2007-01-11 Tests on a 0,6/1 kv LV cable, 4x300 mm 2, Al/XLPE/PVC
TEST REPORT Report no. 70670140-HVL 06-1353 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 Type 4x300 mm 2, Al/XLPE/PVC Manufacturer 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. Hülkenberg 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
MATERIAL DATA Manufacturer Type 4x300 mm 2 Al/XLPE/PVC 0,6/1 kv Year of manufacture 2006 No. of phases 4 Insulation XLPE Conductor material sector shaped aluminium Conductor cross-section 300 mm 2 Outer sheath material PVC (ST 2 ) 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
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 Mr A.A. Mackenbach KEMA Quality B.V. KEMA Quality B.V. PURPOSE OF THE TEST Purpose of the test was to verify whether the material complies with the specified requirements.
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.
Appendix 1 page 1 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 at 90 C Ω.cm 10 12 6,07. 10 14 8,34. 10 14 7,23. 10 14 7,23. 10 14 passed insulation resistance at 90 C MΩ.km 3,67 2226 3056 2648 2816 passed
Appendix 1 page 2 Requirements IEC 60502-1 (2004) clause 17.3 Test period 18 October 2006 1.2 RESULTS OF THE VOLTAGE TEST FOR 4 H Temperature 20 C applied voltage frequency duration observations result (kv) (Hz) (h) 2,4 50 4 no breakdown passed
Appendix 2 page 1 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
Appendix 2 page 2 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
Appendix 2 page 3 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 without ageing item unit requirement measured/determined result yellow blue black red - tensile strength N/mm² 12,5 26,7 23,2 23,5 23,4 passed - elongation % 200 357 332 327 335 passed after ageing without conductor 135 C/7d. - tensile strength N/mm² - 22,9 21,1 22,2 20,7 variation with samples without ageing % ± 25 max. -14-9 -6-11 passed - elongation % - 315 306 308 311 - variation with samples without ageing % ± 25 max. -12-8 -6-7 passed
Appendix 2 page 4 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/mm² 12,5 18,5 passed - elongation % 150 261 passed after ageing 100 C/7days - tensile strength N/mm² 12,5 18,1 passed variation with samples without ageing % ± 25 max. -2 passed - elongation % 150 254 passed variation with samples without ageing % ± 25 max. -2 passed
Appendix 2 page 5 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 100 C/7days - tensile strength N/mm² - 25,0 20,5 19,5 22,1 variation with samples without ageing % ± 25 max. -6 11-17 -6 passed - elongation % - 335 314 288 331 variation with samples without ageing % ± 25 max. -6-5 -12-1 passed outer sheath 100 C/7d. - tensile strength N/mm 2 12,5 18,1 passed - variation with samples without ageing % ± 25 max. -2 passed - elongation % 150 249 passed - variation with samples without ageing % ± 25 max. -5 passed
Appendix 2 page 6 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 - temperature - duration - loss of mass item unit requirement measured result C d mg/cm 2 100 7 1,5 0,8 passed
Appendix 2 page 7 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 - duration - load - depth of indentation C h N % 90 6 13,5 50 20 passed
Appendix 2 page 8 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 - elongation - temperature - cold impact test C % - 15 20 > 225 passed C - 15 no cracks no cracks passed
Appendix 2 page 9 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 - temperature - duration item unit requirement measured result C h 150 1 passed - soundness no cracks no cracks passed
Appendix 2 page 10 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 - temperature - elongation under load - permanent elongation C % % 200 175 15 yellow blue black red 60 1 65 2 70 1 60 1 passed passed
Appendix 2 page 11 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 - temperature - duration - variation of mass C h mg/cm 2 yellow blue black red 85 14 1 0,04 0,06 0,02 0,05 passed
Appendix 2 page 12 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 - length free of charring - downward limit charred surface s mm mm 480 > 50 < 540 360 420 passed passed
Appendix 2 page 13 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 - temperature - duration - shrinkage C h % yellow blue black red 130 1 4 < 1 < 1 < 1 < 1 passed
Appendix 3 page 1 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 Ø 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
Appendix 3 page 2 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 Ω/km 0,100 0,096 0,093 0,092 0,093 passed
Appendix A Drawing of Egytech Cables - Elsewedy of 0,6/1 kv cable, 4x300 mm 2 AL/XLPE/PVC (2 pages)
70670140-HVL06-1353 Egytech Cables Co. El Sewedy Technical Department 4X300-0.6 / 1.0 kv- Cable AL / XLPE / PVC Cable Construction 1. Conductor Material Aluminum Size mm 2 300 No. of wires 48 Conductor Diameter mm Sector Shape 2. Insulation Material Cross Linked Poly Ethylene (XLPE) Thickness mm 1.8 (nominal) mm 1.52 (minimum at any point) Diameter mm Sector Shape Core Identification Red, Yellow, Blue, Black 3. Assembly Filler Poly Propylene Filler Binder Poly Propylene Tape Diameter mm 52.3 (Approx.) 4. Sheath Material Polyvinyl Chloride (PVC) Color Black Thickness mm 3 (nominal) 2.4 (minimum at any point) Outer Diameter mm 58.3 (Approx.) Applicable Standards : - IEC 60502-1 Ref No. : AX1-T104-U30-17 4X300 MM2 0.6/1.0 KV AL/XLPE/ /PVC 1