INSPECTION REPORT No. Egy/MB/08/722477/4 · 2020. 8. 27. · regarding the Type test for 1x630mm2 66Kv Cu Cable destined to project mentioned in first page of this report. El SEWEDY

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Industry & Facilities Division INSPECTION REPORT No. Egy/MB/08/722477/4

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INSP 002 1/21 Copyright Bureau Veritas 09/2006

PROJECT: Complete loop test for 1x630mm2 66Kv Cu Cable with joints & terminations for New Doha Airport

Ref: ---

BV Client: El Sewedy Cables. P/o nr: N/A

Vendor : N/A P/o nr: N/A

Manufacturer: El Sewedy Cables.

P/o nr: N/A

Inspection requested by: El Sewedy Cables.

SUPPLY OF INSPECTION MARKS ITEM VENDOR ITEM CUSTOMER

Q.TY TESTED

Complete loop test for 1x630mm2 66Kv Cu Cable with joints & terminations - - - -

DOCUMENTS OF REFERENCE : See continuation sheet for additional documents: Yes No

Title Reference n° Rev. Approved by Date IEC 60840 - 0 Client -

KAHRAMAA Specs. - 0 Client -

INSPECTIONS : as per approved schedule.

Results of inspection : Satisfactory Unsatisfactory (in reference to scope of work) Outstanding activities

Inspection place & Date or Period: as per approved schedule Stage of inspection :

Before manufacturing During manufacturing Final Packing

Kind of inspection:

Pre-inspection meeting Witnessing tests Final inspection Document review Expediting &vendor assessment Packing

(for details see continuation sheet) Stamping :

No

Non Conformities Reports (NCR): N/A Main Conclusions & Remarks: (for details see continuation sheet): The 66 KV cable & its joints of the above mention order have been passed all the tests successfully according to KAHRAMAA specifications based on IEC 60840. Next visit scheduled: Will be advised by High Voltage Research Center personnel

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GENERAL : On 23rd August 2008, further to an El SEWEDY CABLES request, Bureau Veritas Egypt has attended a pre-inspection meeting regarding the Type test for 1x630mm2 66Kv Cu Cable destined to project mentioned in first page of this report. El SEWEDY facilities are located at 10th of Ramadan City, Sharkeya, Egypt. High Voltage Research Center facilities are located at Cairo-Alex Km 27 desert road THE PRE-INSPECTION MEETING HAS BEEN ATTENDED BY : El SEWEDY Cables : Mr. Hassan Ahmed QA Responsible BUREAU VERITAS : Mr. Mokhtar Bkkar - Inspector High Voltage Research Center : Mr. Ehab Fawzy

AGENDA

1. Stating the needed tests according to client request & the applied code. IEC 60840Approved by KAHRAMAA 2. State Hold points during inspection. Bureau Veritas must witness all listed tests at least in three points for every test (Start , End & Spot check) 3. Needed action from Bureau Veritas as a Third Party, To witness & report the tests & then endorse the test documents of the

testing facility. 4. Inspection Schedule. ‘’Actual’’ Inspections were planned to be ended by 15 Nov 2008, But due to some technical problems at the testing facility of High Voltage Research Center the planned schedule was amended to be as follows in the next page:

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No. Name of test

Sam

ples

Applied Code Start date Finish date

1 Bending 1 IEC 60840

Clause11.3.4 23-08-08 23-08-08

2 Measurement of thickness of insulation 1 IEC 60840

Clause11.3.1 23-08-08 23-08-08

3 Verifying Cable Components 1 IEC 60840

Clause11.4.1 23-08-08 23-08-08

4 Partial Discharge Test at room temperature 1 IEC 60840

Clause11.3.5 15-09-08 15-09-085 Defining the Voltage of Heating Cycle Voltage Test 1 IEC 61442 11-09-08 15-09-08

6 Heating Cycle Voltage Test 1 IEC 60840

Clause11.3.7 25-09-08 16-10-08

7 Prepare Specimens for Test of determining the mechanical properties of Insulation before and after ageing 10

IEC 60840 Clause11.4.2 21-09-08 28-09-08

8 Prepare Specimens for Test of determining the mechanical properties of Non-Metallic Sheath before and after ageing 10

IEC 60840 Clause11.4.3 28-09-08 08-10-08

9 Partial Discharge Test at room temperature after the heating cycle 1

IEC 60840 Clause11.3.5 16-10-08 16-10-08

10 Prepare Specimens for Additional Ageing Test on pieces of completed cable for mechanical properties 5

IEC 60840 Clause11.4.4 08-10-08 15-10-08

11 Partial Discharge Test at temperature of 95--100°C 1 IEC 60840

Clause11.3.5 19-10-08 19-10-08

12 Impulse Voltage Test temperature of 95--100°C 1 IEC 60840

Clause11.3.8 27-10-08 27-10-08

13 AC Voltage Test at room temperature 1 IEC 60840

Clause11.3.8 27-10-08 27-10-08

14 First trial for Tan Delta test but the apparatus broke down 1 IEC 60840

Clause11.3.6 03-11-08 03-11-08

15 Second trial for Tan Delta test but the Power source failed 1 IEC 60840

Clause11.3.6 10-11-08 10-11-08

16 Last trial for Tan Delta test ''Passed'' 1 IEC 60840

Clause11.3.6 16-11-08 16-11-08

17 Measuring of specific resistance of Internal & External Semiconductor layers before and after ageing 4

IEC 60840 Clause11.3.9 19-11-08 19-11-08

18 Performing the mechanical tests for the prepared specimens 25 IEC 60840

Clause11.4.2 19-11-08 19-11-08

19 Hot-Set Test for XLPE Insulation 2 IEC 60840

Clause11.4.10 20-11-08 20-11-08

20 Shrinkage Test for XLPE Insulation 1 IEC 60840

Clause11.4.13 20-11-08 20-11-08

21 Water penetration test 1 IEC 60840

Clause11.4.15 19-11-08 1-12-08

22 Joint Test 1 IEC 60840

Clause11.3.6 1-1-09 7-1-09

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This report will be presented follows:

• Test pictures taken during performing tests in Arab Cables Labs of (EL SEWEDY CABLES) & High

Voltage Research Center Labs

• Tests detailed description & results (Endorsed test Report of EL SEWEDY CABLES & High Voltage

Research Center testing labs)

• Testing equipments calibration certificates.

1. Tests Pictures.

v Bending Test PASSED

The test object was subjected to a bending test in accordance with IEC 60840 The test object was bent around a test cylinder. The diameter of the cylinder was 3300 mm. The test consisted of 3 cycles of wind, unwind, reverse winding direction, wind and unwind.

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v Verifying cable construction & Thickness of insulation PASSED

In this test a 20 cm of cable is totally destructed to its basic components, then every single component is visually & dimensionally checked against product data sheet.

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v Partial Discharge Test at room temp. After bending PASSED

The test object was subjected to a partial discharge test in accordance with IEC 60840 Measurement: The partial discharge was measured between the conductor and metallic screen for each phase. The voltage applied between the conductor & metallic screen was raised up to 1.75 U0 & held for 10 s and then slowly reduced to 1.5 U0. The magnitude of the partial discharge shall not exceed 3 PC.

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v Heating cycle voltage test PASSED

The assembly was heated by conductor current until the cable conductor reaches a steady temperature 5 °C to 10 °C above the maximum conductor temperature in normal operation ‘’ 95 °C in this case.The heating shall be applied for at least 8 h. The conductor temperature shall be maintained within the stated temperature limits for at least 2 h of each heating period. This shall be followed by at least 16 h of natural cooling to a conductor temperature within 10 °C of the test ambient temperature. The conductor current during the last 2 h of each heating period was recorded. The cycle of heating and cooling was carried out 20 times.

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v Tests for determining the mechanical properties of Non-Metallic Sheath & Insulation before and after ageing. PASSED

Two groups of dumb bell specimens (of HDPE sheath & insulation) are made. One group undergoes thermal ageing in the furnace at 100°c for a week & the other remains in room temperature. After ageing completion the two groups (Aged & Non-aged) is mechanically tested to differentiate between mechanical properties of Aged & Non-aged materials.

v Additional Ageing Test on a piece of completed cable PASSED

A complete specimen of cable is aged in the furnace to find out the act of complete cable after ageing & the effect on the mechanical properties of its components & compatibility of components together.

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v Partial Discharge Test at room temp. After Heating cycle PASSED

The same test as before but after heating cycle.

v Partial Discharge Test at temperature of 95--100°C PASSED

Same as above but at elevated temperature of 100°C

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v Impulse Voltage Test followed by AC Voltage Test PASSED

The Impulse test was performed on the assembly with the cable conductor temperature 5 °C to 10 °C above the maximum conductor temperature in normal operation. ‘’ 95 °C to 100 °C’’

The assembly shall withstand without failure or flashover 10 positive and 10 negative voltage impulses of 325 kV After the impulse voltage test, the assembly was subjected to a power frequency voltage test at 2,5 U0 for 15 min No breakdown of the insulation or flashover detected.

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v Tan DELTA Measurement PASSED

The sample was heated up until the conductor temperature reached to 97 C°. The dielectric loss factor (tan δ) was measured with an alternating voltage of 36 KV at the temperature specified above.

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v Measuring of specific resistance of Internal & External Semiconductor layers before and after ageing

PASSED

The resistivity of extruded semi-conducting screens applied over the conductor and over the insulation was determined by measurements on test pieces taken from the core of a sample of cable as manufactured and a sample of cable which has been subjected to the ageing treatment to test the compatibility of component materials. The measurements shall be made at a temperature within ±2 °C of the maximum conductor temperature in normal operation 90 °C The resistivity, both before and after ageing, shall not exceed the following values: – conductor screen: 1 000 Ω � m; – insulation screen: 500 Ω � m.

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v Hot set test for XLPE insulation PASSED

A thin strip of insulation is peeled apart & formed to the dumb bell shape. Then a known load is attached to it (depends on its dimensions) & put in the furnace for certain time & temp. (According to code 200 °C for 15 min.) Then the elongation ‘’ Max 175 %’’ is measured by a laser ray caliber. Then the sample is cooled to the room temperature to see how it will retain its original dimensions ‘’ Max differentiation allowed 4%’’

v Shrinkage test for XLPE insulation PASSED

A 200mm sample of cable is cut out & undergo 130 C for 6 hours then shrinkage in XLPE insulation is measured with max allowable 4% ‘’ 8 mm’’

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v Water penetration test. PASSED

A 6 m length of cable shall be cut from the length which has been subjected to the bending test and placed horizontally. A ring approximately 50 mm wide shall be removed from the centre of the length. This ring shall comprise all the layers external to the insulation screen. Where the conductor is also claimed to contain a longitudinal water barrier, the ring shall comprise all layers external to the conductor. Arrange a suitable device to allow a tube having a diameter of at least 10 mm to be placed vertically over the exposed ring and sealed to the surface of the over sheath. The seals where the cable exits the apparatus shall not exert mechanical stress on the cable. The Test The tube shall be filled within 5 min with tap water at a temperature of (20 ± 10) °C so that the height of the water in the tube is 1 m above the cable centre. The sample shall be allowed to stand for 24 h. The sample shall then be subjected to 10 heating cycles. The conductor shall be heated by a suitable method until it has reached a steady temperature 5 °C to 10 °C above the maximum conductor temperature in normal operation; it shall not, however, reach the boiling point of water. The heating shall be applied for at least 8 h. The conductor temperature shall be maintained within the stated temperature limits for at least 2 h of each heating period. This shall be followed by at least 16 h of natural cooling. The water head shall be maintained at 1 m. The Result No water leakage is noticed on both terminals of cable.After destructing the cable it was found that water penetrated the right side of the cable for 70cm & the left for 130cm

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NO evidence of water leakage on both terminations

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v Joint test. PASSED The sheath insulation used to enclose the joint will be subjected to the following tests; a. Impulse tests in accordance with Engineering Recommendation C55/4 ‘Insulated Sheath Power Cable Systems’ from the Electricity Council, UK. b. Water penetration tests in accordance with CENELEC HD 632 S1:1998 PART 2, Section 6.2.9 (page 2-61).

In this stage a piece of cable will be jointed through a new joint of the same type which was used in the loop test & it go through a heating cycle in a closed tank under 100cm of water seven times between 75°C & 80°C, this will last for seven days. Then two tests will be conducted:

1. DC test between water & every side of cable inside the joint to be sure that there is not any point of failure in the insulation of the joint. According to KAHRAMAA specs it will be 25kV for 5 minutes.

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2. Impulse test three times,

First will be between the two terminals of the joint to insure soundness of the isolation ring, (35kV, 10 positive pulses then 10 negative pulses.)

Second & third impulse tests will be between cable & water for every side of the cable (18kV, 10 positive pulses then 10 negative pulses )

This inspection was made without prejudice fit the ends and purpose for which it was assigned.

ANNEXES Yes (Total number of pages: ) No

Prepared by: Name: Mr. Mokhtar Bkkar Signature: Date of issue: 10 Jan 2009 Inspection centre: BV Cairo

Distribution: CLIENT MANUFACTURER BV Egypt

Documents

INSPECTION REPORT No. Egy/MB/08/722477/4 · 2020. 8. 27. · regarding the Type test for 1x630mm2 66Kv Cu Cable destined to project mentioned in first page of this report. El SEWEDY