tests on a 0,6/1 kv lv cable, , al/xlpe/pvc 06... · 2.10 hot set test for xlpe insulation in...

70670140-HVL 06-1353 2007-01-11

Tests on a 0,6/1 kV LV cable, 4x300 mm2, Al/XLPE/PVC

T E S T R E P O R T

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 Type 4x300 mm2, 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. 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

70670140-HVL 06-1353 MATERIAL DATA Manufacturer Egytech Cables - Elsewedy, Egypt Type 4x300 mm2 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 mm2 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 Test object 4x300 mm2 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

at 90 °C Ω.cm ≥ 1012 6,07. 1014

8,34. 1014

7,23. 1014

7,23. 1014

passed

insulation resistance

at 90 °C MΩ.km ≥ 3,67 2226 3056 2648 2816 passed

70670140-HVL 06-1353

Appendix 1 page 2 Client Egytech Cables - Elsewedy, Egypt Test object 4x300 mm2 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 20°C applied voltage

(kV)

frequency

(Hz)

duration

(h)

observations result

2,4 50 4 no breakdown passed

70670140-HVL 06-1353

Appendix 2 page 1 Client Egytech Cables - Elsewedy, Egypt Test object 4x300 mm2 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 Test object 4x300 mm2 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


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

- minimum mm ≥ 2,45 2,77 passed

70670140-HVL 06-1353

Appendix 2 page 3 Client Egytech Cables - Elsewedy, Egypt Test object 4x300 mm2 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


without ageing


- 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

70670140-HVL 06-1353 Appendix 2 page 4 Client Egytech Cables - Elsewedy, Egypt Test object 4x300 mm2 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


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


% ± 25 max. -2 passed




70670140-HVL 06-1353

Appendix 2 page 5 Client Egytech Cables - Elsewedy, Egypt Test object 4x300 mm2 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

insulation 100°C/7days


- tensile strength N/mm² - 25,0 20,5 19,5 22,1


% ± 25 max. -6 11 -17 -6 passed

- elongation % - 335 314 288 331


% ± 25 max. -6 -5 -12 -1 passed

outer sheath 100°C/7d.

- tensile strength N/mm2 ≥ 12,5 18,1 passed






70670140-HVL 06-1353

Appendix 2 page 6 Client Egytech Cables - Elsewedy, Egypt Test object 4x300 mm2 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 - duration - loss of mass

°C d

mg/cm2

100 7

≤ 1,5

0,8

passed

70670140-HVL 06-1353

Appendix 2 page 7 Client Egytech Cables - Elsewedy, Egypt Test object 4x300 mm2 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 - duration - load - depth of indentation

°C h N %

90 6

13,5 ≤ 50

20

passed

70670140-HVL 06-1353

Appendix 2 page 8 Client Egytech Cables - Elsewedy, Egypt Test object 4x300 mm2 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 - elongation

°C %

- 15 ≥ 20

> 225

passed

- temperature - cold impact test

°C - 15 no cracks

no cracks

passed

70670140-HVL 06-1353

Appendix 2 page 9 Client Egytech Cables - Elsewedy, Egypt Test object 4x300 mm2 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 - duration

°C h

150 1

passed

- soundness no cracks no cracks passed

70670140-HVL 06-1353

Appendix 2 page 10 Client Egytech Cables - Elsewedy, Egypt Test object 4x300 mm2 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 - elongation under load - permanent elongation

°C % %

200 ≤ 175 ≤ 15

60 1

65 2

70 1

60 1

passed passed

70670140-HVL 06-1353

Appendix 2 page 11 Client Egytech Cables - Elsewedy, Egypt Test object 4x300 mm2 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 - duration - variation of mass

°C h

mg/cm2

85 14 ≤ 1

0,04

0,06

0,02

0,05

passed

70670140-HVL 06-1353

Appendix 2 page 12 Client Egytech Cables - Elsewedy, Egypt Test object 4x300 mm2 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 - length free of charring - downward limit charred surface

s mm mm

480 > 50 < 540

360 420

passed passed

70670140-HVL 06-1353

Appendix 2 page 13 Client Egytech Cables - Elsewedy, Egypt Test object 4x300 mm2 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 - duration - shrinkage

°C h %

130 1 ≤ 4

< 1

< 1

< 1

< 1

passed

70670140-HVL 06-1353

Appendix 3 page 1 Client Egytech Cables - Elsewedy, Egypt Test object 4x300 mm2 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 color of the cores color of the outer sheath

ELSEWEDY CABLES EGYTECH 4x300mm 0,6/1 kV AL/XLPE/PVC PROPERTY OF SAUDI ELECTRICITY yellow, blue, black, red 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

70670140-HVL 06-1353

Appendix 3 page 2 Client Egytech Cables - Elsewedy, Egypt Test object 4x300 mm2 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



- resistance Ω/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)

70670140-HVL 06-1353

tests on a 0,6/1 kv lv cable, , al/xlpe/pvc 06... · 2.10 hot set test for xlpe insulation in...

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