SECTION 16305

115 kV CROSSLINKED POLYETHYLENE (XLPE) CABLES

AND ACCESSORIES

REVISE BOLD ITALICIZED SENTENCES SUITABLY BY THE USER

AS APPLICABLE FOR THIS PROJECT. ALSO FILL IN DOTTED LINES.

PART 1 - GENERAL

1.1 DESCRIPTION OF WORK

A. The work includes design, manufacture, supply, installation, testing and

commissioning complete 115 kV cross-linked polyethylene (XLPE) cable system.
Cable configuration and routing shall be as indicated on contract drawings.

B. The cable system shall provide two parallel redundant circuits, each _ _ _ MVA
minimum, consisting of one/two conductors per phase and minimum conductor
size of _ _ _ _ mm2. This continuous power capacity shall be calculated for the
environmental conditions specified in the contract documents.

C. The cable system shall be installed in existing underground duct banks and
manhole system, and within substation in cable trays.

Or

The cable system shall be installed direct buried in concrete encased ducts at
road crossings and within substation in cable trays.

D. The supply of materials and equipment shall include the following:

1. Manufacturing and supply of 115 KV cables and all accessories.

2. Extension of duct banks from the existing stub outs. Modification of

duct banks when required by the existing conditions.

3. Implementation of manufacturer's standards and otherwise specified

quality control program for inspection and testing of products.

4. Sizing and application calculations for cables and accessories and

verification of al specified sizes and quantities

5. Preparation of design and shop drawings.

RCMYAS Guide Spec. 16305-1 Contract No.

Rev A, 27 Nov ‘05
 6. Preparation of installation detail drawings.

7. Preparation of Operation and Maintenance manuals.

8. Testing and certification of specification compliance for all products and

test reports.

9. Delivery of material and equipment to the site.

10. Special tools required for the initial installation and future maintenance.

11. Commissioning spare parts.

E. Installation of cable systems shall include the following:

1. All electrical, civil, structural and mechanical work.

2. Implementation of all manufacturer's standards and otherwise specified

quality control, inspection and testing procedures.

3. Field testing.

4. Commissioning and energization of complete cable systems.

5. Preparation of "As-Built" drawings including revision of existing

interface drawings (originals) to “As-built” condition.

F. The Contractor shall have installed cable systems using materials and equipment
comparable to those specified in these specifications and contract drawings and
that have been in service for at least 5 years and performing satisfactorily in
Saudi Arabia and Middle East countries having similar environment.

G. Related Work

Section 02200 Earthwork

Section 02814 Underground Electrical Power Distribution Duct Banks,
Manholes and Handholes
Section 16395 Fiber Optic Cables
Section 16450 Grounding

1.2 QUALITY ASSURANCE

A. Cable and accessories furnished in accordance with this specification shall

comply with the latest edition of the following applicable Standards and Codes.

RCMYAS Guide Spec. 16305-2 Contract No.

Rev A, 27 Nov ‘05
 1. Association of Edison Illuminating Companies (AEIC):

a. CG4 Guide for Installation of Extruded Dielectric Insulated

Power Cable Systems Rated 69kV through 138kV

b. CS7 Specification for Crosslinked Polyethylene Insulated

Shielded Power Cables rated 69kV through 138kV

2. American Society for Testing and Materials (ASTM):

a. B3 Soft or Annealed Copper Wire

b. B33 Tinned Soft or Annealed Copper Wire for Electrical

Purposes

c. B496 Compact Round Concentric-Lay-Stranded Copper

Conductors

d. D149 Test Methods for Dielectric Breakdown Voltage and

Dielectric Strength of Solid Electrical Insulating Materials
at Commercial Power Frequencies

3. Institute of Electrical and Electronics Engineers (IEEE):

a. 48 Standard Test Procedures and Requirements for High

Voltage Alternating Current Cable Terminations 2.5 kV
through 765kV

b. 442 Guide for Soil Thermal Resistivity Measurements

c. 575 Guide for the Application of Sheath Bonding Methods for

Single-Conductor Cables and the Calculation of Induced
Voltages and Currents in Cable Sheaths

d. 835 Power Cable Ampacity Tables

4. International Electrotechnical Commission (IEC):

a. 60228 Conductors of Insulated Cables.

b. 60229 Tests on Cable Oversheaths Which Have a Special

Protective Function and are Applied by Extrusion

c. 60287 Calculation of the Current Rating

RCMYAS Guide Spec. 16305-3 Contract No.

Rev A, 27 Nov ‘05
 d. 60332 Tests on Electric Cables under Fire Conditions

e. 60529 Degrees of Protection Provided by Enclosures (IP

Code)

f. 60811 Common Test Methods for Insulating and Sheathing

Materials of Electric Cables

g. 60817 Test Procedure for Flame-Retardant Coatings Applied

to Insulated Cables in Cable Trays

h. 60840 Tests for Power Cables with Extruded Insulation for

Rated Voltages above 30 kV up to 150 kV

i. 60859 Cable Connections for Gas Insulated Metal Enclosed

Switchgear for Rated Voltages of 72.5kV and Above

5. Conférence Internationale des Grandes Réseaux Electriques (CIGRE) :

a. WG07 Guide to the Protection of Specially Bonded

of SC21 Cable Systems Against Sheath Overvoltages

6. National Electrical Safety Code (NESC)

7. Royal Commission Electrical Code (RCEC). Use the National Electrical

Code (NEC)

B. Any conflict between this specification and the referenced standards and codes
shall be brought to the attention of the Royal Commission for written resolution.

C. Contractor may, upon the approval of the Royal Commission, use other
standards and publications, the use of which will result in products of comparable
or better quality than that specified. The Contractor shall submit a copy of the
applicable sections of the other standards in the English language for review by
the Royal Commission.

1.3 SUBMITTALS

A. Test Reports: Submit test reports and certification of all manufacturer factory
tests. Test reports shall show compliance with applicable standards. Submit
field test plans and field test reports. All test reports shall be in English language.

B. Design and Shop Drawings. Submit for review the following as a minimum:

RCMYAS Guide Spec. 16305-4 Contract No.

Rev A, 27 Nov ‘05
 1. One line diagram showing the source and destination (from-to) cable type,
size and cable tag number.

2. Three line diagram of the entire route physically oriented, showing

transposition, cross-bonding and shield grounding.

3. Complete routing layout. Site routing layouts and the related underground
installation elements shall be shown on civil drawings.

4. Cable tray layout within Substation identifying cable locations with tag
numbers.

5. Location of splices and cross bonding.

6. Arrangement of joint bays and link boxes.

7. Installation details for items such as grounding, transposition, single-point

bonding, cross-bonding, splices, terminations, supporting and training
cables in manholes and in substation.

8. Location of route markers and joint markers of direct buried runs.

9. Duct bank, trenching and backfilling including duct sections identifying

cable locations and tag numbers including the fiber optic cables.

10. Road Crossing details.

11. Modifications to existing manholes, ductbanks, cable trays and other

routing facilities. This information shall be shown by revising original
existing drawings.

C. Calculations. Submit the following calculations:

1. Cable sizing/ampacity calculations. For these calculations use the

following criteria and the calculation methods of IEEE Std 835 and IEC
60287. For direct burial consider that the soil will dry-out when the soil
reaches its critical temperature due to high cable temperature (90oC
conductor).

a. Air temperature = 40°C average with 50°C

maximum in any 24 hour
period

b. Earth temperature = 40°C

RCMYAS Guide Spec. 16305-5 Contract No.

Rev A, 27 Nov ‘05
 c. Existing undisturbed = 200 K. cm/w
earth thermal resistivity (RHO)

d. *50°C isotherm limit between the outer surface of duct bank and
the selected backfill with maximum 1% moisture.

e. *Selected thermally stable (stabilized) backfill material shall be

used in the trench for direct buried cables. Stabilized backfill
material thermal resistivity shall be determined for a dried-out state,
i.e., zero percent moisture. The determination of thermal resistivity
shall be by laboratory testing of samples of the proposed backfill
material.

f. *Selected backfill thermal resistivity shall be less than 200K cm/W.

Selected stabilized backfill thermal resistivity can be used as a
design means to improve cable ratings under installed conditions.

g. Load factor = 1.0

* Contractor shall verify by laboratory tests of soil samples. Test procedure

shall be per applicable IEEE and IEC standards. Final cable ampacity
calculations shall be based on actual backfill test results. Contractor
shall determine the physical extent of the 50°C isotherm, or consider
oven dry (0% moisture) selected thermally stable (stabilized) backfill
(RHO) throughout.

2. Calculations of induced voltages and currents in cable sheaths and in the

armor of fiber optic cable, under normal and short-circuit conditions in
accordance with IEEE Std 575 and CIGRE Report by Working Group 07
of Study Committee 21 to back-up the shield bonding method.

3. Cable pulling tension and side wall pressure calculations.

D. Product Data: Submit manufacturer’s data sheet and catalog material for
cables and all materials furnished.

E. Specification Analysis: Changes or additions to this specification, together with

the reasons for the suggested departures from this specification, when the
Contractor believes that equally good, better or more suitable product could be
furnished.

F. Samples: Submit samples of cable tags and other material samples when
requested or when convenient for expediting approval.

RCMYAS Guide Spec. 16305-6 Contract No.

Rev A, 27 Nov ‘05
 1.4 TRAINING

A minimum of two (2) weeks training shall be provided for installation,

commissioning, maintenance and operation of the high voltage cables for
not less than three Royal Commission personnel.

PART 2 - PRODUCTS

2.1 CABLE-GENERAL

A. Cable shall be single core copper conductor with cross-linked polyethylene

(XLPE) insulation. Cable shall be suitable for use on 115 kV + 10 percent, three
phase, 60 Hz, solidly grounded system, with a three phase and line to ground
fault capability of 40 kA rms symmetrical, 60kA rms symmetrical. Cable shall
have a minimum BIL rating of 550 kV.

B. Cable sizing shall be done by the Contractor taking into account the specified
load capacity requirement, loading, shield grounding, mode of installation and the
criteria stated in 1.3 C.1.

C. Cables shall be manufactured free from patches, flat spots, and other faults.

D. Shipped cables shall not contain any repairs to correct faults. Cables with
repaired defects will not be accepted by the Royal Commission.

E. Cables shall be round.

F. Cables shall be suitable for use in wet and dry locations, indoors and outdoors, in
cable trays, in trenches, in underground ducts and for direct burial. Cable
construction shall be moisture impervious, longitudinal and radial.

G. Cables shall be suitable for storage outdoors in direct sunlight.

2.2 CONDUCTOR

A. Conductor shall be annealed stranded copper in accordance with ASTM B3 and

ASTM B33 for coated and uncoated respectively. Conductor shall be compatible
with the conductor screen.

B. Conductor shall be compact-round construction in accordance with IEC 60228

Class 2 and ASTM B496.

C. Conductor shall be sealed by either swelling material or filling compound

between conductor strands to prevent longitudinal water penetration.

RCMYAS Guide Spec. 16305-7 Contract No.

Rev A, 27 Nov ‘05
2.3 CONDUCTOR SCREEN

A. Conductor screen shall consist of a black thermosetting, extruded, supersmooth,

semiconducting material that is applied to and completely shields the conductor.
Conductor screen material shall be compatible with insulation and conductor
materials and have a dc volume resistivity not in excess of 100,000 ohm-
centimeters at 90o C. Temperature ratings shall be equal to or greater than those
of the insulation. Conductor screen shall be uniformly and firmly bonded to the
overlying insulation and shall be free-stripping from the conductor.

2.4 INSULATION

A. Insulation shall be super-clean, high-quality, thermosetting, crosslinked

polyethylene (XLPE) unfilled homopolymer.

B. Insulation thickness shall conform to the requirements in AEIC CS7. Average

insulation thickness shall not be less than 20.3 mm with an eccentricity of not
more than 12 percent. Thinner insulation thickness is permissible, providing that
the electrical stress at the conductor shall not exceed 8 kV/mm.

C. Insulation shall be suitable for a continuous conductor temperature of 90o C, an

emergency conductor temperature of minimum 105oC and maximum of 130oC
and conductor short circuit temperature of 250oC.

D. Insulation material shall be inspected for contaminants using a continuous

sampling plan. The manufacturing process used for insulation curing shall be dry
cure using heated inert gas. Steam curing is not acceptable.

E. The extrusion process shall be one that extrudes the inner and outer semi-
conducting screens, together with the insulation layer in one single simultaneous
operation (true triple extrusion process).

2.5 INSULATION SCREEN

A. The insulation screen shall consist of a black thermosetting, supersmooth,

semiconducting material compatible with all cable components with which it is in
contact and having a dc volume resistivity not in excess of 50,000 ohm-
centimeters at 90ºC.

B. Insulation screen shall be bonded firmly and continuously to the underlying

insulation. The interface between screen and insulation shall be smooth.

C. The extruded shield shall be readily distinguishable from the insulation and
plainly identified as semiconducting.

RCMYAS Guide Spec. 16305-8 Contract No.

Rev A, 27 Nov ‘05
 D. Insulation screen shall be removable (strippable) for terminating and splicing
cables. When the insulation screen is removed, the surface of the insulation
shall be left smooth and undisturbed. Sanding shall not be required to remove
residual screen material. Insulation screen temperature ratings shall be equal to
or greater than those of the insulation.

2.6 WATER BARRIER

A. Provide a longitudinal water barrier of semi-conducting material over the

insulation screen (under the metallic shield). The material can be water swelling
tape.

B. There shall be no water between the insulation shield and jacket.

2.7 CABLE METALLIC SHIELD

A. Shield design shall include longitudinally folded copper polyethylene laminated

(encapsulated) with water-tight sealed overlap. As an alternate, shield design
shall include copper wire polyethylene laminated.

B. Shield cross-sectional area shall be adequate to withstand short circuit of 40kA,

60kA for 1.0 second maximum duration without exceeding a temperature of
250ºC after continuous operation at 90ºC conductor temperature.

C. Copper shield shall be laminated (encapsulated) into to the cable jacket during
extrusion.

D. The laminated shield shall be a radial water-tight barrier.

2.8 JACKET

A. Jacket shall be either medium or high density polyethylene (MDPE or HDPE)

meeting ICEA requirements for jacket material. Jacket shall be resistant to
abrasion, oil, and weather including direct sunlight. The color of the jacket shall
be black.

B. Cables in exposed areas such as inside substations, switchyards and manholes,

shall have flame retardant characteristics due either to jacket materials tested per
IEC 60332, or coatings applied to jackets after cables are installed. Flame
retardant layers or coatings shall be halogen-free. The use of a flame retardant
paint or coating is acceptable provided that the coating does not reduce cable
ampacity and complies with IEC 60817.

C. The non-conductive jacket shall have a conductive outer covering such as a

coating of graphite that is applied by simultaneous extrusion. The conductive

RCMYAS Guide Spec. 16305-9 Contract No.

Rev A, 27 Nov ‘05
 covering/coating shall permit jacket tests in the factory, during installation and
throughout the cable service life. The coated jacket shall be capable of
withstanding a DC voltage test of 10kV for one minute for jacket thicknesses of
2.5mm or greater.

D. The jacket shall be insect and rodent repellant.

2.9 IDENTIFICATION

A. The following information shall be durably and clearly embossed or printed

(white) at approximately two (2) meter intervals on the cable jacket for the entire
length of the cable:

1. Manufacturer's name
2. Year of manufacture
3. 1/C copper and size (-- mm2)
4. Type of insulation (XLPE)
5. Nominal insulation thickness
6. 115 kV
7. BIL - 550 kV (minimum)
8. Power cable symbol (lightning bolt) per NESC (Rule 350)

2.10 PACKAGING

A. Cables shall be shipped on substantial non-returnable reels and suitably covered

to protect cables from damage during transit and storage at the jobsite. As a
minimum, reels shall be constructed in accordance with AEIC CS7.

B. Only one continuous (without splices) length of cable shall be shipped on a reel.
Both ends shall be waterproof sealed, secured and protected from damage.

C. Both ends shall be available for testing the cable on the reel. The conductor on
the leading end of the cable shall be fitted with a test lead to allow jacket tests
and with a pulling eye.

D. Contractor shall assume full responsibility for any damage sustained due to
improper packing, sealing, or blocking of the reels during transit to the jobsite.

2.11 REEL MARKINGS

A. The following data, in addition to any further data required by AEIC CS7 shall be
clearly and permanently branded or stamped on metal tags on each side
(outside) of each reel flange:

1. Manufacturer's name.

RCMYAS Guide Spec. 16305-10 Contract No.

Rev A, 27 Nov ‘05
 2. Purchaser's name.

3. Destination.

4. Contract Number.

5. Length of cable (meters) on reel.

6. Voltage rating.

7. Maximum pulling tension.

8. Complete description of cable (e.g., size, type, and thickness of

insulation/jacket).

9. Reel number.

10. Shipped weight of cable and reel.

11. Net Weight

B. A durable corrosion resistant tag containing the same information shall be

fastened to the leading end of the cable.

C. An arrow shall be painted on each reel flange to indicate direction of rotation for
unreeling.

2.12 SPECIAL BONDING

A. Provide cross bonding, single point bonding, solid bonding to neutralize

induced voltage and minimize losses. Bonding method shall be in accordance
with IEEE Std 575 and CIGRE Report by Working Group 07. Link boxes shall be
provided.

B. Link boxes shall be constructed of corrosion resistant materials such as stainless

steel, aluminum or fiberglass. Link boxes shall also be watertight, IP67 in
accordance with IEC 60529, suitable for installation in ground, manholes or
indoors on racks. For direct buried cable installations link boxes shall be
installed in reinforced concrete handholes.

C. Links boxes shall be of two types: direct earthing and equipped with surge
limiters.

D. Permanent warning labels shall be mechanically attached to the link box covers.
Labels shall be laminated plastic with white letters on a red background. The

RCMYAS Guide Spec. 16305-11 Contract No.

Rev A, 27 Nov ‘05
 wording shall be in both English and Arabic and shall read: "DANGER - HIGH
VOLTAGE".

E. Plain annealed circular stranded compacted copper conductor according to IEC

228 Class 2, XLPE insulation rated 1kV, copper wire and tape screen, graphite
coated MD or HD jacket type concentric cable shall be used for connections
between joints and link boxes. The short circuit capacity of this cable shall be
same as the 115kV cables.

F. Connections to ground rods shall use bare lead-sheathed copper conductors.

G. Ground continuity conductor applications shall be in accordance with IEEE Std

575.

2.13 SURGE VOLT LIMITERS (SVLs)

A. SVLs shall be provided in link boxes to protect the cable jacket, shield, screens
and insulated gaps of sectionalizing joints.

B. Characteristic and ratings for SVLs selected by the Contractor shall be based on
shield (metallic sheath) calculations for induced voltages and guidelines in
CIGRE Report by Working Group 07.

C. There shall be no link boxes with SVLs at Substation GIS end of cable run.

2.14 CABLE TERMINATIONS AND JOINTS

A. General Requirements:

1. Terminations and joints when subject to fire shall be self-extinguishing and

nonpropagating.

2. Terminations and joints shall match the voltage, continuous current, short-
circuit current and BIL rating of the cable. Also, terminations and joints
shall match the electrical, thermal and mechanical properties of the cable
for emergency and short circuit conditions. The dielectric geometry of the
terminations and joints shall be compatible with the cable.

3. Electrical shielding at terminations and joints shall be designed to control

electrical stresses due to all normal and abnormal conditions. Stress
distribution shall preclude ionization and corona discharge within the
terminations and joints.

4. Electrical shielding and grounding shall drain-off electrostatically induced

voltages and induced voltages due to charging currents, leakage currents

RCMYAS Guide Spec. 16305-12 Contract No.

Rev A, 27 Nov ‘05
 and switching surges. Electrical shielding and grounding shall ensure
safety of personnel working on or near primary cable accessories.

5. Termination and joint installation shielding design shall maintain required

cable performance capabilities during short circuit conditions.

6. Terminations and joints shall have nontracking exterior surfaces and shall
be suitable for operation under severe external contamination and
environmental pollution.

7. Terminations and joints shall be environmentally sealed and capable of

preventing the ingress of moisture and contamination.

B. Provide complete termination equipment and materials including cable sealing

ends. The cable sealing ends shall match the cable end units manufactured
by SF6 switchgear manufacturer and outdoor transformer oil-filled
termination boxes manufactured by transformer manufacturer, all in
compliance with IEC 60859.

C. Provide prefabricated cable termination and premolded joint kits. Kits shall be
suitable for the environment in which they are installed and shall be designed to
protect against mechanical damage, corrosion and ingress of moisture.

D. Terminations of silicon oil filled type shall have a compensation tank with either
sight glass or with level gauge and copper connected tubing.

2.15 SPECIAL TOOLS

A. Contractor shall furnish one set of all custom made (special) installation tools
necessary to make the following:

1. Complete cable joints and terminations

2. GIS cable end unit degassing/regassing and

3. Bushings to allow dielectric testing of each cable one at a time.

B. Installation tools shall be fully detailed by the Contractor.

2.16 MISCELLANEOUS MATERIALS

A. Cable tags shall be of non-corrosive material such as lead. Tags shall be

resistant to moisture, heat, oil and flame. Tags located exposed outdoors shall
also be resistant to environmental conditions including ultra-violet radiation.
Exposure to heat or sunlight shall not cause relaxation of embossed lettering.

RCMYAS Guide Spec. 16305-13 Contract No.

Rev A, 27 Nov ‘05
 Cable numbers on tags shall be the same as on drawings and cable schedules.

B. Cable clamps and clamp assembly materials shall be capable of withstanding

electromagnetic forces produced by a peak short circuit current of 100 kA.
Clamp assembly materials shall be rated for the environment in which they are
installed. In substations, manholes and in covered trenches, use porcelain
saddles and stainless steel cable hangers unless cables are installed in cable
trays.

C. Refer to Section 16450 for grounding requirements.

D. Provide transport, haulage equipment, complete tools, lifting tackle, pumps, cable
trailers, cable rollers, cable stockings, pulling eyes, winches, mechanical
rammers, hand rammers, steel plates, caution notice boards, red warning lamps,
fencing, lighting, guarding, and other apparatus necessary for the work.

2.17 STORAGE AT JOBSITE

A. Store cable outdoors in a secured area. The Contractor shall give consideration
to worst case environmental conditions and shall provide adequate protection for
all materials. If required, sunshades shall be provided by Contractor.

B. Contractor shall also identify and provide any other special requirements to
maintain cable terminations and joints in the as-shipped condition.

2.18 FACTORY TESTS

A. General:

1. Perform complete factory tests on all cables, termination and joint kits
prior to shipment to demonstrate to the Royal Commission that the cables
and accessories furnished meet the requirements of this Specification.
Tests shall be in accordance with the applicable standards listed in
Section 1.2 and the requirements below. Prior to start of fabrication, the
Contractor shall submit for Royal Commission approval a complete listing
of all routine tests to be performed and type tests to either be performed or
certified. The listing should clearly specify the test criteria and the
methods of sampling and testing. The cable and termination and joint kits
shall not be shipped unless results of tests show compliance with all
requirements of this Specification.

2. Factory tests prescribed by this specification are to be made at the

expense of the Contractor. Test specimens shall be furnished by the
Contractor.

RCMYAS Guide Spec. 16305-14 Contract No.

Rev A, 27 Nov ‘05
 3. In the event of failure of any cable or joint/termination kit to meet the test
requirements, the Contractor shall replace the defective items at his
expense.

4. The Royal Commission reserves the right to witness all tests. Contractor
shall provide written notification to the Royal Commission at least four (4)
weeks in advance of test date. The notice shall include an outline of
procedures to be used in performance of tests. This outline shall include a
brief description of the test equipment, connection diagrams, proposed
test sheets, calculations and minimum/maximum test and performance
values which will be used to determine conformance with the specification
and applicable standards. The cable and termination/joint manufacturer
shall not proceed with the tests until a Royal Commission representative
arrives or until receipt of written notification that the Royal Commission
has elected to waive witnessing a particular test.

5. The Contractor shall maintain a file of all test reports which shall be fully
auditable and accessible to the Royal Commission.

6. Manufacturer's tests, as well as all tests required by the applicable

standards, shall be performed. Tests listed below are representative only
and do not constitute all the required tests.

B. Type Tests - Cable:

1. Perform type tests on cable in accordance with either the “Qualification

Tests” of AEIC CS7 or with the "Type Test" requirements of IEC 60840 for
the size and voltage rating specified and provide test certificates.

2. The Royal Commission may at its own discretion, waive the type test,
provided the Contractor has performed these tests on identical equipment
which are substituted by available certificates. These certified test data
may be submitted in lieu of performing the Type Tests.

C. Routine Tests - Cable:

1. Routine tests shall be performed in accordance with the procedures

specified in applicable sections of the latest revisions of specified AEIC,
ICEA, IEEE and IEC Standards.

2. In addition to visual inspection, the following tests are to be performed on

each reel of completed cable.

RCMYAS Guide Spec. 16305-15 Contract No.

Rev A, 27 Nov ‘05
 a. High-Voltage AC Test: Standard tests in accordance with IEC
60840 shall be performed. The cable shall withstand this test
without breakdown of the insulation.

b. Insulation Resistance Test: Cables shall be subjected to an

insulation resistance test immediately following the high voltage AC
test.

c. Conductor Resistance Test: The standard test shall be performed

on each reel in accordance with IEC 60228 and IEC 60840.

d. Partial Discharge Test: Test method per either AEIC CS7 or IEC
60840 for the specified cable voltage class.

e. Electrical test of jacket: Test in accordance with IEC 60229.

D. Tests - Terminations/Joints:

1. Design Tests: The following tests as well as the manufacturer's standard

design tests shall be performed on terminations and joints that accurately
represent the actual terminations being furnished. Certified test reports of
previously tested terminations/joints identical to those being supplied
under this contract may be submitted.

a. Applicable design tests required per IEEE 48.

b. The dielectric breakdown strength of the termination and joint

materials shall be determined in accordance with ASTM D149.

2. Routine Tests: Applicable routine tests required by IEEE 48 as well as

manufacturer's standard routine tests shall be performed.

E. Test Reports:

1. The Contractor shall submit four (4) copies of certified reports of all
routine, type and special tests performed, including those specified herein.
The report for each test shall include the date of performance, the name of
the company and the signature of the person in charge of the test.
Approval is required prior to shipment of the cables and termination
materials.

RCMYAS Guide Spec. 16305-16 Contract No.

Rev A, 27 Nov ‘05
PART 3 - EXECUTION

3.1 INSTALLATION OF 115 kV CABLE SYSTEM

A. Cables:

1. Cables shall be installed in flat formation per the approved design and
shop drawings. Guidelines specified in AEIC CG4 and IEEE Std 575 shall
be followed.

2. Cable systems shall be installed, tested and commissioned under the

supervision of the cable manufacturer's representative.

3. Provide and install all raceways, cable trays, materials, cable supports and
cable fasteners as required. Cable support system shall include special
raceways and support provisions for routing of cable to switchgear and
transformers inside substation building. The cable support systems shall
be grounded.

4. The cable system installation shall include the fiber optic cables specified
in Section 16395.

B. Indoor and above ground cable installation requirements include the following:

1. Cable, link box, oil compensation tank and earth bonding installations in
Substations shall be coordinated with facility designs.

2. Cable shall be clamped or tied down with non-magnetic materials at least

at every 1.0 meter when laid horizontally in trays and at every 1.5 meters
for vertical arrangement. Provide a minimum 2.0 meter of slack on cable
before termination to the switchgear by using a vertical wave or “S” shape
to allow one future termination. Bends in cable shall comply with
manufacturer’s recommendation for bending radius. In manholes, cable
shall be laid one conductor per supporting arm.

3. Cable support hardware shall be stainless steel unless otherwise

approved by the Royal Commission.

4. Cable in sleeves penetrating substation walls below grade shall be

installed with sealing bushing as specified in Section 02814.

5. Cable penetrations through substation interior walls and floors shall be

provided with environmental seals and fire stop barriers. Types of barriers
proposed shall be submitted to Royal Commission for approval.

RCMYAS Guide Spec. 16305-17 Contract No.

Rev A, 27 Nov ‘05
 6. A grounding conductor shall be run along each cable tray and shall be
bonded to the trays at intervals not exceeding 2 meters.

7. Cable splices are not permitted within substation building.

8. Each cable shall be identified with cable tags at each end and at 5 m
intervals in cable trays

9. Provide warning sign at SVLs at transformer end to alert personnel

for hazard due to voltage rise in cable shield.

C. Underground cable installation requirements include the following:

1. Installation work shall not start before engineering and design work has
been approved.

2. Road crossings shall be in concrete encased ducts. Road crossing ducts

may be filled with bentonite if required to improved heat transfer and cable
rating. Seal duct ends to prevent leaks and to retain moisture in bentonite.

3. Cable shall be direct buried and in concrete encased duct bank and
manhole system in accordance with Section 02814.

4. Trench designs shall be based on soils data obtained by the Contractor.

5. Material excavated from trenches shall be placed so as to prevent

obstruction of traffic or any other unsafe situation. Where this is not
possible, the excavated material shall be removed from the site and then
returned if approved for refilling the trench on completion of cable laying.

6. In the event of slippage or sliding of the trench side or excavated material

into the trench, this material shall be removed and the area made safe
before resuming work. The Contractor shall keep trenches free of water.

7. Cables shall preferably be installed below obstructions such as water

mains, sewer, storm drains and other utility crossings crossing the trench
and be provided with adequate vertical separation from all obstructions.
Cables shall cross above seawater piping.

8. Where possible, provide a maximum vertical separation of 500 mm for

pipes less than 1000 mm diameter and larger and a minimum of 300 mm
for pipes less than 1000 mm diameter. When these requirements cannot
be met, provide encasing of utility crossings or install concrete encased
duct. Design crossings on a case to case basis. Concrete encased duct
shall be designed such that the required cable ampacity rating is not

RCMYAS Guide Spec. 16305-18 Contract No.

Rev A, 27 Nov ‘05
 reduced. The removal, alteration or diversion of water mains, sewers,
storm drains and other utilities shall normally be avoided.

9. Splice and cross bonding link box locations shall be determined by the
Contractor and shown on plan and profile routing drawings. Locations
shall be approved by the Royal Commission. Provide lean concrete
working surface with cable supports before starting splicing or cross
connecting. Cross bonding boxes shall be located to economize on
corridor width usage.

10. Provide a minimum of 2.0 meters of slack in each cable on each side of
joints. Provide this slack by using a horizontal wave or “S” shape laying
configuration adjacent to the joint to allow one future joint. In manholes,
provide this slack using additional supports to obtain vertical wave
or “S” shape. Bends in cable shall comply with manufacturer’s
recommendation for bending radius.

11. Backfill material layering shall be coordinated with placement of cables

and associated equipment such that completed installations comply with
vertical and horizontal dimensions shown on contract drawings. Refer to
Specification Section 02200 for compaction requirements.

12. Provide selected thermally stable (stabilized) backfill material around

direct buried cables that has been tested in laboratory for oven dry
condition (no moisture) and with thermal resistivity used in calculations.
Selected backfill shall extend as a minimum up to the warning tape level.

13. Selected backfill material shall have the consistency of sand having typical
particle size ranging between 0.05 mm and 5 mm with approximately even
distributions of 50 percent of the material in the 0.05 mm to 0.7 mm range
and 50 percent in the 0.7 mm to 5 mm range.

14. Ordinary backfill shall extend from warning tape level up to the finished
grade. Ordinary backfill material can be obtained from the native soil. It
shall not have more than 10 percent stone and the largest size stone shall
not exceed 15 mm.

15. Concrete slabs and warning tapes shall be located in the trench as shown
on contract drawings. The warning tape shall be bright orange colored
plastic at least 300 mm wide by 0.1 mm thick and laid continuously over
each cable circuit for the length of the route. The tape shall be indelibly
marked with black lettering in English and Arabic with the words:

RCMYAS Guide Spec. 16305-19 Contract No.

Rev A, 27 Nov ‘05
 CAUTION CAUTION CAUTION
CHECK CABLE 700 mm BELOW

Care shall be taken to ensure the complete continuity of such tape, and to
avoid displacement of the tape during backfilling.

16. Each cable shall be identified with cable tags at the ends, at joints, at
route marker locations and at the walls in manholes and substation
building.

17. Direct buried cable routes shall be marked by precast concrete markers.
Straight route markers shall be at 50 m intervals staggered on both sides
of the trench. Bends in the route shall be marked with additional markers.

18. Joint locations for direct buried cable shall be marked with precast
concrete markers placed vertically above the center of each joint set.

19. Cable marker shall have a stainless steel or aluminum plate affixed to the
top and embossed or stamped and painted with the words “HIGH
VOLTAGE CABLE”, in Arabic and English, plus the kV rating. The word
“JOINT” shall be added on plate for joint markers.

D. Terminations:

1. Contractor shall provide all cable termination kits to complete the cable
terminations in the switchgear and transformers.

2. Where cables enter the equipment from below the termination point, they
shall be supported by approved grips. Where conductors emerge from the
conduit and cable tray, they shall be neatly formed and trained to the point
of termination. All conductors shall be securely supported within a
maximum of 900 mm from the point of termination to avoid stressing the
bus to which the cable is connected. Where cable supports are not
supplied with the equipment, they shall be provided by the Contractor and
shall be of galvanized or stainless steel with porcelain cable clamps,
aluminum straps, or as otherwise approved by the Royal Commission.

E. Splices:

1. Splices shall be located in manholes or be buried for direct burial cables.

2. The number of splices shall be kept at a minimum.

3. In manholes, supports shall be provided within 150mm from each end of

the cable splice.

RCMYAS Guide Spec. 16305-20 Contract No.

Rev A, 27 Nov ‘05
 F. Additional Requirements:

1. Masking tape or other material stuck or glued to the exterior of switchgear

or other equipment for the purpose of recording cable pulling and
terminating status will not be permitted.

2. The power cable shield shall be grounded in accordance with the shield
bonding plan. Each cable shield shall be checked for continuity.

3. All cables shall be tested out prior to connection to equipment to

determine that they have been correctly installed. Immediately after
ringing out, each cable shall be identified at both ends.

3.2 SITE TESTS

A. The complete cable system shall be tested. Tests shall be carried out by the
Contractor in accordance with Royal Commission approved test
plans/procedures to ensure that cable and accessories comply with
specifications and operational requirements. Tests shall be in accordance with
IEC 60229, IEC 60811 and IEC 60840. The Contractor shall furnish all test
equipment and accessories including test bushings. Valid calibration certificates
for all test equipment shall be provided.

B. At least 8 weeks prior to testing, test plans and procedures shall be prepared by
the Contractor and submitted for Royal Commission approval. Test procedures
shall contain descriptions of test equipment, descriptions of the tests and
minimum/ maximum test and performance values conforming to applicable
standards. Tests shall be witnessed by the Royal Commission representative.

C. The following tests shall be performed:

1. Polarization Index (PI) Test: Perform PI test on each cable before high
voltage test. PI test is the ratio of megger values at ten and one minute
using a 10kV megger. Acceptable value shall be more than 2.

2. High Voltage DC Test: To check insulation and termination integrity after

splicing and terminating, each cable shall be tested individually for 15
minutes with 200kV DC test voltage applied between the conductor and
metallic shield. The cable shall withstand this test without breakdown of
insulation. Perform tests after total installation is complete, just prior to
connection to switchgear or after connection to switchgear but with line
disconnect and /or links open. Prior to the test, either calculate or obtain
from cable manufacturer the value of expected leakage current for
environmental conditions prevailing in Yanbu. Measured leakage current
exceeding the expected leakage current at 200kV DC will not be

RCMYAS Guide Spec. 16305-21 Contract No.

Rev A, 27 Nov ‘05
 acceptable. Verify the linearity and rate of change at leakage current at
each voltage step by plotting “leakage current” vs “applied voltage” and
“leakage current vs “time curves”.

3. As an alternate to high voltage test, test with AC at 160 kV for 30 minutes

per IEC will be acceptable.

4. Insulation Resistance Tests: Tests shall be made using a 10 kV megger.

Tests shall be made with the cable on reel and before and after the high
voltage DC test. Insulation resistance readings before and after high
voltage tests shall be within 10 percent of each other. Cables shall be
energized within 96 hours from cable megger test. Megger test shall be
repeated when the lapse is more than 96 hours.

5. Conductor resistance: Perform tests after cable installation and prior to

connection. Readings shall be comparable with the factory test results.

6. Thermal resistivity of selected stabilized backfill: Perform this test for

samples taken along the direct buried cable route.

a. Perform tests before backfilling work is started to ensure that the

thermal resistivity of the selected stabilized backfill in dry condition
(zero moisture content) and specified compaction does not exceed
the value required by design.

b. Tests shall include measurement of the thermal resistivity, residual

moisture and mechanical suitability for working.

c. After backfilling, collect test specimens at 100 m intervals along the

trench route and perform the thermal resistivity tests on them in
accordance with IEEE Std 442. Results shall be same or less than
previously made laboratory tests for the same moisture content.

7. Cable Jacket Integrity Test: Tests shall be in accordance with IEC 60229.
Tests shall be made with cable on the reel. If the cable fails the test that
reel shall not be used. If the cable passed the test on reel, further tests
shall be made as follows:

a. For direct buried cables this test shall be performed at least at two
stages that are: (1) cable in trench before backfilling and (2) after
backfilling but before the high voltage DC test. If the jacket fails the
test and jacket damage can be repaired in accordance with
manufacturer’s instructions, repairs may be made if approved by
the Royal Commission. Cable sections with jacket damage that are

RCMYAS Guide Spec. 16305-22 Contract No.

Rev A, 27 Nov ‘05
 judged by the Royal Commission to be too extensive for repairs
shall be replaced.

b. For cables pulled in duct and manhole systems this test shall
be preformed after pulling. If the jacket fails the test, the cable
shall be replaced.

8. Phasing check.

9. Capacitance tests.

10. Positive and zero sequence impedance tests.

11. Surge voltage limiter tests.

12. Link box contact resistance test. Link contact resistance shall not exceed
20 micro ohms.

13. Measurement of ground rod resistance to earth at each location in

accordance with requirements in Section 16450.

D. Upon completion of all testing, the Contractor shall submit to the Royal
Commission four (4) copies of a certified report attesting that each test was
performed in accordance with the approved test procedures. The report for each
test shall include the date of performance and the name of the person in charge
of the test.

E. All factory and field test reports shall be included into the Operation and
Maintenance Manuals.

F. Prior to the issue of a Certificate of Final Acceptance pursuant to General

Conditions Article entitled “Initial and Final Acceptance”, Contractor shall perform
soil thermal resistivity tests using selected backfill material samples removed
from the cable trench. The samples shall be selected from four different
locations or at 200 m intervals, whichever is greater, along each direct buried
cable route. Take samples 100 mm above the power cable level. Contractor
shall demonstrate that the selected stabilized backfill materials have retained the
required thermal resistivity value between Initial and Final Acceptance of the
cable system. The Contractor will be required to perform approximately three
additional soil thermal resistivity tests at locations designated by the Royal
Commission

+ + END OF SECTION 16305 + +

RCMYAS Guide Spec. 16305-23 Contract No.

Rev A, 27 Nov ‘05