138-1: 2015 CEB SPECIFICATION. AERIAL BUNDLE CONDUCTORS - 33 kv (95mm 2 and 150mm 2 )

Transcription

1 138-1: 2015 CEB SPECIFICATION AERIAL BUNDLE CONDUCTORS - 33 kv (95mm 2 and 150mm 2 ) CEYLON ELECTRICITY BOARD SRI LANKA Telephone: Fax:

2 CONTENTS Page 1.0 Scope System Parameters Service Conditions Applicable Standards Basic Features Technical Requirements Quality Assurance Additional Requirement Inspection & Testing Information to be furnished with the Offer Annex 9 Annex - A: Price Variation 10 Annex - B: Schedule of Guaranteed Technical Particulars 12 Annex C: Non-Compliance Schedule 15 2/15

3 1.0 SCOPE SPECIFICATION FOR AERIAL BUNDLE CABLES 33 kv (95mm 2 and 150mm 2 ) This specification covers the general requirements of the design, manufacture and test of Three Core Cross-linked Poly-ethylene (XLPE) Insulated 19/33 (36) kv, U 0 /U (U m ) Aerial Bundle Conductors with Circular Compacted Aluminium Core of 95mm 2 and 150mm 2, Copper Tape Screened and PVC & HDPE Oversheathed cable with insulated galvanized steel messenger. The cable conforming to BS 6622, 19 /33 (36) kv voltage designation shall be offered. 2.0 SYSTEM PARAMETERS (a) Nominal voltage (U) 33 kv (b) System highest voltage (U m ) 36 kv (c) System frequency 50 Hz (d) Method of earthing Non Effectively earthed (e) System faults level 13.1 ka (f) Fault duration 1s 3.0 SERVICE CONDITIONS (a) Annual average ambient temperature 30 C (b) Maximum ambient temperature 40 C (c) Maximum relative humidity 90% (d) Environmental conditions Humid tropical climate with heavily polluted atmosphere (e) Operational altitude From M.S.L. to 1900 m above M.S.L. (f) Isokeruanic (Thunder days) level 100 days (g) Solar Radiation 4.5 kwh/m 2 /day 4.0 APPLICABLE STANDARDS The conductor supplied shall be in accordance with the latest editions of the s specified below and amendments thereof. (a) (b) (c) (d) (e) BS 6622:2007 IEC : 2014 IEC 60840:2011 Electric cables. Armoured cables with thermosetting insulation for rated voltages from 3.8/6.6 kv to 19/33 kv. Requirements and test methods Power cables with extruded insulation and their accessories for rated voltages from 1 kv (Um = 1,2 kv) up to 30 kv (Um = 36 kv) Part 2: Cables for rated voltages from 6 kv (Um = 7,2 kv) up to 30 kv (Um = 36 kv) Power cables with extruded insulation and their accessories for rated voltages above 30 kv (Um = 36 kv) up to 150 kv (Um = 170 kv) Test methods and requirements BS EN/IEC 60228:2004 Conductors of insulated cables BS EN/IEC , 202,203,501:2012 Electric and optical fibre cables - Test methods for non-metallic materials - Part 201: General tests - Measurement of insulation thickness, Part 202: General tests - Measurement of thickness of non-metallic sheath, Part 203: General tests - Measurement of overall dimensions, Part 501: Mechanical tests - Tests for determining the mechanical properties of insulating and sheathing compounds Electric cables - Tests on extruded oversheaths with a special protective function (f) BS EN/IEC : 2007 (g) BS 183:1972 Specification for general purpose galvanized steel wire strand (h) BS EN :2009 Steel wire and wire products. Non-ferrous metallic coatings on 3/15

4 steel wire. Zinc or zinc alloy coatings (i) BS 2627:1970 Wrought Aluminium for Electrical Purpose CEB SPECIFICATION 138-1: BASIC FEATURES Aerial Bundle Conductor shall comprise of three numbers of phase cores and a steel messenger core. Three cores and the messenger shall be twisted together with right-handed lay (Z-lay) direction. 5.1 Phase Conductor Phase conductor shall be of Plain Aluminium manufactured in accordance with BS 2627 and with following features Conductor Conductor material shall be of Circular Compacted Aluminum with cross sectional area of 95mm 2 and 150mm 2. The resistance of each conductor at 20ºC shall be in accordance with BS EN / IEC s Conductor screen Conductor screen shall be of Extruded Semi-conducting Compound type. The extruded layer shall be continuous and shall cover the surface of the conductor completely. The Conductor Screen shall be applied in the same operation as the insulation and shall be fully bonded to the insulation. The volume resistivity of the conductor screen shall not exceed 500 Ω.m at 90 C when measured in accordance with Annex J of BS The thickness of the conductor screen shall be in accordance with BS Insulation The insulation shall be XLPE and shall be applied by extrusion and cross-linked to form a compact and homogeneous layer in accordance with the Standards specified. The thickness of insulation shall conform to the BS Insulation screen Insulation screen shall consist of non-metallic semi-conducting layer in combination with a metallic layer. Non-metallic semi-conducting layer shall be extruded in the same operation as the insulation. The extruded layer shall be continuous and shall cover the surface of the insulation completely. The insulation screen shall be cold strippable. The thickness of the insulation screen shall be in accordance with BS Note: The conductor screen, the insulation and the non-metallic insulation screen shall be extruded simultaneously in a single-head triple extrusion process Semi-Conductive water blocking tape Semi-Conductive water blocking tape shall be extruded or lapped with materials suitable for the operating temperature of the cable and compatible with the insulating materials. Conditions of cable hang above the ground in tropical humid conditions should be considered Metallic screen The core shall be covered with a Copper sheet screen complying to BS The cross sectional area of the metallic screen shall be able to withstand the specified fault current & duration in accordance with clause Longitudinal water barrier Non-Conducting water barrier swelling tape or powder shall be provided to protect against longitudinal water penetration. 4/15

5 5.1.8 Oversheath Oversheath shall be comprised of two sections as Inner Sheath and Outer Sheath stipulated below Inner Sheath The inner sheath shall be of Polyvinyl Chloride (PVC-ST2) and shall be suitable for the maximum operating temperature in accordance with clause 6. The colour of the inner sheath shall be black. The mean value of the thickness shall not be less than 1.0 mm Outer Sheath The outer sheath shall be of High Density Polyethylene (HDPE ST 7) and Black in colour (Ultra Violet - UV resistant). The mean value of the thickness shall not be less than 1.5mm. The outer sheath shall be embossed with figures 1, 2, 3 or Ribs. When Ribs are provided to identify cores, they shall be so made to enable workmen to identify the cores easily. The combined inner and outer sheath shall withstand the DC voltage test in accordance with the relevant BS This test shall be carried out on each delivery length Graphite Coating A coating of Graphite shall be applied over the over sheath to carry out D.C. Voltage Test. 5.2 Messenger Wire Messenger shall bear the weight of the conductor with the support of hardware accessories and shall prevent the stretching of the conductor Conductor Material of the messenger shall be circular compacted galvanized steel. The minimum breaking loads of the messenger with respect to 95mm 2, 150mm 2 phase conductors are stipulated below. Nominal cross sectional area of the phase conductor Minimum breaking load of the messenger 95mm 2 150mm 2 49kN 62kN Insulation The insulation shall be of High Density Polyethylene (HDPE-ST7), UV resistant, and shall be suitable for the maximum operating temperature in accordance with clause 6. The colour of the insulation shall be black. The mean value of the thickness shall not be less than 1.5mm and compliance shall be checked by carrying out tests given in the relevant BS s. 6.0 TECHNICAL REQUIREMENTS (a) Nominal Voltage (U) 33 kv (b) System Highest Voltage (U m ) 36 kv (c) Maximum Fault Current and Duration 13.1 ka, 1s (d) Basic Insulation Level (BIL) 194 kv (e) Maximum Normal Operating Temperature 90 C (f) Maximum Design Stress 5 kv/mm (g) Insulation Medium XLPE 5/15

6 7.0 QUALITY ASSURANCE The manufacturer shall possess ISO 9001:2008 Quality Assurance Certification valid throughout the delivery period of this bid, for the manufacture of XLPE Insulated 33 kv Aerial Bundle Conductors for the plant where manufacturing is being done. The Bidder shall furnish a copy of the ISO certificate certified as true copy of the original by the manufacturer, along with the offer. 8.0 ADDITIONAL REQUIREMENTS 8.1 Manufacturing Experience The manufacturer shall have minimum of eight (8) years experience in manufacturing XLPE Insulated 33 kv Aerial Bundle Conductors. In addition, minimum of five (5) years experience shall be in manufacturing for orders from outside the country of the manufacturer. The product offered has to be in same voltage range of offered item and shall have been used in service utilities over past 5 years. Manufacturer shall furnish a list of purchasers with year and quantity of the product offered with the offer to prove his manufacturing experience. 8.2 Packing The cables shall be supplied in non-returnable drums. Drums shall be made of steel and a polythene lining shall be provided to prevent any damage to cable from the chemical used for preservation of timber battens. The drum shall be lagged with closely fitted battens to protect cable from damage. The ends of cables shall be sealed with heat shrinkable caps to prevent the ingress of moisture during transportation and storage. The length of cable per drum shall be 500 meters. The cable length per drum shall not vary more than ±2%. 8.3 Identification and Labeling The word "CEB", voltage rating as U 0 /U (U m ), adopted, conductor size, year of manufacture, manufacturer s name or trade mark and travel length shall be embossed at intervals as stipulated in BS s, on the outside of the over sheath. The embossing shall be weatherproof and abrasion proof Drum Each drum shall be labeled (with clear stencil) with the following; 8.4 Technical Literature (a) PROPERTY OF CEYLON ELECTRICITY BOARD (b) Bid No Serial No... (c) Manufacturer's identification. (d) Cable Type, Voltage Rating, Conductor Size and Number of Cores. (e) Number and year of adopted. (f) Net Weight & Gross Weight in kg. (g) Length of cable in meter. (h) Direction of rolling (i) Year of Manufacture. Adequate consideration shall have been given in the design of the conductor and in the manufacturing process on the following. (a) Maximum design electrical stress shall be such that purity of raw materials, manufacturing conditions and ageing of cables have been taken into account. Maximum design stress shall not be more than 5kV/mm. (b) Purity of raw materials. 6/15

7 (c) Close control of extrusion process to achieve smooth extruded surfaces, homogeneous extrudates and prevention of void formations. Documentary evidence on the above shall be provided along with the offer. 9.0 INSPECTION AND TESTING 9.1 Type Test It is mandatory to provide Type Test certificates conforming to the requirements stipulated either in Section G.3 of Annex G of BS6622 (as denoted in below) or in Section 14 of IEC (as denoted in below), provided; (a) The type tested cable should have same insulation material, same form of semi-conductor screen, same manufacturing process but the conductor material can be aluminium or other. (b) Type tested cable should be of equal or higher voltage designation. (c) Cross sectional area of the cable type tested shall not be smaller than the requested cable. In addition, messenger wire shall undergo type tests as stipulated in irrespective of the type tests carried out in or For cable conforming to BS 6622 (a) Conductor screen resistivity (b) Insulation material (c) Insulation screen resistivity (d) Insulator screen cold strippability (e) Semi-conducting lapped inner covering resistance (f) Separation sheath material (g) Tests on oversheath Material (h) Compatibility test (i) Test under fire conditions (j) Partial discharge test (k) Bending test (l) Tan δ in relation to voltage (m) Tan δ in relation to temperature (n) Heating cycle test (o) Impulse voltage test (p) Four-hour voltage test (q) Adherence of screens at short circuit temperature (r) Resistance of the cable at 20 C For cable conforming to IEC (a) Bending test followed by installation of the test terminations and a partial discharge test (b) Tan δ measurement (c) Heating cycle voltage test, followed by a partial discharge measurement at ambient temperature, which shall be carried out after the final cycle or alternatively, after the lighting impulse voltage test (d) Partial discharge test (e) Examination of the cable on completion of the above tests (f) The resistivity of the semi-conducting screen shall be measured on a separate sample. (g) Check of cable construction (h) Test for determining the mechanical properties of insulation before and after ageing (i) Tests for determining the mechanical properties of oversheath before and after ageing (j) Ageing test on piece of complete cable to check compatibility of materials (k) Loss of mass test on PVC sheaths of type ST2 (l) Pressure test at high temperature on oversheaths (m) Test on PVC oversheaths at low temperatures (n) Heat shock test for PVC oversheaths (o) Test under fire conditions (p) Water penetration test (q) Shrinkage test for XLPE insulations 7/15

8 9.1.3 For Messenger Wire conforming to BS 183, BS EN (a) Mass of zinc coating (b) Adhesion of coating (c) Wrapping Test (d) Wet compatibility test (e) Ultimate tensile strength of the messenger Type Test Certificates should clearly indicate the relevant, Items concerned, showing the manufacturers identity, type No. /catalogue No. and basic technical parameters. Test certificates referred to shall be from an accredited independent testing laboratory acceptable to the purchaser. Proof of accreditation by a national/ international authority shall be forwarded with the offer. Test reports shall be complete including all the pages as issued by the testing authority. Type test reports shall be in English language. Parts of test reports shall not be acceptable. 9.2 Routine Test The following Routine Tests in accordance with BS 6622 shall be carried out on all cable drums irrespective of type tests given under clause or clause and test reports shall be furnished for the observation of the Engineer appointed by the purchaser at the time of inspection. 9.3 Inspection (a) Spark test on oversheath (b) Conductor resistance (c) Copper sheet screen resistance (d) Partial discharged test (e) Voltage test on complete cable (f) Cable marking (g) D.C. voltage test on oversheath (h) Galvanize thickness of messenger wires (i) Dimensional test on messenger wires The Successful bidder shall make necessary arrangements for inspection by an Engineer appointed by the CEB and also to carry out in his presence necessary Acceptance tests on equipment and material. CEB may waive off the inspection with the condition of witnessing the acceptance tests by an independent testing authority acceptable to CEB. In such a situation a notice of waive off will be issued in advance to the supplier. 9.4 Acceptance Test The following Acceptance/Sample tests in accordance with BS 6622 shall be carried out irrespective of type tests given under clause and clause and witnessed by the Engineer. (a) Conductor material and construction (b) Conductor screen application (c) Insulation, hot set test (d) Insulation, thickness (e) Insulation, concetricity (f) Circularity of cores (g) Insulation tests on screen (h) Metallic screen, application (i) Measurement of messenger wire (j) Oversheath thickness (k) Four-hour voltage test (l) Conductor resistance test 8/15

9 10.0 INFORMATION TO BE FURNISHED WITH THE OFFER The following shall be furnished with the offer. (a) A comprehensive catalogue on the types and sizes of Aerial Bundle Cables 33 kv offered. It shall necessarily include details about construction of the cable, mechanical properties and electrical properties of the earth rod (And material used). (b) Type Test Certificates in accordance with the clause 9.1. (c) Duly filled and signed Guaranteed Schedule of Technical Particulars. (d) Documents to prove manufacturer s experience in accordance with Clause 8.1. (e) Documentary evidence in accordance with clause 8.4. (f) ISO 9001:2008 Quality Assurance Certificate in accordance with clause 7. (g) Overall dimensional drawings. (h) A dimensional drawing of the drum. Failure to furnish the above information will result in the offer being rejected ANNEX Annex A : Price Variation Annex B : Schedule of Guaranteed Technical Particulars Annex C : Non-Compliance Schedule 9/15

10 Annex- A PRICE VARIATION The Bidders shall forward their offers on the basis of the Price Variation stipulated below. 1.0 BASIS OF THE OFFER (a) Bidders are required to make their offers on the basis of a Base Price (Bo) plus a Fixed Price Margin (FP). (b) The Base Price shall be the Cash Seller's Midday Official Average Price of Aluminium High Grade 99.7%, Steel and Copper (Grade A) at London Metal Exchange (LME) in US Dollars on the day of the closing of Bids or the previous working day if the day of closing of Bid is a non working day at the LME. (c) The Fixed Price Margin shall be quoted in the currency of choice of the Bidder in the case of foreign Bidders and in Sri Lanka Rupees in the case of Local Bidders. (d) Accordingly FOB Price of foreign Bidders offering cables from outside the country and the exfactory price of Local Bidders shall be computed as; Where; [( Bo X MT x US ) + ( BS x MTS x US ) +( BC x MTC x US ) + ( FP x CC )] x TL Bo - Base Price which is the Cash seller's midday official average price of Aluminium High Grade 99.7% in USD per Metric Ton at the LME on the fixed date (Clause (b) above). BS - Base Price which is the Cash seller's midday official average price of steel in USD per Metric Ton at the LME on the fixed date (Clause (b) above). BC - Base Price which is the Cash seller's midday official average price of Copper Grade-A in USD per Metric Ton at the LME on the fixed date (Clause (b) above). FP - Fixed Price Margin per kilometre of Cable in the Currency of choice. MT - Quantity of Aluminium High Grade 99.7% required to manufacture one kilometre of cable in Metric Ton. MTS- Quantity of Steel required to manufacture one kilometre of cable in Metric Ton, as MTC- Quantity of Copper Grade-A required to manufacture one kilometre of cable in Metric Ton, as TL - Total Length of Cable as CC - Conversion rate from the currency of choice to Sri Lankan Rupees prevailing on the Date of Bid opening. US - Conversion rate from the US Dollars to Sri Lankan Rupees prevailing on the date of Bid opening. 2.0 AWARD PRICE (a) The FOB Award Price for Bidders offering Cables from outside the Country and the Ex-factory Award Price of Local Bidders offering Cables shall be computed as; Where; [( B1 X MT x US ) + ( B1S x MTS x US ) + ( B1C x MTC x US ) + ( FP x CC )] x TL B1 - Base Price which is the Cash seller's midday official average price of Aluminium High Grade 99.7% in USD per Metric Ton at the first working day immediately after the day of award B1S - Base Price which is the Cash seller's midday official average price of Steel, in USD per Metric Ton at the first working day immediately after the day of award 10/15

11 B1C - Base Price which is the Cash seller's midday official average price of Copper Grade-A, in USD per Metric Ton at the first working day immediately after the day of award (b) Intimation of the award will be faxed/telexed to the successful Bidder and or his agent in Sri Lanka. 3.0 CONVERSION OF CURRENCY (a) For the purpose of the evaluation the Price Bo in US Dollars and the Fixed Price Margin (FP) in the currency of choice of the Bidder will be converted to Sri Lanka Rupees at the official Middle Exchange Rate of the Central Bank of Sri Lanka prevailing on the day of opening of Bids. (b) The payment for the supply of Cables outside the country will be made to the Supplier at the contract price in the currency quoted for the Fixed Price Margin (FP). The base price B1 in US Dollars will be converted to the currency of the FP at the exchange rates indicated in the bulletin of the LME on the first working day immediately after the date of the award of the offer; where such exchange rate is not available for the currency of the FP in the Bulletin the official middle exchange rate at the Central Bank of Sri Lanka shall be. (c) The payment for supply of Cables from within the Country by Local Suppliers will be made in Sri Lanka Rupees. The Base Prices, B & B1 in US Dollars will be converted to Sri Lanka Rupees at the official Middle Exchange rate at the Central Bank of Sri Lanka prevailing on the date of the letter of award. 4.0 VARIATION FIGURES The Bidders shall furnish Fixed Price Margin and the weight of Aluminium/Steel required to manufacture one kilometre of Cables of each type and size as indicated below. Failure to furnish these particulars will result in the offer being rejected. (I) Description of the ABC offered Voltage Rating U/U 0 (Um) (kv) - Material of Conductor - Area of the Conductor (mm2) - (II) Fixed Price Margin for manufacture of one kilometre of Cable in the currency of choice (FP) - (III) Weight of Aluminium High Grade 99.7%required to manufacture one kilometre of Cable (kg/km) - (IV) Weight of Steel required to manufacture one kilometre of Cable as (kg/km) - (V) Weight of Copper Grade-A required to manufacture one kilometre of Cable as (kg/km) -.. Signature of the Manufacturer and seal.. Date I/We certify that the above data are true and correct Signature of the Bidder and seal.. Date 11/15

12 Annex- B SCHEDULE OF GURANTEED TECHNICAL PARTICULARS (Following Information shall be furnished with the offer) CEB Requirement 1. Name of the Manufacturer 2. Country of Origin 3. Rated Voltage category, U 0 /U (U m ) 19/33 (36) kv BS 6622/ IEC 4. Applicable Standards as 5. Conductor Particulars A) Phase Conductor (a) Nominal cross sectional area. mm 2 95mm 2 /150mm 2 (b) Diameter mm (c) Number of strands. Nos. (d) Diameter of strands. mm (e) Material Aluminium (f) Shape Round (g) Type I. Solid / Stranded Stranded II. Compact / Non compact Compact (h) Overall diameter of the conductor (i) Maximum DC Resistance of the conductor at 20 C (j) Maximum AC Resistance of the conductor at 20 C (k) Maximum Current Carrying Capacity at 27 C (In Air) 12/15 mm (l) Capacitance µf/ km B) Messenger (a) Nominal cross sectional area. mm 2 (b) Diameter mm (c) Number of strands. Nos. (d) Diameter of strands. mm (e) Material Ω Ω A As per the As per the As per the Galvanized Steel Round (f) Shape (g) Type III. Solid / Stranded Stranded IV. Compact / Non compact Compact (h) Oversheath I. Material II. Nominal thickness mm (i) Overall diameter of the messenger (j) Ultimate Tensile Strength of the Messenger 6. Conductor Screen Particulars (a) Material (b) Thickness (c) Method of Application (d) Whether applied in the same operation as insulation mm kn mm High Density Poly Ethylene Extruded Semi- Conducting compound As per Extruded Offered

13 7. Insulation Particulars (a) Material XLPE (b) Extrusion process 13/15 Triple As per I. Minimum average mm As per II. Minimum at a point mm 8. Insulation Screen Particulars Non-metallic (a) Type semiconducting I. Semi-conducting layer Extruded II. Metallic No III. Strippability Cold Extruded semi (b) Material conducting compound As per (c) Maximum Electrical Stress 9. Metallic Screen Particulars (a) Fault withstand capability in accordance with clause 5.1.6? I. Fault current ka 13.1 ka II. Duration sec 1 s (b) Is metallic screen a Copper Sheet I. Thickness of a Copper Sheet mm (c) Resistivity of Copper Sheet in accordance with clause 5.1.6? 10. Semi-Conductive water blocking tape 11. Longitudinal water blocking (a) Form of water blocking material 12. Oversheath Particulars for Phase Conductors (a) Inner Sheath I. Type/Material II. Nominal thickness mm (b) Outer sheath III. Type/Material IV. Nominal thickness mm (c) Whether Graphite layer provided (d) Whether DC test on oversheath carried out 13. Overall diameter of Complete Conductor mm 14. Approximate weight of Complete Conductor kg/ km 15. Minimum bending radius of Complete Conductor mm 16. Whether the cable ends are sealed before shipping Indicate the details of marking provided on the over sheath. (a) Cable Designation (b) Identification of manufacturer Whether the maximum symmetrical short circuit current rating curves for 0.2 to 3 Sec. duration furnished Maximum allowable conductor temperature at short circuit condition Yes As per the Yes Yes Yes As per 8.2 As per the clause Yes

14 (a) Full Load conditions C/ Duration (b) Short Circuit conditions C/ Duration (c) Over load conditions C/ Duration (d) Allowable maximum overloading in determining the above %/A 20. Drum Particulars (a) Material of the drum Steel (b) Dimensions. mm x mm (c) Weight kg (d) Standard cable length m 500m (e) Weight of length with drum kg Whether a certified copy of ISO 9001:2008 furnished with the offer? Whether the entire Type Test Certificates in accordance with clause 9.1 furnished with the offer? Signature of the Manufacturer and seal.. Date I/We certify that the above data are true and correct Signature of the Bidder and seal.. Date 14/15

15 Annex C Non-Compliance Schedule On this schedule the bidder shall provide a list of non-compliances with this specification, documenting the effects that such non-compliance is likely to have on the equipment life and operating characteristics. Each non-compliance shall be referred to the relevant specification clause. Clause No. Non-Compliance. Signature of the Manufacturer and seal. Date I/We certify that the above data are true and correct Signature of the Bidder and seal.. Date 15/15