SPECIFICATION NO. 2.

3
(Revised in May 2002)

SPECIFICATION FOR HEAT SHRINKABLE KITS FOR

11KV AND 33KV XLPE AND PAPER INSULATED CABLES
AND TRANSITION JOINTS FROM PAPER TO XLPE CABLES

1.1 Standard Specifications:

The Heat Shrinkable terminations and joints shall conform to the latest edition of
ESI-09-13 or any other equivalent international standard, which shall be subject to the
approval of the Authority. One copy of each specification in English language to which
the terminations and joints are manufactured and tested shall be submitted with the
offer.

1.2 Site conditions:

The joints and terminations shall be installed indoors and outdoors in U.A.E. in salt
laden dusty atmosphere where the maximum humidity of 100% and maximum
ambient temperature of 50 Deg.C. can be experienced. The terminations and joints
shall be suitable for continuous operation at the above site conditions.

1.3 Scope of nature of work:

The specification provides for design, manufacture, test at manufacturer's works in

presence of FEWA representatives, suitable packing, transportation and off loading at
FEWA stores in satisfactory condition and proper stacking as directed by FEWA or
otherwise specified else- where. These terminations and joints shall be used for XLPE
and paper insulated cable, indoor or outdoor for 11kv and 33kv system and also for
transition joints from paper to XLPE insulated cables.

1.4 System voltage, quality of joints etc.

Heat shrinkable kits are required for XLPE and paper insulated cables in 11kv and
33kv nominal voltage, 50Hz, 3 phase system with system highest voltages of 12kv
and 36kv respectively. Both outdoor and indoor type of joints and terminations are
required as per the Bill of Quantities. For outdoor and indoor terminations, the tubing
length shall be stated during tendering for items requested in the Bill of Quantity.

Components shall not be adversely affected in any manner by contact with other
materials normally used in the construction of cable joints and terminations, and
shall not increase the rate of corrosion of any metal with which they may come into
contact. Assembled components forming part of a supply system shall perform
without distress under the following conditions.

i) Normal conditions : Continuous operation at a conductor

temperature of 90 Deg. C. for XLPE
insulated cables.
: Continuous operation at a conductor
temperature of 70 Deg. C. for paper
insulated cables.

ii) Fault conditions : Operation at a conductor and screen

temp. of 250 Deg.C. for XLPE.
: Operation at a peak transient
conductor/metal sheath temp. of
160 Deg.C. and 250 Deg.C.
respectively for Paper.
 2.3/2

1.5 Type of cables for which joints/terminations are required.

1.5.1 11 KV Cables:

3 core, XLPE insulated, copper tape/wire screened, single steel wire armoured, PVC
Sheathed Aluminium conductor cables or otherwise as stated in the Bill of Quantity.

Single core copper conductor of compacted circular stranded annealed plain wires,
XLPE insulated, copper tape/wire as stated in B.O.Q.

3 core, Aluminium/Copper conductor, paper insulated, MIND cable as stated in the Bill
of Quantity.

1.5.2 33 KV Cables:

Single core copper conductor of compacted circular stranded annealed plain wires,
XLPE insulated, copper tape/wire screened and PVC over sheathed cables as per
IEC 502/78 or otherwise as stated in the Bill of Quantity.

Three core copper conductor XLPE insulated, copper tape/ wire screened steel wire
armoured, PVC sheathed cable as per IEC 502/78 or otherwise as stated in bill of
quantity.

1.6 Technical Specifications:

The term "heat shrinkable" is applied to extruded or moulded polymeric materials,

which are cross-linked either by irradiation or chemical means, such that when their
temperature is raised beyond the normal base polymer crystalline melting point, they do
not melt but merely become rubbery. In this state if the material is then
mechanically expanded and held in this position until the temperature falls below the
crystalline melting point, it remains in the expanded state. Sub- sequent heating in an
unconstrained state will then result in the material recovering or "shrinking" to its
original extruded or moulded size and shape.

Electric stress control for the cable insulation screen in termination and joints shall be
achieved by heat shrinkable tubing. Joints shall include ferrules and all
necessary items.

This tubing shall have defined impedance characteristic, volume receptivity, and
dielectric constant in accordance with IEC. 93 and IEC. 250.

Sealing of the interfaces between heat shrinkable materials and/or cable surfaces
shall be achieved by using a track resistant sealant or a hot melt adhesive. This
sealant/ adhesive shall be precoated inside the heat shrinkable components and
activated by the heat applied to shrink the components.

Complete external leakage insulation between the high voltage conductor and
ground shall be achieved by utilizing heat shrinkable tubing and moulded parts. No
filling medium shall be required.

These components shall be weather, ultra violet light and salt pollution resistant.

Full drawing of a joint and termination including all parts must be forwarded with the
tender documents.
 2.3/3

Technical characteristics already established for termination and joints must meet
the minimum requirements of lists 1,2,3 and 4 of ESI standard 09-13.

1.7 Component types and sealants:

1.7.1 Tubing components:

The tubing components shall consist of following tubes and shall conform to the
requirements given in List 1 of ESI-09-13.

i) Internal insulating tubing.

ii) Stress control tubing.
iii) Anti-track tubing (Indoor)
iv) Anti-track tubing (Outdoor)
v) External protective tubing.

1.7.2 Moulded components:

The moulded components shall consist of following components and shall conform
to the requirements given in List 2 of ESI 09-13.

i) Anti-track insulating Glove (Indoor)

ii) Anti-track insulating Glove (Outdoor)
iii) Conducting Glove.
iv) Anti-track shroud (Indoor)
v) Anti-track weather shed (outdoor)
vi) Crutch Di-electric Fillers.

1.7.3 Sealants:

The sealants shall conform to the requirements given in List 3 of ESI 09-13.

1.8 GENERAL REQUIREMENTS OF INSTALLED JOINTS

AND TERMINATIONS:

The installed joints and terminations must provide the following:

1.8.1 Complete external leakage insulation between the high voltage conductor and earth
potential using anti-track heat shrink material.

1.82 Electrical stress control using semi-conducting heat shrinkable tubing over the cores
and by the insertion of high di-electric strength insulating material into the crutch of the
termination such that electrical discharge activity does not occur in the
termination after it has been energized at its rated voltage.

1.8.3 Hermetic sealing of the interfaces between heat shrinkable materials and cable
surfaces, bushings or cable lugs by use of track resistant hot melt adhesive which
can accommodate the creep and relaxations that may occur with recovered heat
shrink materials.

This sealant shall be pre-coated inside the heat shrinkable components and
activated by the heat applied to shrink the components, which shall be in excess of
125 Deg. C.

Uniform adhesive flow from the adhered heat shrink component into the adjoining
surfaces will be used as an indicator that shrinking is complete, and therefore, the
adhesive must be suitable for this purpose.
 2.3/4

1.8.4 The installed terminations and joints shall meet the electrical requirements laid down
in this Specification.

1.8.5 Outdoor terminations shall incorporate a design feature to prevent flexing of the
terminated cores under short circuit conditions.

1.8.6 Joints and terminations must be insensitive to cable manufacturers tolerances

allowed under BSS 6480-1969.

1.8.7 The successful tenderer will be required to supply overhead line insulators and
support brackets for outdoor terminations in line with the schedule of quantities.
These brackets must be designed for mounting on wooden poles such that the
terminating cores may be cut to the same length, measured up from the sheath
terminus of the cable termination.

1.8.8 The length of core insulation required with switchgear and transformer terminations
is 450 mm per phase.

1.8.9 The length of core insulation required with outdoor pole-top terminations is 900 mm
per phase.

1.8.10 Cable crutch filling shall be such that it blocks the oil of paper insulation from
draining out.

1.8.11 Copper braid should be provided to connect the metal shield of XLPE cable to the
lead sheath of paper cable and to make electrical contact with the outer screen of
the joint for transition joints.

1.8.12 Galvanized steel joint case comprising two interlocking half shells should be
provided for mechanical strength of joints.

1.9 SUPPLY OF TECHNICAL INFORMATION,

TEST CERTIFICATES AND SAMPLES:

1.9.1 Tenderers must submit full specification and samples of the materials offered.

1.9.2 Tenderers must submit a detailed design of the overhead line support brackets for
outdoor terminations offered, including details of the materials used in manufacture
of the bracket.

1.9.3 Manufacturers who have not previously supplied heat shrinkable joints and
terminations to FEWA must submit a list of all electrical utilities in the Middle East to
whom they have supplied heat shrinkable joints and terminations at voltages of 11kv
and above. The information listed below must be supplied for each order quoted.

1. Name of utility
2. Order Number
3. Order period (From........to... .)
4. Order value
5. Total number of joints and terminations supplied
6. Number and details of each size of joint or terminations supplied.
7. System voltage for which joints and terminations were supplied.
8. Specification of the cable for which the joints or terminations were supplied.
9. Set of installation instructions for the joints and terminations supplied
showing clearly the components used in making the joint or termination.
 2.3/5

1.10. Testing:

Electrical performance tests mentioned in clause 1.10.4 shall be carried out on

samples chosen at random in presence of FEWA representatives at manufacturer's
works. Certified copies of the type test certificates mentioned in clause 1.10.2 &
1.10.3 shall be supplied along with the offer. The supplier shall make provision in his
offer to bear all costs that are incurred in carrying out these tests to the
satisfaction of FEWA. However, costs towards travel, accommodation etc. of FEWA
representatives shall not be included in the quoted price.

1.10.1 Material Tests:

The following tests shall be performed to verify the quality of material requirements.
The tests shall be carried out in the manner specified in ESI 09-13, Parts 3 and 4
and shall satisfy the requirements stated therein:

1.10.2 Tests for Tubing and Moulded Components:

1. Corrosion Resistance
2. Density
3. Dimensions
4. Electric strength
5. Flame Retardance
6. Fungus resistance
7. Heat Shock
8. Low Temperature Flexibility
9. Relative permittivity
10. Secant Modulus
11. Solvent Resistance
12. Tensile strength and ultimate elongation
13. Thermal Ageing
14. Tracking Resisting
15. Visual Examination
16. Volume Resisting
17. Water Absorption
18. Water Vapour Permeability
19. Weather Resistance

1.10.3 Tests for Sealants:

1. Corrosion Resistance
2. Electric strength
3. Flow at elevated temperature
4. Internal pressure sealing ability
5. Low temperature flexibility
6. Peel strength
7. Solvent Resistance

1.10.4 Electrical Performance Tests:

The following tests shall be carried out to check the electrical performance of the
components:
 2.3/6

Standard

i) A.C. Voltage withstand - for indoor termination IEC.60

ii) Partial discharge - for screened cables IEC.270
ii) Impulse voltage withstand IEC.60 & IEC.230
iv) Load cycling IEC.230
v) Thermal short circuit VDE.0278
vi) D.C. Voltage withstand I EC.60
vii) Humidity - for termination IEC.466
viii) Dynamic short circuit VDE.0278
ix) Salt fog - Outdoor termination IEC.507

Test values shall be forwarded in four copies to FEWA representative.

The preferred test sequence shall be :

1. A.C. Voltage withstand

2. Partial discharge
3. Impulse voltage withstand
4. Load cycling
5. Partial discharge
6. Thermal short circuit
7. Load cycling
8. Partial discharge
9. Impulse voltage withstand
10. D.C. voltage withstand
11. Humidity
12. A.C. Voltage withstand
13. Dynamic short circuit
14. Salt Fog.

1.10.5 Test Methods:

1. A.C. Voltage Withstand:

This test shall be carried out in accordance with IEC 60. For test No. 1 in the
Sequence, the test voltage shall be applied for 1 minute. For outdoor terminations, the
test shall be carried out under rain. The rain shall have an incidence angle of 45 Deg.,
a rate of 3mm/minute and a conductivity of 100uS/cm.

The test voltage shall be 35KV for the 11KV system and 75KV for the 33KV system.
The voltage shall be applied between the phase and ground.

For test No. 12 in the sequence, the test voltage shall be 24KV for the 11KV and
72KV for the 33KV system, and the voltage shall be maintained for 4 hours.

2. Partial Discharge:

This test shall be carried out in accordance with IEC 270. The test voltage shall be
7.5KV phase/ground for the 11KV and 22.5KV for the 33KV system. The
requirement is that the discharge level shall not exceed 20 pc.
 2.3/7

3. Impulse Withstand Test:

The test shall be in accordance with IEC 60 and IEC 230. The phase/ground test
values for indoor and outdoor use shall be 75KV/95KV (peak) for 11KV and
170KV/200KV (peak) for 33KV systems. 10 positive and 10 negative, 1.2/50 uS
impulse shall be applied.

4. Load Cycling Test:

The test shall be in accordance with VDE 0278 or IEC 230. The test voltage shall be
15KV and 45KV for 11KV and 33KV systems respectively.

5. Thermal Short Circuit Test:

Test shall be in accordance with VDE 0278. Two of one second tests each shall be
performed.

6. D.C. Voltage Withstand Test:

The D.C. Voltage withstand Test shall be in accordance with IEC 60 for 11KV and
33KV systems respectively.

7. Humidity Test:

Terminations shall be tested in accordance with IEC 466 Appendix C. The sample
shall be subjected to an A.C. Voltage for 100 hours in a humidity chamber, where
water with a conductivity of 800 uS/cm. shall be sprayed at a rate of 0.4 L/h per
cubic metre of the test chamber. The test voltages shall be 7KV and 21KV for 11KV
and 33KV systems respectively.

8. Dynamic Short Circuit:

The test shall be in accordance with VDE 0278 on accessories for 3 core cables.
The cable used shall be of a cross-sectional area not less than 120 sq.mm.

9. Salt Fog Test:

This test shall be carried out in accordance with IEC 507 on outdoor terminations
only. The sample shall be exposed for one hour to a salt solution with a
concentration of 160 g/litre. The phase/ground test voltages shall be 7.5KV
and
22.5KV for 11Kv and 33KV systems respectively.

1.11 Identification and Packaging:

For the purposes of identification, gloves shall be marked clearly and permanently in a
prominent position with the supplier's name and reference number.

Electrically conducting components shall be marked "Conducting clearly and

permanently".

Components shall normally be supplied in a package as a complete joint or

termination, which shall be clearly marked with the supplier's name, reference
number, batch references, voltage, application and cable size. In addition, FEWA
part numbers as indicated in the bill of quantity shall be marked on the package.
 2.3/8

Packaging shall be designed to protect against ingress of moisture and mechanical

damage. Components supplied with adhesive coatings shall have means to prevent
the coated surfaces from adhering to each other.

The complete heat shrinkable components, required to complete in all respects one
termination shall be supplied in a kit form; one joint to be supplied in kit form.

1.12 Storage:

Components shall be capable of being stored without deterioration within the

temperature range of - 10 Deg.C. to + 45 Deg.C. Components or materials, if
subject to a shelf life limitation shall have the final date of use prominently and
permanently shown on all packaging.

T-2-3
sm
 2.3/9

SCHEDULE ‘A’

SUB-MANUFACTURERS

The Tenderer shall state below the names of the sub-manufacturers to the main
manufacturer and details of the equipment proposed to be manufactured or supplied by
them:

Name & Address of the Sub-Manufacturer Description of Equipment

Signature :_________________________

Designation :_________________________

Name of Tenderer ;_________________________

Date :_________________________
 2.3/10

SCHEDULE ‘B’

PLACE OF MANUFACTURE, TESTING AND INSPECTION

The Tenderer to complete the following schedule for all materials he proposes to supply

Item Place of Place of testing

No. Description Manufacturer manufacture and inspection

Signature :_________________________

Designation :_________________________

Name of Tenderer ;_________________________

Date :_________________________
 2.3/11

SCHEDULE ‘C’
DEVIATION FROM TENDER SPECIFICATION
The Tenderer to state in the following schedule the deviations from the tender specifications
proposed in his offer. Deviations other than those specifically listed below will not be taken
note of:
Item
No. Description Precise Details of the Deviations

Signature :_________________________

Designation :_________________________

Name of Tenderer ;_________________________

Date :_________________________
 2.3/12

SCHEDULE 'D'

GUARANTEED PARTICULARS FOR HEAT SHRINKABLE KITS

Tenderers ared to give the following particulars for straight through joints and terminations.
Tenderers are also required to submit a detailed list of the components of each joint and termination.

Termination
Sl Indoor with Straight
No. Description Outdoor Right Straight Joint
Angle Boot Angle Boot
33KV 11KV 33KV 11KV 33KV 11KV 33KV 11KV

1. Manufacturer's Name

2. Applicable Standard

3. Nominal Voltage KV

4. One minute dry withstand voltage KVrms

5. One minute wet withstand voltage KVrms

6. D.C. withstand voltage for 30 minutes in KV

7. Impulse withstand voltage dry in KV

(Peak)

8. Partial discharge level in pc

9. a) Discharge inception voltage KV

b) Discharge extinction voltage KV

10. Material of the heat shrinkable kit

11. Dielectric strength KV/mm

12. Volume resistivity OOhm/cm

13. Dielectric constant

14. Dissipation factor

15. Tensile strength N/mm²

16. Elongation %

17. Moisture absorption %

18. Brittle temperature

Signature of Tenderer ; ___________________________

S-2-3 (4) xls. Sm.

 2.3/13
SCHEDULE 'D'
GUARANTEED PARTICULARS FOR HEAT SHRINKABLE KITS

Termination
Sl Indoor with Straight
No. Description Outdoor Right Straight Joint
Angle Boot Angle Boot
33KV 11KV 33KV 11KV 33KV 11KV 33KV 11KV

19. Standards

20. Safe continuous operating temp.

21. Tail length in termination 1200 900 450 450 450 450 - -

22. Stress control distribution, attach literature

for joints and terminations

23. Provision of catalogues for joints & terminations

Signature of Tenderer : __________________________

Designation : __________________________

Name of Tenderer : __________________________

Date : __________________________

S-2-3 (4) xls. Sm.

 2.3/14

SCHEDULE ‘E’

DETAILS OF PAST EXPERIENCE OF MANUFACTURER

Year
Quantity
Name and address of
Supplied remarks
supply

Signature :_________________________

Designation :_________________________

Name of Tenderer ;_________________________

Date :_________________________
 SPECIFICATION NO. 2.4
(Revised in May 2002)

SPECIFICATION FOR (A) COLD SHRINKABLE TERMINATION

(B) PRE-MOULDED JOINT AND TERMINATION KITS FOR
11KV AND 33KV XLPE INSULATED CABLES

(Straight Joints and Indoor/Outdoor Terminations)

1 Standard Specifications:

The joint and termination shall conform to the latest edition of VDE 0278, IEEE 48-
1990 and B.S.C -89, IEEE-404 for completed cable accessories and for
components ASTMD 149-90, D150-87, D412-87 and D2303-90, or any other
equivalent international standard, which shall be subject to the approval of the
Authority. One copy of each specification in English language to which the joints and
terminations are manufactured and tested shall be submitted with the offer.

2 Site Conditions:

The joints and terminations shall be installed indoors and outdoors in U.A.E. in salt
laden dusty atmosphere where the maximum humidity of 100% and maximum
ambient temperature of 50 deg.C. can be experienced. The joints and terminations
shall be suitable for continuous operation at the above site conditions.

3 Scope and nature of work:

The specification provides for design, manufacture test at manufacturer's works in

presence of FEWA represent- atives, suitable packing, transportation and off loading at
FEWA stores in satisfactory condition and proper stacking as directed by FEWA or
otherwise specified elsewhere. These joints and terminations shall be used for
XLPE insulated cable, indoor or outdoor, for 11KV and 33KV system.

4 System voltage, quality of joints and terminations etc.:

Joints and terminations kits are required for XLPE insulated cables in 11KV and
33KV nominal voltage, 50Hz, 3-phase system with system highest voltages of 12KV
and 36KV respectively. Both outdoor and indoor type of joints and terminations are
required as per B.O.Q. The length of cold shrink tubing shall be stated during
tendering for items requested in the Bill of Quantity.

Components shall not be adversely affected in any manner by contact with other
materials normally used in the construction of cable terminations and shall not
increase the rates of corrosion of any metal with which they may come into contact.
Assembled components forming part of a supply system shall perform without
distress under the following conditions:

i) Normal conditions:

Continuous operation at a conductor temperature of 90 deg.C. for XLPE

insulated cables.

ii) Fault conditions:

Operation at a conductor and screen temperature of 250 deg.C. for XLPE.

 2.4/2

5 Types of cables for which joints and terminations are required.

5.1 11 KV Cables

3 core, XLPE insulated, copper tape/wire screened, steel wire armoured, PVC
sheathed Aluminium conductor cables or otherwise as stated in the Bill of Quantity.

Single core copper conductor for compacted circular stranded annealed plain wires,
XLPE insulated, copper tape/wire screened, PVC sheathed as stated in Bill of
quantity.

5.2 33 KV Cables

Single core copper conductor of compacted circular stranded annealed plain wires,
XLPE insulated, copper tape/wire screened and PVC over sheathed cables as per
IEC 502/94 or otherwise as stated in the Bill of Quantity.

Three core copper conductor XLPE insulated copper tape/ wire screened, steel wire
armour, PVC sheathed cable as per IEC 502/94 or other wise stated in Bill of
Quantity.

A. Cold Shrinkable Termination Kits

A.6 Technical Specifications:

The term cold shrink applies to materials, which are capable of shrinking without
raising the material above the ambient temperature of its immediate surroundings.
The material of the rubber insulator used in the Cold Shrink Terminations shall be
silicone which is factory expanded and placed on a removable core. The removing of
the core when the termination is positioned over the cable shall cause the
termination to shrink. The termination shall maintain a compressive force on the
cable continuously throughout the life of the product. This pressure will ensure a
complete moisture seal without the use of adhesives.

Electric field stress control shall be achieved by using a high dielectric constant cold
shrink electrometric tube. This tube shall be completely covered by a cold
shrinkable silicone insulator having adequate track resistance. The two pieces shall
be prestretched in the factory and placed on the one removable core.

The term PST refers to Pre Stretched Tubing.

The material used for the terminations shall display a high surface tension or
hydrophobic property. This is essential to minimize surface wetting and in turn
minimize or eliminate damaging leakage currents.

These components shall be weather, ultra violet light and salt pollution resistant.

A full drawing of the termination including all parts must be forwarded with the
tender documents.

A.7 Main Components

A.7.1 3-finger PST silicone rubber cold shrink break out boot.
 2.4/3

A.7.2 PST silicone rubber insulator.

a) PST silicone rubber cold shrink insulator with water shed skirts and with a high
dielectric constant PST cold shrink stress relief tube (11kv outdoor
termination).

b) PST silicone rubber cold shrink insulator with water shed skirts and with a high
dielectric constant PST cold shrink stress relief tube (33kv outdoor
termination).

c) PST silicone rubber cold shrink insulator without water shed skirts and with a
high dielectric constant PST cold shrink stress relief tube (indoor termination
11KV).

d) PST silicone rubber cold shrink insulator with water shed skirts and with a high
dielectric constant PST cold shrink stress relief tube (Indoor termination 33
KV).

e) Straight & right angle boots shall be provided for indoor terminations.

A.7.3 Termination accessories including sealing and semi conductive tapes, earthing
clamps and earthing braid.

A.8 General requirements of installed joints & terminations:

The installed joints and terminations must provide the following:

A.8.1 Complete external leakage insulation between the high voltage conductor and earth
potential using anti-track cold shrink material.

A.8.2 Electrical stress control using a stress relief tube incorporated inside the PST
silicone rubber cold shrink insulator.

A.8.3 The installed terminations shall meet the electrical requirements laid down in this
specification.

A.8.4 Outdoor terminations shall incorporate a design feature to prevent flexing of the
terminated cores under short circuit conditions.

A.8.5 Terminations must be insensitive to cable manufacturers tolerances allowed under

BSS 6480-1988 or IEC 55.

A.8.6 The successful tenderers will be required to supply overhead line insulators and
support bracket for outdoor terminations in line with the schedule of quantities.
These brackets must be designed for mounting on wooden poles such that the
terminating cores may be cut to the same length measured up from the sheath
terminus of the cable termination.

A.8.7 The length of core insulation required with switchgear and transformer terminations
is 450mm for three and single core 11 KV and 450mm for single and three core
33KV cables.

A.8.8 The length of core insulation required with outdoor pole-top terminations is 900mm
per phase for three and single core 11 KV and 1200mm for single and three core 33
KV.

A.8.9 Copper braid should be provided to connect the metal shield of XLPE cable.
 2.4/4

B. Pre-moulded Kits

B.6 Technical Specifications

Premoulded shall mean factory moulded ETHYLENE-PROPYLENE - DIENE
TERPOLYMERS (EPDM) rubber cable joints and terminations for XLPE insulated
power cables. Moulding shall be in the shape that it will take when installed. They
shall conform to the following design criteria:-

Material for cable joint housing termination stress and rain sheds shall be of
Peroxide cured EPDM rubber.

Housing and stress cone shall have stress relief, conductive insert, insulation and
conductive outer layer moulded as to form one unit per phase.

Joint shall be fully submersible for direct burial, vault or cable tray applications.

No special tools will be required for the installation of complete jointing and
termination kits. Installation is performed by sliding the pre-moulded joint housing
over the cable. The use of heat is not a part of the installation procedure for the
premoulded joint housing.

Internal diameter of the housing shall be of a size suitable for the specified cable so as
to produce a waterproof and airtight interface with insulation and semi-conductive layer
of cables.

Joint or termination kits shall come with all required components to produce a
complete cable joint or termination including compression ferrule to suit specified
conductor. The components of the joints and termination shall be weather, U.V. light
and salt pollution resistant.

Ampacity of completed joint and termination shall be equal to the cable to which it
has been installed.

Full drawing of the joint and termination including all parts must be forwarded with
the tender documents.

B.7(i) Main Components for Joints

1. Pre-moulded joint housing.

2. Crimp connectors
3. Armour wrap kit (for mechanical strength) (for armoured cables).
4. Aluminium back-up ring (for armoured cables)
5. Worm drive clip (for armoured cables)
6. Constant force spring
7. Silicon grease.
8. Copper mesh
9. Outer jacket tube (heat shrinkable)
10. PVC tape
11. Installation manual.

B.7(ii) Main Components for Terminations

1. Two hole crimping lugs/connectors.

2. Sealant mastic butyl tape.
3. Silicon rubber tape (for outdoor termination).
 2.4/5

4. Non-tracking rubber module skirts.

5. Pre-moulded stress cone (s).
6. Ground clamp.
7. Ground wire.
8. Jacketing tape/PVC tape.
9. Constant force spring.
10. Grounding flat copper braid.
11. Trifurcating boot (for 3 core cables).
12. Heat shrinkable tubings (for 3 core cables - outdoor terminations).
13. Heat shrinkable straight right angle boots (for indoor terminations only).
14. Silicon grease.
15. Complete with lubricant, wiping cloth, installation instructions.
16. Stand-off insulator with bracket (3 Nos. insulators + 1 No. bracket) (For
outdoor terminations only).

B.8 General requirements of installed joints & terminations

The installed joints and terminations shall provide the following :-

B.8.1 Complete external leakage insulation between the high voltage conductor and earth
potential. Factory moulded EPDM rubber joint housing.

B.8.2 The joint kit has to supplied with adhersive pre-coated heat shrinkable external
protective tubing. The adhesive to be activated by the heat application to shrink the
tubing, which shall be in excess of 125 Deg.C.

Uniform adhesive flow from the adhered heat shrink tubing into the adjoining
surfaces will be used as an indicator that shrinking is complete, and therefore, the
adhesive must be suitable for this purpose.

B.8.3 The installed joints and terminations shall meet the electrical requirements laid down
in this specification.

B.8.4 Joints and terminations must be insensitive to cable manufacturers tolerances

allowed under BS 6480, IEC 55 or any other equivalent International Standards.

B.8.5 Galvanized steel joint case comprising of wrap around shell shall be provided for
mechanical strength (For armoured cable).

9 Supply of technical information, test certificates and samples

(Common to both cold shrink and premoulded)

9.1 Tenderers must submit full specification and samples of the materials offered.

9.2 Tenderers must submit a detailed design of the overhead line support brackets for
outdoor terminations offered, including details of the materials used in manufacture
of the bracket. For each outdoor kit a suitable approved type bracket made of
galvanised steel shall be supplied within the quoted price.

9.3 Manufacturers who have not previously supplied cable accessories to FEWA must
submit a list of all electrical utilities in the Middle East to whom they have supplied
cable accessories at voltages of 11KV and above. The information listed below must
be for each order quoted:

1. Name of utility

2. Order Number
 2.4/6

3. Order period (From... ...... ...To... ..........)

4. Order value

5. Total number of joints/terminations supplied

6. Number and details of each size of joints/ termination supplied.

7. System voltage for which joints/terminations were supplied.

8. Specification of the cable for which the joints/ terminations were supplied.

9. Set of installation instructions for the joints/ terminations supplied showing

clearly the components used in making the termination.

10 Testing :

Electrical performance tests mentioned in clause 10.4 shall be carried out on

samples chosen at random in presence of FEWA representatives at manufacturer's
works. Certified copies of the type test certificates mentioned in clause 10.2 and
10.3 shall be supplied along with the offer. The supplier shall make provision in his
offer to bear all costs that are incurred in carrying out these tests to the satisfaction of
FEWA. However, costs towards travel, accommodation etc. of FEWA
representatives shall not to be included in the quoted price.

A. COLD SHRINKABLE KITS :

A.10.1 Material tests :

The following tests shall be performed to verify the quality of material requirements.
The tests shall be carried out in the manner specified in ASTM D412, D150, D149
and shall satisfy the requirements stated therein.

A.10.2 Tests for components :

a) Silicone Rubber Insulator

1) Permanent Set - 22 Hours "100 deg.C,

100% Elongation,
5 Minute recovery

2) Ultimate Tensile Strength - ASTM D412-87

3) Dielectric Constant - ASTM D150-87 23 deg.C

- 90 deg.C, 130 deg.C

4) Dissiption Factor - ASTM D150-70 23 deg.C

- 90 deg.C, 130 deg.C

5) Dielectric Strength - ASTM D149-90

- 75 mil gap

6) Track Resistance - ASTM 2303-90

2.5 KV 10K Ohms
3.25 KV 50K Ohms
 2.4/7

b) Stress Control Tube

1) Permanent Set - 22 Hours @ 100 deg.C,

100% Elongation,15 Minute
recovery.

2) Ultimate Tensile Strength - ASTM D412-87

3) Dielectric Constant - ASTM D150-87 23 deg.C

65 deg.C, 90 deg.C

4) Dissipation Factor - ASTM D150-87 23 deg.C

65 deg.C, 90 deg.C

B. PREMOULDED KITS :

B.10.1 Material/component tests :

The premoulded joint components shall be tested as per IEEE-404 and termination
components to IEEE-48 and type test (design test) certificates provided.

B.10.2 i) Type test (Design tests) :

Type tests shall be performed an randomly selected joints and terminations ordered as
per IEEE 404 and IEEE 48 in the presence of FEWA representatives. The results of
these tests shall be recorded in the form of a report certifying that a
joint/termination design meets the requirements of the standard.

If these tests have been earlier witnessed by FEWA reprehensive and design has
not been changed, the witnessing may be waived at the sole discretion of FEWA.

For cyclic aging test FEWA may accept type test certificate of a reputed
independent laboratory at its sole discretion.

ii) Routine Tests (Production tests) :

The following production tests shall be performed on 100% of all joints ordered as
per IEEE 404 in the presence of FEWA representatives:

a) Partial discharge (corona) voltage level.

b) AC voltage withstand test.

10.3 Electrical Performance Tests :

(Common to cold shrink and premoulded kits)

The following tests shall be carried out to check the electrical performance of the
joints and terminations as per VDE 0278, IEEE 48 or 404 or any other equivalent
standards.

1) A.C. Voltage withstand

2) Partial Discharge
3) Impulse Voltage withstand
4) Load Cycling/Pressure tests/Water tightness
5) Thermal Short Circuit
 2.4/8

6) D.C. Voltage withstand

7) Humidity & Condensation/salt-fog
8) Dynamic short circuit

Test values shall be forwarded in four copies to FEWA representative.

10.4 Test Methods : (Common to cold shrink & premoulded kits)

1. Nominal A.C. Voltage Withstand

This test shall be carried out in accordance with VDE 0278/IEEE 48/IEEE 404. For
test No. 1 in the sequence, the test voltage shall be applied for 1 minute. For
outdoor terminations, the test shall be carried out under rain. The rain shall have an
incidence angle of 45 deg., a rate of 3mm/minute and a conductivity of 100 uS/cm.

The test voltage shall be 35/28kv for the 11kv system and 75/70kv for the 33kv
system. The voltage shall be applied between the phase and ground.

For outdoor terminations, the test shall be run a second time (before the salt fog
test) but without rain.

2. Partial Discharge

This test shall be carried out in accordance with VDE 0278/IEEE 48/IEEE 404. The
test voltage shall be 12kv phase/ground for the 11kv and 36kv for the 33kv systems.
The requirement is that the discharge level shall not exceed 5 pC.

3. Impulse Voltage Withstand Test

The test shall be in accordance with VDE 0278/ IEEE-404. The phase/ground test
values for indoor and outdoor use shall be 75kv/110kv (peak) for 11kv and
170kv/220kv (peak) for 33kv systems. 10 positive and 10 negative, 1.2/50 us
impulses shall be applied.

4. Load Cycling Test

The test shall be in accordance with VDE 0278/ IEEE-404. The test voltages shall
be 15kv and 45kv for 11kv and 33kv systems respectively.

5. Thermal Short Circuit Test

Test shall be in accordance with VDE 0278/IEEE 404. Two of one second tests
each shall be performed.

6. Water Tightness Test

The test shall be carried out in accordance with VDE 0278/IEEE-404. The entire
joint shall be submerged in water filled tank. In this position terminations shall be
exposed to 9 Load Cycles (as in 4).

7. D.C. Voltage Withstand Test

The D.C. Voltage withstand test shall be in accordance with VDE 0278/IEEE48 and
404 at test voltages of 48kv and 144kv (30 minutes) for 11kv and 33kv systems
respectively.
 2.4/9

8. Humidity Test

Terminations shall be tested in accordance with VDE 0278/IEEE-48. The sample

shall be subjected to an A.C. Voltage for 100 hours in a humidity chamber, where
water with a conductivity of 700+/-100 uS/cm. shall be sprayed at a rate of 0.3+/-0.1
L/h per cubic meter of the test chamber. The test voltages shall be 7kv and 21kv for
11kv and 33kv systems respectively.

9. Salt Fog Test

This test shall be carried out in accordance with VDE 0278/IEEE-48 on outdoor
terminations only. The sample shall be exposed for 1000 hours to a salt-water spray
with a conductivity of 16+/-2mS/cm at a rate of 0.4+/-0.1 L/m3/h. The phase/ground
test voltages shall be 7kv and 21kv for 11kv and 33kv systems respectively.

11. Identification and Packaging

Components shall normally be supplied in a package as a complete termination,

which shall be clearly marked with the supplier's name, reference number, batch
reference, voltage, application and cable size. In addition FEWA part No. as
indicated in the B.O.Q. shall be marked on the package.

Packaging shall be designed to protect against ingress of moisture and mechanical

damage. Self fusing tapes shall have means to prevent the fusing of surfaces from
each other.

The complete cold shrinkable components, required to complete in all respects one
termination, shall be supplied in a kit form.

For Cold shrink kits

For the purposes of identification, PST silicone cold shrink break out boots shall be
marked clearly and permanently in a prominent position with the supplier's name.

Electrically semi-conducting tape shall be marked "Semi Conducting" clearly and

permanently.

12 Storage

Components shall be capable of being stored without deterioration within the

temperature range of -10 deg.C to 45 deg.C. Components or materials, if subject to a
shelf life limitation shall have the final date of use, date of manufacture
prominently and permanently shown on all packaging.

T-2-4
sm.
 2.4/10
SCHEDULE ‘A’

SUB-MANUFACTURERS

The Tenderer shall state below the names of the sub-manufacturers to the main
manufacturer and details of the equipment proposed to be manufactured or supplied by
them:

Name & Address of the Sub-Manufacturer Description of Equipment

Signature :_________________________

Designation :_________________________

Name of Tenderer ;_________________________

Date :_________________________
 2.4/11

SCHEDULE ‘B’

PLACE OF MANUFACTURE, TESTING AND INSPECTION

The Tenderer to complete the following schedule for all materials he proposes to supply

Item Place of Place of testing

No. Description Manufacturer manufacture and inspection

Signature :_________________________

Designation :_________________________

Name of Tenderer ;_________________________

Date :_________________________
 2.4/12

SCHEDULE ‘C’

DEVIATION FROM TENDER SPECIFICATION

The Tenderer to state in the following schedule the deviations from the tender specifications
proposed in his offer. Deviations other than those specifically listed below will not be taken
note of:

Item
No. Description Precise Details of the Deviations

Signature :_________________________

Designation :_________________________

Name of Tenderer ;_________________________

Date :_________________________
 2.4/13
SCHEDULE ' D '
GUARANTEED PARTICULARS FOR COLD SHRINKABLE/PREMOULDED KITS

Tenderers are to give the following particulars for the joints/terminations.

Tenderers are also required to submit a detailed list of the components of each termination.

Termination
Indoor with Straight
Sl. Description Outdoor Right Straight Joint
No. angle boot angle boot
33KV 11KV 33KV 11KV 33KV 11KV 33KV 11KV

1. Manufacturers Name

2. Applicable Standard

3. Type of termination/Joint-cold shrink/pre-

moulded

4. Nominal Voltage KV

5. One Minute dry withstand voltage KVrms

6. One Minute wet withstand voltage KVrms

7. D.C. withstand voltage for

30 minutes in KV

8. Impulse withstand voltage dry in KV

9. Partial discharge level in pc

10. a) Discharge inception voltage KV

b) Discharge extinction voltage KV

11. Material of the cold shrinkable/

premoulded components KV

12. Cold shrinkable terminations :

a) Silicone Rubber Insulator :

I) Permanent Set
ii) Ultimate Tensile Strength
iii) Dielectric Constant
iv) Dissipitation Factor
v) Dielectric Strength
vi) Track Resistance

Signature of Tenderer : ________________________

S-2-4(4) xls.
 2.4/15

SCHEDULE ‘E’

DETAILS OF PAST EXPERIENCE OF MANUFACTURER

JOINTS/TERMINATION KITS

Year
Quantity
Name and address of Purchaser of
Supplied Remarks
supply

Signature :_________________________

Designation :_________________________

Name of Tenderer ;_________________________

Date :_________________________
 2.4/14
SCHEDULE ' D '
GUARANTEED PARTICULARS FOR COLD SHRINKABLE/PREMOULDED KITS

Termination
Indoor with Straight
Sl. Description Outdoor Right Straight Joint
No. angle boot angle boot
33KV 11KV 33KV 11KV 33KV 11KV 33KV 11KV

b) Stress Control Tube :

I) Permanent Set
ii) Ultimate Tensile Strength
iii) Dielectric Constant
iv) Dissipitation Factor

13. Tail length in termination 1200 900 450 450 450 450

14. No.of modules (for premoulded termination)

based on breakdown voltage of 50 mm/kV.

15. Stress control distribution attach literature

for terminations

16. Provision of catalogues for terminations.

17. Support bracket for outdoor terminations.

18. Type test report submitted Yes/No.

Signature of Tenderer :

Designation :

Name of Tenderer :

Date :

S-2-4(4) xls.