08-1003

TYPE TEST CERTIFICATE OF COMPLETE TYPE TEST

OBJECT single-core power cable

TYPE 19/33 kV 1x500 mm2 AL/XLPE/HDPE

Rated voltage 19/33 (36) kV Conductor material AL Conductor cross-section 500 mm2 Insulation material XLPE

MANUFACTURER Elsewedy Cables Damascus, Syria

CLIENT Elsewedy Cables Cairo, Egypt

TESTED BY KEMA HIGH-VOLTAGE LABORATORY Arnhem, the Netherlands

DATES OF TESTS 17 December 2007 until 21 January 2008

The object, constructed in accordance with the description, drawings and photographs incorporated in this Certificate, has been subjected to the series of proving tests in accordance with

IEC 60502-2

This Type Test Certificate has been issued by KEMA following exclusively the STL Guides. The results are shown in the record of Proving Tests and the oscillograms attached hereto. The values obtained and the general performance are considered to comply with the above Standard and to justify the ratings assigned by the manufacturer as listed on page 4.

The Certificate applies only to the object tested. The responsibility for conformity of any object having the same designations with that tested rests with the Manufacturer. This Certificate consists of 36 pages in total.

© Copyright: Only integral reproduction of this Certificate is permitted without written permission from KEMA. Electronic copies in e.g. PDF-format or scanned version of this Certificate may be available and have the status “for information only”. The sealed and bound version of the Certificate is the only valid version.

KEMA Nederland B.V.

P.G.A. Bus KEMA T&D Testing Services Managing Director Arnhem, 27 March 2008

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TABLE OF CONTENTS

TABLE OF CONTENTS .......................................................................................................................... 2

1 Identification of the test object......................................................................................................4 1.1 Ratings assigned by the manufacturer ........................................................................................4 1.2 Description of the test object........................................................................................................4 1.3 List of drawings ............................................................................................................................5

2 General information......................................................................................................................6 2.1 The tests were witnessed by........................................................................................................6 2.2 The tests were carried out by.......................................................................................................6 2.3 Subcontracting .............................................................................................................................6 2.4 Purpose of the test .......................................................................................................................6 2.5 Measurement uncertainty.............................................................................................................6 2.6 Applicable standards....................................................................................................................6

3 Electrical Type Tests....................................................................................................................7 3.1 Bending tests................................................................................................................................7 3.2 Partial discharge test....................................................................................................................8 3.3 Tan δ measurement .....................................................................................................................9 3.4 Heating cycle test .......................................................................................................................10 3.5 Partial discharge test..................................................................................................................11 3.6 Impulse test followed by a voltage test ......................................................................................12 3.6.1 Impulse test ................................................................................................................................12 3.6.2 Voltage test ................................................................................................................................15 3.7 Voltage test for 4 hours ..............................................................................................................16 3.8 Resistivity of semi-conducting screens ......................................................................................17

4 Non-electrical type tests.............................................................................................................18 4.1 Measurement of thickness of insulation.....................................................................................18 4.2 Measurement of thickness of non-metallic sheaths ...................................................................19 4.3 Tests for determining the mechanical properties of the insulation before and after ageing ......20 4.4 Tests for determining the mechanical properties of non-metallic sheaths before and after

ageing.........................................................................................................................................21 4.5 Additional ageing test on pieces of completed cables ...............................................................22 4.6 Pressure test at high temperature on non-metallic sheaths ......................................................23 4.7 Hot set test for XLPE insulation .................................................................................................24 4.8 Water absorption test on insulation............................................................................................25 4.9 Measurement of carbon black content of black PE oversheaths...............................................26 4.10 Shrinkage test for XLPE insulation.............................................................................................27

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4.11 Shrinkage test for PE oversheaths.............................................................................................28 4.12 Water penetration test ................................................................................................................29

5 Verification of cable construction ...............................................................................................30

APPENDIX A MEASUREMENT UNCERTAINTIES......................................................................... 32

APPENDIX B MANUFACTURERS DRAWINGS/DATA SHEET..................................................... 33

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1 IDENTIFICATION OF THE TEST OBJECT 1.1 Ratings assigned by the manufacturer Rated voltage 19/33 (36) kV Conductor cross-section 1x500 mm2 Insulation material XLPE

1.2 Description of the test object Manufacturer Elsewedy Cables Type 19/33 kV 1x500 mm2 Al/XLPE/HDPE

(marked by sign of JEPCO) Drawing(s) see appendix B, drawing no. AB5-TX01-U50-00-01 Year of manufacture 2007 Quantity submitted 40 m approximately - quantity used for electrical type tests 31 m - quantity used for non-electrical type tests 4 m Rated voltage 19/33 (36) kV No. of cores 1 Conductor - material Aluminium, stranded - cross-section 500 mm2 - maximum rated temperature 90 °C Conductor screen extruded semicon Insulation material extruded XLPE Insulation screen extruded semicon (bonded type) Metallic screen - material copper wires and tape screen (open helix) - cross-section 70 mm2 Oversheath - material HDPE (type ST7) - colour black Longitudinally watertightness - along insulation screen yes - along the conductor not claimed Flame retardancy not claimed Standard IEC 60502-2 (2005)

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1.3 List of drawings The manufacturer has guaranteed that the object submitted for the tests has been manufactured in accordance with the following drawing/datasheet. KEMA has verified that this drawing and datasheet represent the object tested. The following drawing and datasheet are included in this Report: - AB5-TX01-U50-00-01 (cable constructional drawing) - AB5-TX01-U50-00-01 pages 1 and 2 - (technical specification of cable construction)

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2 GENERAL INFORMATION 2.1 The tests were witnessed by Name Company

Imad N. Nur JEPCO, Amman. Jordan 2.2 The tests were carried out by Name Company

J.J.M. Mooren KEMA Nederland B.V. A.P.M. Derksen Arnhem, the Netherlands G.J.A. Jansen 2.3 Subcontracting The following tests were subcontracted to KEMA Quality B.V.: - Measurement of resistivity of semi- conducting screens in accordance with clause 18.1.9 of IEC 60502-2. - Non-electrical type tests in accordance with clause 19 of IEC 60502-2 with exception of water penetration test. - Verification of cable construction in accordance with clauses 5 14 of IEC 60502-2. 2.4 Purpose of the test Purpose of the test was to verify whether the material complies with the specified requirements. 2.5 Measurement uncertainty A table with measurement uncertainties is enclosed in appendix A. Unless otherwise indicated in the report, the measurement uncertainties of the results presented are as indicated in this table. 2.6 Applicable standards When reference is made to a standard and the date of issue is not stated, this applies to the latest issue, including amendments which have been officially published prior to the date of the tests.

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3 ELECTRICAL TYPE TESTS 3.1 Bending tests The bending test was carried out in accordance with clause 18.1.3 of IEC 60502-2. The results are presented below. Atmospheric conditions Ambient temperature 5 °C Characteristic test data Temperature of test object 18 °C Date of test: 17 December 2007 outer diameter of cable D (mm)

diameter of cable conductor d (mm)

required bending diameter Dr

(mm)

actual bending diameter Da

(mm)

observations

55,0 26,8 1554 ≤ Dr ≤ 1718 1580 3 cycles (wind/unwind and wind/unwind in opposite directions)

Procedure The test sample shall be bent around a test cylinder at ambient temperature for at least one complete turn. It shall then be unwound and repeated, except that the bending of the sample shall be in the reverse direction without axial rotation. This cycle of operation shall be carried out three times. Observation The test was carried out successfully.

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3.2 Partial discharge test On completion of the bending test, the partial discharge test was carried out in accordance with clause 18.1.4 of IEC 60502-2. The results are presented below. Atmospheric conditions Ambient temperature 18 °C Characteristic test data Circuit direct Calibration 5 pC Noise 2 pC Bandwidth 40-400 kHz Power frequency 50 Hz Coupling capacitor 2600 pF Temperature of test object 18 °C Rated voltage Uo 19 kV Date of test: 20 December 2007 core voltage applied, 50 Hz duration partial discharge level ... x U0 (kV) (s) (pC) (single) 2 38 10 ≤ 2 1,73 33 - ≤ 2

Requirement There shall be no detectable discharge exceeding the declared sensitivity from the test object at 1,73U0. Additionally, (upon request of client) no detectable discharge exceeding the declared sensitivity from the test object at 2U0 is measured. Result The test was passed.

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3.3 Tan δδδδ measurement The capacitance and tan δ measurement was carried out in accordance with clause 18.1.5 of IEC 60502-2. The results are presented below. Atmospheric conditions Ambient temperature 18 °C Characteristic test data Length of test object 12,9 m Standard capacitor 100 pF Temperature of test object 96 °C Date of test: 21 December 2007 core voltage applied, 50 Hz core capacitance1) tan δ (kV) (µF/km) (single) 5 0,273 6,4x10-4 1) for information only

Requirement The measured value shall not be higher than 40x10-4. Result The test was passed.

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3.4 Heating cycle test The heating cycle test was carried out in accordance with clause 18.1.6 of IEC 60502-2. The results are presented below. Atmospheric conditions Ambient temperature 18 - 20 °C Characteristic test data Temperature of test object ambient - 96 °C Date of test: 2 January until 8 January 2008 no. of heating-cycles

required stable conductor temperature

heating current

heating per cycle cooling per cycle

(°C)

(A)

total duration (hours)

duration of conductor at stable temperature (hours)

total duration (hours)

20 95-100 1050 5 2 3

Result The test was carried out successfully.

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3.5 Partial discharge test On completion of the heating cycle test, the partial discharge test was carried out in accordance with clause 18.1.4 of IEC 60502-2. The results are presented below. Atmospheric conditions Ambient temperature 20 °C Characteristic test data Circuit direct Calibration 5 pC Noise 2 pC Bandwidth 40-400 kHz Power frequency 50 Hz Coupling capacitor 2600 pF Temperature of test object 20 °C Rated voltage Uo 19 kV Date of test: 10 January 2008 core voltage applied, 50 Hz duration partial discharge level ... x U0 (kV) (s) (pC) (single) 2 38 10 ≤ 2 1,73 33 - ≤ 2

Requirement There shall be no detectable discharge exceeding the declared sensitivity from the test object at 1,73U0. Additionally, (upon request of client) no detectable discharge exceeding the declared sensitivity from the test object at 2U0 is measured. Result The test was passed.

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3.6 Impulse test followed by a voltage test 3.6.1 Impulse test The impulse test was carried out in accordance with clause 18.1.7 of IEC 60502-2. In order to achieve the elevated temperature of the test object, current was induced in the cable. The impulse test was performed two hours after thermal equilibrium had been established. The wave shape of the impulse voltage was determined at approximately 50 percent of the specified test value (see figure). The results are presented below. Atmospheric conditions Ambient temperature 20 °C Characteristic test data Temperature of test object 96 °C Date of test: 11 January 2008 Specified test voltage: 170 kV

Requirement No breakdown of the insulation shall occur. Result The test was passed.

testing arrangement polarity voltage applied (% of test voltage)

no. of impulses

see figure

voltage applied to earthed conductor screen positive 50 1 1 65 1 2 80 1 2 100 10 3 and 4 conductor screen negative 50 1 5 65 1 6 80 1 6 100 10 7 and 8

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3.6.2 Voltage test The power frequency voltage test was carried out in accordance with clause 18.1.7 of IEC 60502-2. After the impulse test, the test object was subjected to a power frequency voltage test, at ambient temperature. The results are presented below. Atmospheric conditions Ambient temperature 19 °C Characteristic test data Temperature of test object 19 °C Date of test: 14 January 2008 testing arrangement voltage applied, 50 Hz duration voltage applied to earth connected to ... x U0 (kV) (min) conductor metal screen 3,5 66,5 15

Requirement No breakdown of the insulation shall occur. Result The test was passed.

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3.7 Voltage test for 4 hours The voltage test for four hours was carried out in accordance with clause 18.1.8 of IEC 60502-2. The results are presented below. Atmospheric conditions Ambient temperature 19 °C Characteristic test data Temperature of test object 19 °C Date of test: 14 January 2008 testing arrangement voltage applied, 50 Hz duration voltage applied to earth connected to ... x U0 (kV) (hours) conductor metal screen 4 76 4

Requirement No breakdown of the insulation shall occur. Result The test was passed.

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3.8 Resistivity of semi-conducting screens The measurement of the resistivity of semi-conducting screens was carried out in accordance with clause 18.1.9 of IEC 60502-2. The results are presented below. Characteristic test data Temperature 100 °C Duration 7 days Measured temperature 90 °C item unit requirement measured/determined conductor screen - without ageing Ωm ≤ 1000 103,3 - after ageing Ωm ≤ 1000 8,7 insulation screen - without ageing Ωm ≤ 500 4,7 - after ageing Ωm ≤ 500 0,9 Result The test was passed.

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4 NON-ELECTRICAL TYPE TESTS The non-electrical type tests were carried out in the period from 17 December 2007 up to and including 15 January 2008. 4.1 Measurement of thickness of insulation The measurement of the thickness of insulation was carried out in accordance with clause 19.1 of IEC 60502-2. The results are presented below. thickness unit requirement specified measured/determined - nominal mm 8,0 - average mm 8,1 - minimum (tmin) mm ≥ 7,1 7,81 - maximum (tmax) mm 8,25 - (tmax - tmin) / tmax ≤ 0,15 0,05 Result The test was passed.

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4.2 Measurement of thickness of non-metallic sheaths The measurement of the thickness of the non-metallic sheaths was carried out in accordance with clause 19.2 of IEC 60502-2. The results are presented below. Oversheath thickness unit requirement specified measured/determined - nominal mm 2,5 - average mm 3,4 - minimum mm ≥ 2,03 2,61 Result The test was passed.

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4.3 Tests for determining the mechanical properties of the insulation before and after ageing

The tests for determining the mechanical properties of the insulation before and after ageing were carried out in accordance with clause 19.3 of IEC 60502-2. The results are presented below. item unit requirement measured/determined without ageing - tensile strength N/mm² ≥ 12,5 28,1 - elongation % ≥ 200 576 after ageing (135°C / 7days)

- tensile strength N/mm² - 27,6

- variation with samples without ageing

% ± 25 max. -2

- elongation % - 566

- variation with samples without ageing

% ± 25 max. -2

Result The test was passed.

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4.4 Tests for determining the mechanical properties of non-metallic sheaths before and after ageing

The tests for determining the mechanical properties of the non-metallic sheaths before and after ageing were carried out in accordance with clause 19.4 of IEC 60502-2. The results are presented below. Over sheath (HDPE ST7) item unit requirement measured/determined without ageing

- tensile strength N/mm² ≥ 12,5 34,8

- elongation % ≥ 300 785

after ageing (110°C / 10days)

- tensile strength N/mm² - 34,3

variation with samples without ageing

% - -1

- elongation % ≥ 300 784

variation with samples without ageing

% - -1

Result The test was passed.

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4.5 Additional ageing test on pieces of completed cables The additional ageing tests on pieces of completed cable were carried out in accordance with clause 19.5 of IEC 60502-2. The results are presented below. item unit requirement measured/determined insulation (100°C / 7days)

- tensile strength N/mm² - 28,8

- variation with samples without ageing

% ± 25 max. 3

- elongation % - 557

- variation with samples without ageing

% ± 25 max. -3

oversheath (100°C / 7days)

- tensile strength N/mm² - 36,3

- variation with samples without ageing

% - 4

- elongation % ≥ 300 824

- variation with samples without ageing

% - 5

Result The test was passed.

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4.6 Pressure test at high temperature on non-metallic sheaths The pressure test was carried out in accordance with clause 19.7 of IEC 60502-2. The results are presented below. Characteristic test data Temperature 110 °C Duration 6 h Load 13,3 N Oversheath item unit requirement measured/determined - depth of indentation % ≤ 50 2 Result The test was passed.

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4.7 Hot set test for XLPE insulation The hot set test was carried out in accordance with clause 19.11 of IEC 60502-2. The results are presented below. Characteristic test data Temperature 200 °C item unit requirement measured/determined - elongation under load % ≤ 175 80 - permanent elongation % ≤ 15 5 Result The test was passed.

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4.8 Water absorption test on insulation The water absorption test was carried out in accordance with clause 19.13 of IEC 60502-2. The results are presented below. Characteristic test data Temperature 85 °C Duration 14 d item unit requirement measured/determined - variation of mass mg/cm2 ≤ 1 0,1 Result The test was passed.

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4.9 Measurement of carbon black content of black PE oversheaths The carbon black test was carried out in accordance with clause 19.15 of IEC 60502-2. The results are presented below. item unit requirement measured/determined - carbon black content % 2,5 ± 0,5 2,6 Result The test was passed.

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4.10 Shrinkage test for XLPE insulation The shrinkage test was carried out in accordance with clause 19.16 of IEC 60502-2. The results are presented below. Characteristic test data Temperature 130 °C Duration 1 h item unit requirement measured/determined - shrinkage % ≤ 4 2

Result The test was passed.

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4.11 Shrinkage test for PE oversheaths The shrinkage test on the oversheath was carried out in accordance with clause 19.20 of IEC 60502-2. The results are presented below. Characteristic test data Temperature 80 °C Duration 5 h Cycles 5 item unit requirement measured/determined - shrinkage % ≤ 3 2 Result The test was passed.

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4.12 Water penetration test The water penetration test was carried out in accordance with clause 19.22 of IEC 60502-2. The results are presented below. Atmospheric conditions Ambient temperature 17-20 °C Characteristic test data Length of cable sample 3 m Water height above cable centre 1 m Temperature of test object ambient - 96 °C Date of test: 17 January 2008 until 21 January 2008 no. of heating-cycles

required steady conductor temperature

heating current

heating per cycle cooling per cycle

(°C)

(A)

total duration (hours)

duration of conductor at steady temperature (hours)

total duration (hours)

10 95-100 1050 5 2 3

Note The manufacturer has claimed that barriers have been included, which prevents longitudinal water penetration in the region of the metallic layers. Requirement No water shall emerge from the ends of the cable sample Result The test was passed.

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5 VERIFICATION OF CABLE CONSTRUCTION Verification of cable construction was carried out in accordance with clauses 5-14 of IEC 60502-2. The results are presented below. item required/specified measured/determined conductor (IEC 60228 Class 2)

material: stranded Aluminium wires (circular compacted)

circular compacted construction 1-6-12-18-24

- resistance at 20 °C (Ω/km) ≤ 0,0605 0,0601 - no. of wires ≥ 53 61xØ 3,4mm approx. - diameter min-max (mm) 25,3 ≤ d ≤ 27,6 26,8 screening conductor screen yes present - thickness, minimum (mm) 0,4 (datasheet) - insulation screen non-metallic part yes present - thickness, minimum (mm) 0,3 (datasheet) - metallic part - nominal wire thickness (mm) 79xØ1,05mm, 70 mm2

(datasheet)

copper wires 79xØ1,1mm approx.

insulation material: extruded XLPE see result of non-

electrical type tests see results of non-electrical type tests

water blocking tapes material: semi conducting waterblocking tape

yes present

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item required/specified measured/determined binder tape material: copper tape open helix copper tape open helix copper tape open helix

0,1x20mm approx. - thickness, average (mm) 0,1 (datasheet) 0,1 - width, average (mm) - 20 oversheath material: HDPE (ST7) see results of non-

electrical type tests see results of non-electrical type tests

graphite coating yes present marking of the cable - ELSEWEDY CABLES

1x500mm² 19/33kV AL/XLPE/HDPE 2007 JEP 096/2007 JEPCO

colour of the core - black colour of the oversheath - black outer diameter of the cable average (mm) 53,1 (datasheet) 55,0 outer diameter of the core average (mm) 44,6 (datasheet) 45,6 Result The test was passed.

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APPENDIX A MEASUREMENT UNCERTAINTIES The measurement uncertainties in the results presented are as specified below unless otherwise indicated.

measurement measurement uncertainty dielectric tests and impulse current tests

peak value: ≤ 3% time parameters: ≤ 10%

capacitance measurement tan δ measurement

0,3% ± 0,5% ± 5x10-5

partial discharge measurement < 10 pC : 2 pC 10 - 100 pC : 5 pC > 100 pC : 20 %

measurement of impedance ac-resistance measurement

≤ 1%

measurement of losses ≤ 1% measurement of insulation resistance ≤ 10% measurement of dc resistance 1 µΩ - 5 µΩ : 1%

5 µΩ - 10 µΩ : 0,5% 10 µΩ - 200 µΩ : 0,2%

radio interference test 2 dB calibration of current transformers 2,2 x 10-4 Ii/Iu and 290 µrad calibration of voltage transformers 1,6 x 10-4 Ui/Uu en 510 µrad measurement of conductivity 5% measurement of temperature -50 °C - -40 °C : 3 K

-40 °C - 125 °C : 2 K 125 °C - 150 °C : 3 K

tensile test 1% sound level measurement type 1 meter as per IEC 651 and

ANSI S1.4.1971 measurement of voltage ratio 0,1%

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APPENDIX B MANUFACTURER’S DRAWINGS/DATA SHEET Number of pages : 4 (including this page) drawing no. description date rev. AB5-TX01-U50-00-01 pages 1 and 2

technical specification of cable construction - -

AB5-TX01-U50-00-01 cable constructional drawing - -

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