy, Egypt

REQUIREMENTS
The requirements as specified in the standard IEC 60502-1.

TEST PROGRAMME
For the test programme we refer to pages 2 and 3.

SUMMARY AND CONCLUSION

The results obtained relate only to the work ordered and to the material tested. The tests as mentioned
in the test programme were passed.

Author P.J. Hlkenberg KEMA Nederland B.V.

P.G.A. Bus
This report consists of: KEMA T&D Testing Services
21 pages Managing Director
1 appendix
Arnhem, 11 January 2007

Copyright: Publication or reproduction of the contents of this report in any other form than a complete copy to the letter, is not allowed without
our written consent.
Electronic copies in e.g. PDF-format or scanned version of this report may be available and have the status "for information only". The bound
version of this report is the only valid version.
Utrechtseweg 310, 6812 AR Arnhem. Telephone +31 26 3 56 31 85. Telefax +31 26 4 43 38 43
 70670140-HVL 06-1353

MATERIAL DATA

Manufacturer Egytech Cables - Elsewedy, Egypt

2
Type 4x300 mm Al/XLPE/PVC 0,6/1 kV
Year of manufacture 2006
No. of phases 4
Insulation XLPE
Conductor material sector shaped aluminium
2
Conductor cross-section 300 mm
Outer sheath material PVC (ST2)
Sheath colour black
Rated voltage 0,6/1 kV
Rated frequency 50 Hz
Standard IEC 60502-1 (2004)
Sampling procedure by the manufacturer

The manufacturer has guaranteed that the object submitted for tests has been manufactured in
accordance with the drawing as shown in appendix A of this report.
KEMA has verified that this drawing adequately represents the object tested.

TEST PROGRAMME

1 Electrical type tests

1.1 Insulation resistance measurement at maximum conductor temperature in accordance with
IEC 60502-1 (2004) clause 17.2
1.2 Voltage test for 4 h in accordance with IEC 60502-1 (2004) clause 17.3

2 Non-electrical type tests

2.1 Measurement of thickness of insulation in accordance with IEC 60502-1 (2004)
clause 18.1
2.2 Measurement of thickness of non-metallic sheaths in accordance with
IEC 60502-1 (2004) clause 18.2
2.3 Tests for determining the mechanical properties of insulation before and after ageing in
accordance with IEC 60502-1 (2004) clause 18.3
2.4 Tests for determining the mechanical properties of non-metallic sheaths before and after ageing
in accordance with IEC 60502-1 (2004) clause 18.4
2.5 Additional ageing tests on pieces of completed cables in accordance with
IEC 60502-1 (2004) clause 18.5
2.6 Loss of mass test on PVC outer sheath of type ST2 in accordance with
IEC 60502-1 (2004) clause 18.6
2.7 Pressure test at high temperature on non-metallic sheath in accordance with
IEC 60502-1 (2004) clause 18.7
 70670140-HVL 06-1353

2.8 Test on outer sheath at low temperatures in accordance with

IEC 60502-1 (2004) clause 18.8
2.9 Test for resistance of PVC outer sheath to cracking (heat shock test) in accordance with
IEC 60502-1 (2004) clause 18.9
2.10 Hot set test for XLPE insulation in accordance with IEC 60502-1 (2004) clause 18.11
2.11 Water absorption test on XLPE insulation in accordance with IEC 60502-1 (2004)
clause 18.13
2.12 Flame retardance test accordance with IEC 60502-1 (2004) clause 18.14
2.13 Shrinkage test for XLPE insulation in accordance with IEC 60502-1 (2004) clause 18.16

3 Verification of cable construction

3.1 Verification of cable construction in accordance with IEC 60502-1 (2004) clauses 5-13
3.2 Measurement of resistance of conductors in accordance with IEC 60502-1 (2004) clause 5

SUBCONTRACTING

The tests were subcontracted to KEMA Quality B.V.

PERSONS ATTENDING THE TEST

Neither the manufacturer nor the purchaser was represented during the tests.

THE TEST WAS CARRIED OUT BY

Mr R. van Daalen KEMA Quality B.V.

Mr A.A. Mackenbach KEMA Quality B.V.

PURPOSE OF THE TEST

Purpose of the test was to verify whether the material complies with the specified requirements.
 70670140-HVL 06-1353

DESCRIPTION AND RESULTS OF THE TEST

1 ELECTRICAL TYPE TESTS

The cable was subjected to the electrical type tests in accordance with clause 17 of
IEC 60502-1 (2004).
The results of the tests are presented in appendix 1.
The tests were passed.

2 NON-ELECTRICAL TYPE TESTS

The cable was subjected to all relevant non-electrical type tests in accordance with clause 18 of
IEC 60502-1 (2004).
The results of the tests are presented in appendix 2.
The tests were passed.

3 VERIFICATION OF CABLE CONSTRUCTION

The verification of the cable was carried out in accordance with clause 5 of IEC 60502-1 (2004).
The results of the tests are presented in appendix 3.
The tests were passed.
 70670140-HVL 06-1353

Appendix 1 page 1

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 17.2
Test period 20 October 2006

1.1 RESULTS OF THE INSULATION RESISTANCE MEASUREMENT AT MAXIMUM

CONDUCTOR TEMPERATURE IN NORMAL OPERATION

item unit requirement measured result

yellow blue black red
volume
resistivity
12
at 90 C .cm 10 6,07. 8,34. 7,23. 7,23. passed
14 14 14 14
10 10 10 10

insulation
resistance
at 90 C M.km 3,67 2226 3056 2648 2816 passed
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Appendix 1 page 2

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 17.3
Test period 18 October 2006

1.2 RESULTS OF THE VOLTAGE TEST FOR 4 H

Temperature 20C
applied voltage frequency duration observations result

(kV) (Hz) (h)

2,4 50 4 no breakdown passed

 70670140-HVL 06-1353

Appendix 2 page 1

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 18.1
Test period 9 November 2006

2.1 RESULTS OF THE MEASUREMENT OF THICKNESS OF XLPE INSULATION

item unit requirement measured/determined result

yellow blue black red

- nominal (average) mm 1,8 2,4 2,3 2,2 2,2 passed

- minimum mm 1,52 1,75 2,02 1,99 1,77 passed

 70670140-HVL 06-1353

Appendix 2 page 2

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 18.2
Test period 9 November 2006

2.2 RESULTS OF THE MEASUREMENT OF THICKNESS OF OUTER SHEATH

item unit requirement measured/determined result

- nominal (average) mm 3,0 3,2 passed

- minimum mm 2,45 2,77 passed

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Appendix 2 page 3

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 18.3
Test period 16 until 22 November 2006

2.3 RESULTS OF THE TESTS FOR DETERMINING OF THE MECHANICAL PROPERTIES OF

INSULATION BEFORE AND AFTER AGEING

item unit requirement measured/determined result

yellow blue black red

without ageing

- tensile strength N/mm 12,5 26,7 23,2 23,5 23,4 passed

- elongation % 200 357 332 327 335 passed

after ageing without

conductor 135C/7d.

- tensile strength N/mm - 22,9 21,1 22,2 20,7

variation with samples % 25 max. -14 -9 -6 -11 passed

without ageing

- elongation % - 315 306 308 311

- variation with % 25 max. -12 -8 -6 -7 passed

samples without
ageing
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Appendix 2 page 4

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 18.4
Test period 16 until 23 November 2006

2.4 RESULTS OF THE TESTS FOR DETERMINING OF THE MECHANICAL PROPERTIES OF

NON-METALLIC SHEATHS BEFORE AND AFTER AGEING

Outer sheath

item unit requirement measured/determined result

without ageing

- tensile strength N/mm 12,5 18,5 passed

- elongation % 150 261 passed

after ageing 100C/7days

- tensile strength N/mm 12,5 18,1 passed

variation with samples % 25 max. -2 passed

without ageing

- elongation % 150 254 passed

variation with samples % 25 max. -2 passed

without ageing
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Appendix 2 page 5

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 18.5
Test period 16 until 22 November 2006

2.5 RESULTS OF THE ADDITIONAL AGEING TESTS ON PIECES OF COMPLETED CABLES

Item unit requirement measured/determined result

yellow blue black red

insulation 100C/7days

- tensile strength N/mm - 25,0 20,5 19,5 22,1

variation with samples % 25 max. -6 11 -17 -6 passed

without ageing

- elongation % - 335 314 288 331

variation with samples % 25 max. -6 -5 -12 -1 passed

without ageing

outer sheath 100C/7d.

2
- tensile strength N/mm 12,5 18,1 passed

- variation with samples

% 25 max. -2 passed
without ageing

- elongation % 150 249 passed

- variation with samples

% 25 max. -5 passed
without ageing
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Appendix 2 page 6

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 18.6
Test period 9 until 17 November 2006

2.6 RESULTS LOSS OF MASS TEST ON PVC OUTER SHEATH OF TYPE ST2

item unit requirement measured result

- temperature C 100
- duration d 7
2
- loss of mass mg/cm 1,5 0,8 passed
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Appendix 2 page 7

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 18.7
Test period 17 November 2006

2.7 RESULTS OF THE PRESSURE TEST AT HIGH TEMPERATURE ON OUTER SHEATH

item unit requirement measured result

- temperature C 90
- duration h 6
- load N 13,5
- depth of indentation % 50 20 passed
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Appendix 2 page 8

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 18.8
Test period 9 November 2006

2.8 RESULTS OF THE TESTS ON OUTER SHEATH AT LOW TEMPERATURES

item unit requirement measured result

- temperature C - 15
- elongation % 20 > 225 passed
- temperature C - 15
- cold impact test no cracks no cracks passed
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Appendix 2 page 9

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 18.9
Test period 9 November 2006

2.9 RESULTS OF THE TEST FOR RESISTANCE OF OUTER SHEATH TO CRACKING

item unit requirement measured result

- temperature C 150
- duration h 1 passed
- soundness no cracks no cracks passed
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Appendix 2 page 10

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 18.11
Test period 13 November 2006

2.10 RESULTS OF THE HOT SET TEST FOR XLPE INSULATION

item unit requirement measured result

yellow blue black red
- temperature C 200
- elongation under load % 175 60 65 70 60 passed
- permanent elongation % 15 1 2 1 1 passed
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Appendix 2 page 11

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 18.13
Test period 8 November 2006

2.11 RESULTS OF THE WATER ABSORPTION TEST ON XLPE INSULATION

item unit requirement measured result

yellow blue black red
- temperature C 85
- duration h 14
2
- variation of mass mg/cm 1 0,04 0,06 0,02 0,05 passed
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Appendix 2 page 12

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 18.14
Test period 13 November 2006

2.12 RESULTS OF THE FLAME RETARDANCE TEST

item unit requirement measured result

- time flame application s 480

- length free of charring mm > 50 360 passed
- downward limit charred surface mm < 540 420 passed
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Appendix 2 page 13

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 18.16
Test period 8 November 2006

2.13 RESULTS OF THE SHRINKAGE TEST FOR XLPE INSULATION

item unit requirement measured result

yellow blue black red
- temperature C 130
- duration h 1
- shrinkage % 4 <1 <1 <1 <1 passed
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Appendix 3 page 1

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 5-13
Test period 17 November 2006

3.1 RESULTS OF THE VERIFICATION OF CABLE CONSTRUCTION

determinations remarks
marking of the cable ELSEWEDY CABLES EGYTECH 4x300mm
0,6/1 kV AL/XLPE/PVC
PROPERTY OF SAUDI ELECTRICITY

color of the cores yellow, blue, black, red

color of the outer sheath black

construction -4 sector shaped conductors consisting
48 aluminum wires each approx 2,6 mm, conductor
assembly 21-15-9-3
-XLPE insulation
-synthetic fibre filling
-synthetic tape wrapping
-outer sheath type PVC ST2
outer diameter of the
cable (mm) 59,6 average
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Appendix 3 page 2

Client Egytech Cables - Elsewedy, Egypt

2
Test object 4x300 mm Al/XLPE/PVC 0,6/1 kV power cable
Requirements IEC 60502-1 (2004) clause 5
Test period 16 November 2006

3.2 RESULTS OF THE MEASUREMENT OF RESISTANCE OF CONDUCTORS

item unit requirement measured/determined result

yellow blue black red

- resistance /km 0,100 0,096 0,093 0,092 0,093 passed

 70670140-HVL 06-1353

Appendix A

Drawing of

Egytech Cables - Elsewedy

of

0,6/1 kV cable,
4x300 mm2 AL/XLPE/PVC

(2 pages)
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