A Saudi Joint Stock Company

EWA Staff Training on HV Cable Systems

W: www.saudicable.com
Innovation, Commitment, Appreciation, Respect and Excellence
The discovery of oil & gas had a monumental impact on the socio-economic
development of the kingdom
Established in 1975
Founded by Xenel Industries, Anaconda and Chevron utilizing NKF, Philips,
Nokia and AT&T technologies
Offices in JED-RYD-DAM, Dubai, Abu Dhabi, Doha, Beirut, London and USA
The “First Cable Manufacturer” in the region
Transformed into Publicly Traded Company in 1988
Strong Global Presence with Export to over 60 countries
In 1999 : Awarded the King Abdul Aziz Ideal Factory Award
Innovation, Commitment, Appreciation, Respect and Excellence
Group Operations
Mass Kablo is a total solution provider,
Founded in 1982
Supplying power cables,
telecommunication cables, signalling
cables (Kavel Kablo), accessories and
services ELIMSAN
The biggest producer and exporter in Established in 1980
Turkey and Middle East of HV & EHV Product line includes:
cables Metal Clad/ enclosed
ISO 9001 & ISO 14000 Certified switchgear, CT, VT
In 1994 SCC completed full acquisition TURKEY In 2009, SCC acquired
of Mass Kablo BAHRAIN 79% of the group shares

KSA

Midal Cable
Established in 1977
SCC became an equal partner in 1984
Products includes: Aluminum ROD & WIRE, Aluminum Alloy
ROD & WIRE, OVHD Lines and extruded products.
300000 MT /year ISO9001 Certified
Global Coverage…………Over 60 Countries

Innovation, Commitment, Appreciation, Respect and Excellence

Leaders in the HV/EHV cables

THE 1ST CABLE

MANUFACTURER IN THE
MIDDLE EAST AND NORTH
AFRICA TO BE QUALIFIED
FOR THE SUPPLY OF 380KV
WITH SEC

Innovation, Commitment, Appreciation, Respect and Excellence

SCC Facilities in Saudi Arabia
• Power Cable Plant

• Telecable Plant

• Rod Mill

• PVC Plant

• Reel Manufacturing Plant

Innovation, Commitment, Appreciation, Respect and Excellence

Power Cable
Building Wires

THHN

Flexible Cables

LV Cables (up to 1 KV)

MV Cables Systems (up to 36 KV)

HV Cable Systems (up to 300 KV)

EHV Cable Systems (up to 400 KV)

Overhead Transmission Line Cable Systems (up to 500 KV)

Innovation, Commitment, Appreciation, Respect and Excellence

Telecommunication & Specialty Cables
Metallic
Telecommunication
Cables
Optical Fiber Cables
FTTH Specialty Cable including:
Control Cables
Instrumentation Cable
Fire Resistance cable
Thermocouple cable
Signaling Cable
Foundation Field bus (FF84)
Innovation, Commitment, Appreciation, Respect and Excellence
SCC Capital Growth (MSR)
800

760
700

640
600
500

500
400
300

300
270
200

200
10.5
3.5

100
70

0
1975 1979 1982 1983 1987 1992 1997 20042015/16

Innovation, Commitment, Appreciation, Respect and Excellence

Group Capacity
180,000
160,000
140,000
120,000
In MT

100,000
80,000
60,000
40,000
20,000
0
2013 2014 2015 2016 2017 2018 2019

SCC MIDAL
Innovation, Commitment, Appreciation, Respect and Excellence
SCC Group Companies

• SCC acquired major stakes in Midal Cable • SCC acquired a Major Stake in 2009

• Major Producer of Aluminium Bars and OH Conductors • Electric Power Transmission and Distribution Products

• 5 Manufacturing Facilities • Worldwide Presence & ongoing Projects

• Worldwide Presence

Innovation, Commitment, Appreciation, Respect and Excellence

HV & EHV
POWER CABLES
Manufacturing Process

Innovation, Commitment, Appreciation, Respect and Excellence

NATIONAL STANDARDS

SDMS

STANDARDIZATION
ORGANIZATION FOR
G.C.C (GSO)

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Innovation, Commitment, Appreciation, Respect and Excellence
CONDUCTOR STRANDING
Stranding of round compacted, or straight, and
prespiralled sectoral conductors.
Synchronized cages, for wires up to 61 wires
Yarn application for water tight conductor.
On line resistance measurement.

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Innovation, Commitment, Appreciation, Respect and Excellence
CONDUCTORS

Wire Drawing:
Copper Rods (diameter 8.0 mm) are drawn on Heavy Drawing Machines to reduce the diameter in drawing stages
from 8.0 mm down to 1.7 or 1.5 mm (depending on number of drawing stages of the machine).
STRANDING:

It is an operation to strand a group of wires to form the conductor according to its design construction, using a stranding mach
- Conductors are either Plain copper or aluminum, stranded circular compacted or sector shaped, or Milliken for HV Cables.
- All are in accordance with IEC 60228.
- No. of wires and wire diameter are adjusted to the specified resistance, so the
Specification allows the manufacturer to choose the no. and diameter of wires within

Types of Stranding

• Concentric
• Compact
• Sector

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Innovation, Commitment, Appreciation, Respect and Excellence
MILLIKEN CONDUCTOR
1000 mm2 to 2500 mm2

Why « Milliken » construction :

To achieve better electric
current distribution in the
Conductor, and eliminate Skin
Effect, eddy current losses

Wires characteristics for conductors:

To produce a good strand, it is
important to define the following
parameters :
• Effective Wires tolerances
• Valuable Wires Elongation.
To obtain a good compacted strand,
MILLIKEN CONDUCTOR FORMATION BY ASSEMBLY OF FIVE
the minimum recommended copper
SEGMENTS (SECTORS)
wire elongation is not less than 36%.

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Innovation, Commitment, Appreciation, Respect and Excellence
TRIPLE INSULATION LINE

Insulation is made on a production line called the Catenary Continuous Vulcanization line CCV with
heat treatment ongoing – Catenary Continuous Vulcanization and in some factories use vertical line and
for high voltage cables, high voltage and called VCV Vertical Continuous Vulcanization

Semi Conductive Materials

Semi conductive materials are used to control electrical field on both conductor and insulation outer surface.
Material is copolymer, highly hygroscopic, containing 30 to40 % carbon black. Therefore it has to be
maintained dry and usually dried before use.
Border between the semicon and insulation layer must be smooth as ever to avoid electric field concentration.

INSULATION MATERIAL
Normally, the Peroxide XLPE is used as insulation for all MV, HV and EHV cables.

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Innovation, Commitment, Appreciation, Respect and Excellence
(CCV LINE)

CCV LINE

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Innovation, Commitment, Appreciation, Respect and Excellence
SCHEMATIC DIAGRAM OF CCV LINE

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Innovation, Commitment, Appreciation, Respect and Excellence
CROSS-HEAD, SIKORA, CURING TUBE

1- Taped Conductor (or Bare conductor)

2- Triple X-Head
3- Sikora X-Ray dimensional scan
4- Heating / Curing Tube

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Innovation, Commitment, Appreciation, Respect and Excellence
Insulation Process
Insulation Process on CV Line:
• Compound feed
• True Triple Extrusion
• X-ray dimensional scanning
• Dry curing
• Dry cooling
• Stress relaxation
• Post extrusion scanning
Semi conductive materials are used to control electrical field on both conductor and insulation outer surface.
• Material is copolymer, highly hygroscopic, containing 30 to 40 % carbon black.
Therefore it has to be maintained dry and usually dried before use.
• Border between the semicon and insulation layer must be smooth as ever to avoid electric field concentration, and
minimize any local high stress.
• There is however universal agreement that to achieve the highest design stresses it is necessary to have:
(a) no cavities within the insulation or at the interfaces with the screens;
(b) the smoothest interfaces between the screens and insulation to minimize local stresses;
(d) the best insulation circularity and concentricity to minimize stress variations and to facilitate the precise assembly of
accessories.
• Dry curing method using pressurized nitrogen inert gas inside the tube is most commonly used today.
• Pressure is needed in order to avoid bubble forming in the insulation
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SLICE OF INSULATION IN MV/HV/EHV CORE

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Innovation, Commitment, Appreciation, Respect and Excellence
DEGASSING of PEROXIDE XLPE

 When the process of the X-linking is complete, the insulation will contain a specific quantity of
by-products resulted from the chemical reaction of the x-linking, which is limited according to
the insulation process parameters stability.

 This byproducts gases should be degassed to avoid creating problems during cable jointing
and termination.

 Degassing is conducted mainly through Degassing Rooms and/or Current Transformers.

 If degassing is insufficient, we face the following problems when installing the Cable:

1- Shrinkage in lead or metal cover over the cable

2- Exit of gases to the ends of cable Termination making it swell and fail.

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Innovation, Commitment, Appreciation, Respect and Excellence
Time taken for Degassing

Degassing Time (days)

Degassing Rooms

Wall Thickness (mm)

Degassing Transformer
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Innovation, Commitment, Appreciation, Respect and Excellence
METALLIC SCREEN or METALLIC SHEATH:
1. It represents the metallic part of the insulation screen, and its purpose is to prevent
electromagnetic interference from the cable to surrounding or from the cable to itself.
2. It is agreed now that the cables should have a moisture waterproofing mechanism whether
metal such as Lead sheath or aluminum or non-metallic such as barrier strips waterproofing
tapes, and this prevents the formation of water trees which will reflect in presence of electric
stresses.
3. Metallic shield works as a grounding path for both AC Capacitive Currents and for
Short Circuit Currents

Types of Metallic Shield:

1. Spiral Screen Wires
2. Copper Tapes, or Aluminum Laminated Tapes.
3. Lead Alloy sheath extruded longitudinally on cable.
4. Combination of both Lead sheath and Copper wires.

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Innovation, Commitment, Appreciation, Respect and Excellence
Concentric Layer of Copper Wires:
Advantages:
1. Effective design with moderate weight
2. Withstand high short circuit
Disadvantages
Low resistance which require special connections for
screen (grounding in one point or link via cross
bonding) in order to limit the losses due to rotational
movements.

26
Innovation, Commitment, Appreciation, Respect and Excellence
Extruded Lead Alloy:
Advantages:
1. Good protection against water penetration
2. High resistance, so it losses energy in low rate in
case of continuous earthing
3. High resistance to wear
Disadvantages
 Heavy weight & expensive
 Poisonous and needs special care
 Limited in withstanding Zero-Sequence Short Circuit
Currents

Combined Lead Sheath & Copper Wire Screen:

Contains combined advantages of both Lead & Copper wire screen.
1. It is expensive in addition to Lead content as a poisonous member.
2. Copper wire placed under the Lead, which can share the characteristics
of corrosion Resistant in the latter.
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Innovation, Commitment, Appreciation, Respect and Excellence
LEAD EXTRUSION

Lead
Sheath

 A lead sheath can be used as a chemical barrier in

LV/MV/HV/EHV & instrumentation cables, and for
all kinds of petrochemical projects.
 The advantages of lead sheathed cables are:
Protection against the entry of hydrocarbons.
Protection against moisture ingress.
 Can withstand short circuit current.
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Innovation, Commitment, Appreciation, Respect and Excellence
OUTER SHEATH

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Innovation, Commitment, Appreciation, Respect and Excellence
QUALITY CONTROL

Final Product
Raw Material In-Process Controls
Controls Controls

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Innovation, Commitment, Appreciation, Respect and Excellence
Quality Control – In-Process Control

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Innovation, Commitment, Appreciation, Respect and Excellence
Quality Control – Final Control

Test Voltage

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Innovation, Commitment, Appreciation, Respect and Excellence
www.masscable.com
Quality Control – Routine Tests

Faraday Cage :
HV Test, PD test,
Dissipation Factor,
Capacitance Meas.
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Innovation, Commitment, Appreciation, Respect and Excellence
Test Transformer :
500 kV , 20 MVA

34
Innovation, Commitment, Appreciation, Respect and Excellence
Quality Control – Type Tests

Impulse Generator
1400 kV , 42 kJ 35
Innovation, Commitment, Appreciation, Respect and Excellence
www.masscable.com
QUALITY
MANAGEMENT SYSTEM
in SCC

Innovation, Commitment, Appreciation, Respect and Excellence

SCC Quality Structure
• Comprehensive Quality Teams managing both Quality Management System and Quality
Control and Inspection activities both reporting directly to President.
• Dedicated Team and Facilities for
 Inspection Lab
 HV & EHV Test Cages
 MV & LV Test Cages

SCC Quality Structure :

Innovation, Commitment, Appreciation, Respect and Excellence

Organization of Quality and Operation Excellence

KSA President

Director QA/QC &

Excellence

QC Labs.& QMS HV Test Cage LV/MV Test QC TCP

Calibration Manager Manager Cage Manager. Manager.
Manager

PVC-Plant QC & QMS & Q.C. MV/HV Q.C. Q.C. Fiber Optic
RM Test Calibration Eng test Final Test Test
(1) Abdulbasit (11) (Metallic) (2)
(4)

FG Cable & Lab

Calibration Lab Q.C.
Test Q.C. LV
(2) Material, Lab&
(5) Test
In process test
(7)
(2)
Document
Controller(1)

Issue date : 19 June 2017

Document No. : 100-ORG-QS Rev.4 38
Innovation, Commitment, Appreciation, Respect and Excellence
Laboratory Structure SCC -QC

PCP TCP

Metallic
Cu Rod Lab LV Test Cage OFC Lab
Cables Lab

PCP Lab MV Test Cage

EHV/EHV Test
PVC Lab
Cage

Innovation, Commitment, Appreciation, Respect and Excellence

Data Management and Control
The whole business process of SCC is executed through one of the leading and renowned ERP solution
used today globally which is SAP. All the business process of the SCC is integrated in SAP system which
covers all the business modules including Quality. Automation , transparency and efficiency are the
fundamentals of the system.

Customer ADVARIS SAP

Requirement Integrated
Business Testing
and Cable design
Specification Software software

7/31/2019 bjaseen
Innovation, Commitment, Appreciation, Respect and Excellence
SCC QC Methodology & Data Management

SCC Quality Activities :

Core QC Finished-good Inspection by

Inspection Customer
Testing Raw material
testing
In-process
inspection [Electrical and [Client inspector
Activities Sample] and TPI]

7/31/2019 41
Innovation, Commitment, Appreciation, Respect and Excellence
Quality Plan

In Process QC
Armouring
Raw Wire Conductor Insulation Metallic Outer Finished
Filling / Lead
Material Drawing Stranding (CV) Screening Sheathing Goods
Shielding

Dimension Diameter Dia. of wire Dia of wire Dimensional verification all

Physical & Mass of cond. Thick. Of tape Thick lead/tape layers
Chemical Properties Resistance No. of wires/tapes Dia of Lead Hot set test
Raw Material Specification No. of wires Lay length Mass of lead Conductor examination
Physical check Dia. of core No. of wires/tapes HV testing
Physical check Lay length P.D testing
[ At the machine] Dia. of core Resistance cond.
Diameter Physical check D.C jacket test[graphite
Elongation [ At the machine] cables]
Mass of wire Diameter Physical check
Resistivity Thickness
Eccentricity Diameter
Physical check Thickness
Mass of core Diameter
Hot set test Mass of filling
Thickness
Protrusions Eccentricity
Note: Actual Tests based Mass of Sheath
Voids/Contamination Physical check
Eccentricity
on agreed ITP Strippability (if applic) Physical check
By-product gas test[HV]
Physical check
Innovation, Commitment, Appreciation, Respect and Excellence
MANAGEMENT SYSTEM AND PRODUCT TYPE TEST Certifications

• ISO 9001: 2015[SCC is the first cable company in the middle east awarded for ISO]
• SASO certification
• KEMA /DNV-GL Netherland for various products including extra high voltage cables and
accessories
• FGH/CESI Germany for HV cables and overhead conductors
• KINETRICS for HV cables
• BRE Global UK for fire resistance cables and low smoke cables
• CPRI India for medium voltage , Low voltage cables and OH conductor
• UL USA for instrumentation cables
• ITS USA for optical fiber cables
• BSI UK for instrumentation cable
• NTS USA for optical fiber cables

7/31/2019 bjaseen
A word of Appreciation

Innovation, Commitment, Appreciation, Respect and Excellence

LIST OF MAJOR PRESTIGIOUS COMPLETED & ON GOING PROJECTS
(OVERHEAD TRANSMISSION LINE & UNDER GROUND PROJECTS )
Quantity
Contract Year of
SN Project Description (Route Name of Client
No. Supply
Length)

TURNKEY PROJECTS – KINGDOM OF SAUDI ARABIA

SEC Construction of 110kV Underground Cable for: 45 Completed Saudi Electricity Company -
- 4.2 km underground cable circuit from Al-Hamrah S/S to Sharafia S/S kms. Western Region, Jeddah
1 11.0 km Underground Cable Circuit from Al-Hamrah S/S to Jamia S/S
Transformer Termination at Jamia S/S

30641126/0 Reinforcement of 69kV Underground Cables to Muraikbat S/s and 7 kms Saudi Electricity Company –
2 0 Sport City S/s Completed Eastern Region, Dammam

152/1/23 Construction of 110kV XLPE Power, Pilot, FO Cables and associated 9 kms. Completed Saudi Electricity Company –
3 equipment/materials required for 110/13.8kV Al-Aous Substation Western Region, Jeddah
Madinah
148/1/23 Supply and Installation of Underground Fiber Optic Cable in Rabigh 44 Completed Saudi Electricity Company –
4 along 380kV Overhead Transmission Line (Rabigh U/G Fiber Optic Kms. Western Region, Jeddah
Cable)
20331097/0 Construction of Naeem, Rabwah & KM-8 S/Ss – 110kV/13.8kV Power, 123 Completed Saudi Electricity Company –
5 0 Pilot and F.O. Cables kms. Western Region, Jeddah

20331019/0 Construction of Banimalik, Wazeeriah and EEH S/Ss – 110kV/13.8kV 52 Completed Saudi Electricity Company –
6 0 Power, Pilot and F.O. Cables kms. Western Region, Jeddah
20631069/0 Construction of 110kV, Cable to Connect Al-Newariyah Substation 43.8 Saudi Electricity Company –
7 0 with Makkah Al-Mukarramah Network kms. Completed
Western Region, Jeddah
20731032/0 Construction of 110kV Power & Fiber Optic Cable to Connect Al- 30.12 Saudi Electricity Company –
8 0 Nuzlah-2 Substation with Jeddah Network kms. Completed
Western Region, Jeddah
20631221/0 Construction & Installation of 110kV Power & Fiber Optic Cable to 14 Saudi Electricity Company –
9 0 Connect New Al-Nakheel Substation at Jeddah kms. Completed
Western Region, Jeddah

Construction & Installation of 110kV Underground Cables for HERAA 110kV

10 4400006142 Substation in Jeddah
3.1Km On going Saudi Electricity Company (SEC)

Construction & Installation of 110kV Underground Cables for RAWABI 110kV

11 4400006143 Substation in Jeddah
5.5Km On going Saudi Electricity Company (SEC)

Innovation, Commitment, Appreciation, Respect and Excellence

LIST OF MAJOR PRESTIGIOUS COMPLETED & ON GOING PROJECTS
(OVERHEAD TRANSMISSION LINE & UNDER GROUND PROJECTS )

Quantity
Contract Year of
SN Project Description (Route Name of Client
No. Supply
Length)

TURNKEY PROJECTS – UNITED ARAB EMIRATES

CE/024B/ Supply, Installation, Testing & Commissioning of 132kV Cable 55 Completed Electricity and Water
2006 Laying Works for 132kV Cable Laying Works for Sport-1, Ryad kms. Authority,
1
& Sport-3 132/11kV Substations and Associated Works

CE/455E/ Supply, Installation, Testing & Commissioning of 132kV Cable 29 Completed Electricity and Water
2006 Laying Works for Qusais East 132/11kV Substation and kms. Authority,
2
Associated Works

CE/0509B/ Supply, Installation, Testing and Commissioning of 132kV Cable 8.2 kms Completed Electricity and Water Authority,
2008 Laying Works for Hightech (HTEC) 132/11kV Substation and
3
Associated Works

TURNKEY PROJECTS – KUWAIT

1
MEW/C/ Supply, Installation, Testing & Commissioning of 132kV Cable Laying Ministry of Electricity & Water
192Kms. Completed
4408/11-12 Works for 132kV Cable Laying Works (MEW)

2
MEW/C/ Supply, Installation, Testing & Commissioning of 132kV Cable Laying Ministry of Electricity & Water
180Kms. Completed
4420/11-12 Works for 132kV Cable Laying Works (MEW)

Innovation, Commitment, Appreciation, Respect and Excellence

LIST OF MAJOR PRESTIGIOUS COMPLETED & ON GOING PROJECTS
(OVERHEAD TRANSMISSION LINE & UNDER GROUND PROJECTS )

Quantity
Year of
SN Contract No. Project Description (Route Name of Client
Supply
Length)

TURNKEY PROJECTS – QATAR

89 Km
Qatar Power Transmission System Expansion – Cables – Phase VII Qatar General Electricity &
1 GTC/124/2006/D 152 Km Completed
- 1X1200mm2/24C FOC Water Corp., Doha - Qatar
335 Km

Qatar General Electricity &

2 GTC/283/2009 Establishment of 66kV RAF ‘A’ – Barwa Village XLPE Power Link 21.6 Km Completed
Water Corp., Doha - Qatar

66kV Cable Establishment – Education Super Substation to Sidra Qatar General Electricity &
3 GTC/295/2009 10.7 Km Completed
Hospital Substation Water Corp., Doha - Qatar

Qatar General Electricity &

4 GTC/394/2010 Establishment of 66kV and 132kV Urgent Cable Lines 74.31 Km Completed
Water Corp., Doha - Qatar
-
Qatar General Electricity &
5 GTC/429/2011 EHV XLPE Cable Repair and Maintenance Completed
Water Corp., Doha - Qatar
-
Qatar General Electricity &
6 GTC/723/2015 EHV XLPE Cable Repair and Maintenance On-going
Water Corp., Doha - Qatar
20 km Qatar General Electricity &
Qatar Power Transmission System Expansion – Cables – Phase 12
7 GTC-642-2014 On-going Water Corp., Doha - Qatar

7 km
Qatar Power Transmission System Expansion – Substations– Phase Qatar General Electricity &
8 GTC-643-2014 On-going
12 Water Corp., Doha - Qatar

Innovation, Commitment, Appreciation, Respect and Excellence

LIST OF MAJOR PRESTIGIOUS COMPLETED & ON GOING PROJECTS
(OVERHEAD TRANSMISSION LINE & UNDER GROUND PROJECTS )

Quantity
Year of
SN Contract No. Project Description (Route Name of Client
Supply
Length)

TURNKEY PROJECTS – BAHRAIN

L5//15 ALBA 220kV Expansion Project 7.5 kms. Completed Aluminium Bahrain B.S.C (C)
1 Line 5 Expansion Project Diversion of Riffa-Alba 220kV Circuits at Manama
Alba
Ministry of Electricity & Water
127/2001/3100-A- 220kV - Supply of Cables & accessories, Installation of
2 - Completed Manama, Bahrain
Original Joints/Termination & Testing - 13Sections

Ministry of Electricity & Water

127/2001/3100- 220kV - Supply of Cables & accessories, Installation of
3 - Completed Manama, Bahrain
A(VO) Joints/Termination & Testing - 7Sections

306/2004/3100 PM- 220kV - Supply of Cables & accessories, Installation of Ministry of Electricity & Water
4 142Km Completed
VO Joints/Termination & Testing / 9Sections Manama, Bahrain

220kV - Supply of Cables & accessories, Installation of

Ministry of Electricity & Water
5 4604/2006/3100 Joints/Termination & Testing / 2Sections 220kV XLPE - 24C FOC / 25Km Completed
Manama, Bahrain
61Pilot Cable
66kV - Supply of Cables &accessories, Installation of
0532/2003/3100- Ministry of Electricity & Water
6 Joints/Termination & Testing / 1X 550/800mm2 - 24C FOC 250Km Completed
VO9&10 Manama, Bahrain
20Sections

66kV - Supply of Cables &accessories, Installation of 248Km / Ministry of Electricity & Water
7 4608/2008/3100 On going
Joints/Termination & Testing - 1X 800/550 mm2 87Sections 228 Km Manama, Bahrain
-
Bahrain Field Ministry of Electricity & Water
8 220kV & 66kV - Installation of Joints/Termination & Testing Completed
Support(BFS) Manama, Bahrain

Innovation, Commitment, Appreciation, Respect and Excellence

•LIST OF MAJOR FIELD SUPPORT PROJECTS
(OVERHEAD TRANSMISSION LINE & UNDER GROUND PROJECTS )

Year of
SN No of Projects Project Description Total Amount
Supply

FIELD SUPPORT PROJECTS – KSA

Field support services including Accessories installation , Testing 2.5 MSR
1 13 2015
Commissioning including PD Measurement Test

Field support services including Accessories installation , Testing

2 16 2016 6 MSR
Commissioning including PD Measurement Test

FIELD SUPPORT PROJECTS – QATAR

Field support services including Accessories installation , Testing
1 6 2015 11 MQAR
Commissioning including PD Measurement Test

Field support services including Accessories installation , Testing

2 4 2016 14 MQAR
Commissioning including PD Measurement Test

FIELD SUPPORT PROJECTS – BAHRAIN

Field support services including Accessories installation , Testing
1 7 2016 0.17 MBD
Commissioning including PD Measurement Test

Innovation, Commitment, Appreciation, Respect and Excellence

HV Transmission Cable System Design & Engineering

Innovation, Commitment, Appreciation, Respect and Excellence

HV Underground cable Systems

51
Overview of the HV Cable System Design

Innovation, Commitment, Appreciation, Respect and Excellence

53
54
Types of Conductor
There are two designs of conductor, compact round stranded and segmental “Milliken” stranded

Compact round conductors, composed of several layers of concentric spiral-

wound wires. In round stranded compact conductors, due to the low resistance
electrical contacts between the wires, the skin and proximity effects are virtually
identical to those of solid plain conductor.

Segmental conductors, also known as “Milliken” conductors are composed of several

segment shaped conductors assembled together to form a cylindrical core.

The large cross-section conductor is divided into several segment-shaped conductors. There
are from 4 to 7 of these conductors, which are known as segments or sectors. They are
insulated from each other by means of semi-conductive or insulating tape. The Milliken type
structure reduces the highly unfavourable skin effect and proximity effect

55
56
Cable Conductor

The aluminium or copper conductor carries the electrical current. The conductor behaviour is characterized by two
particularly noteworthy phenomena: the skin effect and the proximity effect
skin effect
The skin effect is the concentration of electric current flow around the periphery of the conductors This phenomenon is known
as skin effect A longitudinal element of the conductor near the center of the axis is surrounded by more lines of magnetic
force than near the rim. This results in an increase in inductance toward the center. The decreased area of conductance causes
an apparent increase in resistance
• the alternating current I causes an alternating H field
• the alternating H field causes eddy currents I in the conductor
• the eddy currents I are superimposed to the current I
• in accordance with Lenz law, the current density in the centre of the conductor is reduced,
while it is increased in the outer area

57
Proximity effect

The short distance separating the phases in the same circuit generates the proximity effect. When the conductor diameter is
relatively large in relation to the distance separating the three phases, the electric current tends to concentrate on the surfaces
facing the conductors. The wires of the facing surfaces indeed have a lower inductance than wires that are further away. The
current tends to circulate in the wires with the lowest inductance.

In practice, the proximity effect is weaker than the skin effect and rapidly diminishes when the cables are moved away from
each other. The proximity effect is negligible when the distance between two cables in the same circuit or in two adjacent
circuits is at least 8 times the outside diameter of the cable conductor.

58
Semi-conductor screen on conductor.

• To prevent electric field concentration,

• smoothing of the conductor surface
• firmly bonded to the insulation
• smooth transition from (semi) - conducting to insulating components
• material: XLPE with carbon black
• Semi-conductor screen on conductor.
• an interface of ultra-smooth semi-conductor XLPE
• between the conductor and the insulation.
• the electric field lines would be straight lines taking the shortest path from
the conductor to the ground
• This would form a cylindrical capacitor and would make the most A conductor shield is added to provide
effective use of the dielectric a smooth inner electrode

59
The XLPE Insulation
• As its name suggests, the insulation insulates the conductor when working at high voltage from the screen working at earthing
potential.
• firmly bonded to the inner and outer semi-conductor no voids or contaminations
• maximum electrical stress at the inner semi-conductor
• The insulation must be able to withstand the electric field under rated and transient operating conditions.
• Excellent Electrical & Physical Properties Capable Of Carrying Large Current At High Temperature Normal ~ 90 C Emergency
~ 130 oC Short Circuit Conditions ~250 oC Easy To Install – XLPE Easier To Joint

Semi-conductor screen on Insulation.

This layer has the same function as the conductor screen:

Progressive transition from an insulating medium, where the electric field is non- null, to a conductive medium (here the metal cable
screen) in which the electric field is null.

60
The XLPE Insulation

61
Functionality and Design of the Metallic screen / Sheath

When the voltage reaches tens or even hundreds of kV, a metallic screen is necessary. Its main function is to nullify the
electric field outside the cable.
It acts as the second electrode of the capacitor formed by the cable.
Use of a metallic screen implies:
• The need to connect it to earth at least at one point along the route.
• Draining the capacitive current that passes through the insulation.
• Draining the zero-sequence short-circuit currents, or part of them. This function is used to determine the size of the metallic screen.
The second function of the metallic screen is to form a radial barrier to prevent humidity from penetrating the cable, particularly its
insulation system

62
Anti-Corrosion Protective Jacket
The jacket has a dual function:
• It insulates the metallic screen from ground (particularly for lines with special screen connections)
• It protects the metal components of the screen from humidity and corrosion.
The outer jacket must also withstand the mechanical stresses encountered during installation and service, as well other risks such as
termites, hydrocarbons, etc.

The most suitable material for this is polyethylene.

PVC is still used but increasingly less so. Indeed, one of the advantages of PVC is its fire-retardant properties,
These materials however have mechanical properties that are inferior to those of polyethylene and are more costly. They should be
reserved for installations or parts of installations where fire protection is required.

To verify the integrity of the outer jacket, a semi-conducting layer is often applied to this jacket.

This layer is made of semi-conducting polymer co-extruded with the outer jacket.

63
A brief Overview of the cable Component

64
Overview of the Cable System Design and Project Engineering
• EHV cable system design and engineering includes
• Project Feasibility study and commercial evaluation
• the preparation of technical specifications,
• project technical evaluations,
• cable circuit route design,
• current carrying capacity calculations,
• power cable electrical calculations, computational analysis,
• design of sheath bonding schemes
• Detail cable route drawings
• Cable arrangements inside substations
• Cable support structure design
• Drawings preparations and project submittals.
• Schematic Diagram
• Topographical Survey Drawing
• Trial Pit Location Plan
• Typical Joint Bay Arrangement & Earthing Details
• Detailed Cable Route and Profile Drawing
• The basis of the underground design and installation is developed from the target power transfer requirement
• A cable size and the total number of cables is determined using predetermined system operating characteristics

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Overview of the Cable System Design and Project Engineering

Project Site based cable engineering calculations:

1.CCC calculation for proposed trench cross sections using the following possible thermal backfill
materials combinations;
a. Power cable Bedding Fluidize Thermal Backfill (FTB) and top FTB
b. Power cable Bedding Fluidize Thermal Backfill (FTB) and top Cement Bound Sand
(CBS)
c. Power cable Bedding Fluidize Thermal Backfill (FTB) and top Scalping Powder (SP)
d. Power cable Bedding Fluidize Thermal Backfill (FTB) and top Dune Sand

2. CCC calculation of joint bays using Scalping powder as thermal backfill

3. CCC calculation of joint bays using CBS as thermal backfill
4. CCC calculation at the location where cable burial depths is more than 1100mm
5. CCC calculation for road crossings / pipelines crossings with HDD method
6. CCC calculations at critical open cut crossings locations
7. CCC calculation when 220KV cable cross existing power cables

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Project Quality Control

1. Project quality plan

2. Project quality assurance procedures
3. Project HSE plan

Project Planning

1. Preparation of base line programme (using Primavera Project

Planner) as per contract milestone
2. Project Monitoring & Controlling
3. Site progress report charts in EXCEL

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Reconnaissance / Topographical survey

1. Route verification as per tender documents and site reconnaissance survey

2. Collection of government control points from GIS department for survey works
3. Collection of future plans of the route area from Urban Planning Department
4. Topographical survey of finally proposed route based on site studies and future plans

5. Preparation of Topographical Survey Reports

6. Preparation of Topographical Survey Drawing
7. Route Site investigation for critical crossings and proposed joint bays location
8. Collection of Pipe Lines and Existing Cable routes as built drawings from concerned Authorities.

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Route investigation drawings and reports

1. Preparation of cable route trial pits drawings

2. Preparation of trial pits reports for underground services
3. Reporting of soil samples thermal resistivity values

Material Investigation

1 Thermal backfill material mix design preparation as per required Thermal Resistivity values
2. Existing soils Thermal resistivity values investigation
3. Maximum dry density Testing / calculation for back fill material

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Cable route design drawings

1. Preparation of cable route bonding schematic diagram

2. Preparation of Typical Joint Bays arrangement drawings
3. Preparation of Typical Joint Bays Earthing arrangement drawing
4. Preparation of cable route joint bays and road crossings location drawings
5. Preparation of detailed cable route drawings based on trial pits reports.
6. Preparation of route profile drawings as per existing and route area planned future levels
7. Preparation of AS BUILT drawings after completion of site activities
8. Preparation of cable route marker location drawings

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Road Crossings / pipe lines crossings Drawings

1. Preparation of Horizontal Directional Drilling (HDD) Profile drawings for important road crossings
2. Preparation of Open Cut (OC) crossings details as per site requirements
3. Preparation of PIPE LINES crossings details as per the concerned Authorities requirements
4. Design / drawing preparation of Reinforced Concrete duct banks to bridge over open trench
pipe line crossings

Concrete structure Design

1. Joint bays concrete structure design calculation

2. Preparation of joint bays structural details drawing
3. Link Box Pit concrete structure design calculation
4. Preparation of Link Box Pit structural details drawing
5. Fibre Optic Cable splice pit structure design calculation
6. Preparation of Fibre Optic Cable splice pit structural details drawing
7. PD sensor pit (in case separate pit) structure design calculation
8. Preparation of PD sensor pit structural details drawing

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Cable support structures design inside substation

1. Cable supports structure design calculation inside substation

2. Preparation of Cable supports structure details drawings
3. Preparation of Fibre Optic Cable and DTS cable routing details drawings inside substations
4. Preparation of cable terminations Tags and identification marks drawings inside substation
5. Power cables substation entry location ducts design / drawings preparation
6. Preparation of core hole / slot opening drawings for cable entry into existing substation basement

Cut / Fill estimation & Design

1. Estimation of Cut & Earth Fill quantities as per approved route profile drawings
2. Drawings preparation for bund construction

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AC Mitigation Studies

1. Preparation of AC Mitigation studies at Petroleum / gas pipe line crossings location

2. Design / drawing preparations of Cathodic Protection / Earthing system based on AC Mitigation study

Uplift Pressure Calculation

1. Uplift pressure calculation on 220KV power cables under submerged conditions at shallow ground
water table locations.
2. Design of Duct Banks for power cable crossings under pipe lines to eliminate the possibility of any
damage to pipelines due to uplift pressure

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Electrical Works & Pre-Commissioning Testing of Completed Jobs

1. EHV & HV Cable jointing and terminations

2. All electrical testing as per client requirement
3. Resonant Frequency AC testing at site along with all arrangements of test chambers
4. Partial Discharge Measurement at installed cable accessories
5. Distributed Temperature Sensing (DTS) Cable & System installation and testing
6. FO cable installation in pipe by air blowing method and direct burial
7. FO cable fusion splicing
8. FO cable testing & commissioning using OTDR and power meter light source method
9. Communication (Metallic) cables, installation; jointing termination and testing

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Engineering Software Packages

• CYMCAP

• ETAP

• PSCAD / EMTDC

• PLS Cad

• AUTOCAD

• Staad Pro V8

• Expert GPS

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Cable System Rating
• The ampacity, or current rating, of a cable is one of the most important factor to consider when designing an underground
cable system
• The determination of the maximum current that a cable can sustain without deterioration of any of its electrical and/or
mechanical properties has always been of prime interest to system design engineers and constitutes an important design
parameter for both system planning and operations.
• Calculation encompasses many aspects of the cable construction and installation.
• There are many factors that come into play when trying to design the optimal and most economical underground cable
systems.
The thermal performance of the underground cable system depends mostly on the following factors
• Voltage level and Cable Size
• Soil Thermal Resistivity
• Cable installation Depth
• Cable circuit Separation

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Electrical field

Electric field distribution or voltage gradient is therefore represented by a

homogenoius radial field. The value of the voltage gradient at a point x within the
insulation can therefore be calculated as:

with
Uo = Operating voltage (kV)
rx = Radius at position x (mm)
ra = External radius above the insulation (mm)
ri = Radius of the internal field delimiter (mm)
The electrical field strength is highest at the inner
semiconductor and lowest above the insulation
(below the external semiconductor, rx = ra).

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Bonding & Earthing methods

High voltage cables have a metallic sheath, along which a voltage is induced as a function of the operating current.
In order to handle this induced voltage, both cable ends have to be bonded sufficiently to the earthing system. The
following table gives an overview of the possible methods and their characteristics

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Comparison: trefoil vs. flat laying of HV cables

▪ lower ampacity ▪ higher ampacity

▪ less space required ▪ more space required
▪ lower induced voltages ▪ higher induced voltages
▪ lower magnetic fields ▪ higher magnetic fields

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Cable laying parameters influencing the ampacity

important laying parameter Remarks

thermal resistivity of soil natural soil or, if necessary, special
backfill material with low thermal
resistivity
maximum ambient soil temperature
laying conditions e.g. directly buried, ducts, troughs, in
air
distance between the phases
laying depth
formation of laying flat or trefoil

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SVL for cable sheaths

Lightning strokes or switching pulses might induce over-voltages in cable sheaths. Without SVL these over-
voltages can destroy the cable sheaths. SVL limit the induced voltages.

During normal operation the end of the cable screen is insulated to ground (reduction of losses).
In case of induced over-voltages (caused by lightning strikes or
switching pulses) the surge voltage limiter becomes conductive
and protects the cable sheath from puncture.

SVL are surge arresters. Typically they consist on varistors

based on ZnO, which is doped with different elements.
(Varistor: Variable Resistor)

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SVL for cable sheaths

• The rated voltage Ur is the highest permissible

voltage at power frequencies for a limited
duration and is given by the manufacturer of the
surge arrester (for example: Ur = 1.25 Uc)

• The residual voltage Ures defines the protection level of the

surge arrester. The residual voltage is the maximum voltage at the
arrester during a 8/20 current impulse of the nominal discharge
current (e.g. 10 kA)

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Construction Methodology and Typical Trench Arrangement

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Construction Methodology and Typical Trench Arrangement

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Construction Methodology and Typical Trench Arrangement

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Construction Methodology and Typical Trench Arrangement

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Construction Methodology and Typical Trench Arrangement

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Cables Rating Simulations in different Installation conditions

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Cables Rating Simulations in different Installation conditions

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Short-Circuit Operating Conditions

Short-circuit currents in an electric network are a result of the accidental connecting of one or more phase conductors, either
together, or with ground.

1. Symmetrical short-circuits

(3 phase short-circuits) where the currents in the three phases form a balanced system. These currents therefore only circulate
in the main conductors of the cables.

2. Zero-sequence short-circuits

result from an asymmetrical, i.e. unbalanced current system. Zero-sequence currents return via the ground and/or by the
conductors that are electrically parallel to ground. These conductors are mainly:
• ground conductors,
• metallic screens connected to ground at the line terminations
• the ground itself
The metallic screens of the cables must therefore have a large enough cross-section to withstand these so-called zero-
sequence short-circuits

103
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DTS: Distributed Temperature Sensing

How The System Works: Optical Time Domain Reflectometry

Laser pulses are sent into the optical fibre and the Interaction of laser light with vibrating glass molecules in optical fibre
leads to a back scattering (Raman-Scattering) of the light with two different frequencies (Stokes line and Anti-Stokes line).

Because the intensity of the back-scattered Anti-Stokes light depends on the temperature, one can determine from the
measured intensity the temperature at the location of scattering in the optical fibre From the time difference between sending
the laser pulse and the detection of the scattered light one can determine the location in the optical fibre where the light was
scattered.

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Distributed Temperature Sensing

DTS can not only be used for monitoring the temperature of a cable system, it can be also used for real time thermal rating
(RTTR) of the cable system.

From DTS data one can calculate the temperature of the cable conductor along the cable route.

With real time determined conductor temperature one can increase the current in the cable without a danger of overheating
locally the cable.

Real time thermal rating based on distributed temperature sensing allows an optimization of the energy transmission in HV
cables.

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Maintenance of HV Cables & Accessories

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Maintenance for HV Cables & accessories,

• What maintenance practices are being applied at present?

• What are the causes of failure for cables and accessories?
• How can potential failures be detected?
• What guidelines can be given to improve?

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Why maintenance?

• To ensure system reliability and continuous performance

• To avoid more expensive maintenance later
• To extend the life of the equipment
• To avoid unsafe situations
• To repair failed components
• To avoid legal and financial penalties

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Maintenance for HV Cables & accessories,
• Maintenance: the combination of all technical and administrative actions, including supervision actions,
intended to retain an item in, or restore it to, a state in which it can perform a required function
• Predictive Maintenance: an equipment maintenance strategy based on measuring the condition of
equipment in order to assess whether it will fail during some future period, and then taking appropriate
action to avoid the consequences of that failure
• Preventive maintenance: the maintenance carried out at predetermined intervals or according to prescribed
criteria and intended to reduce the probability of failure or the degradation of the functioning item
• Corrective Maintenance: to repair or to replace broken components Time Based Maintenance: to perform
maintenance on a predetermined schedule= preventive maintenance Condition Based Maintenance: to
perform maintenance, based on the results of condition assessment of the component= predictive
maintenance

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Maintenance for HV Cables & accessories,

• According to a CIGRE questionnaire comparing maintenance on switchgear, transformers, lines and cables,
cables have the lowest expenditure on predictive maintenance and the highest expenditure on corrective
maintenance Possible explanation: Cables are usually invisible Cables do not have moving parts Cables have
low risk of explosion

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Survey of presently used maintenance programs

• To avoid 3rd party damage: Inspections of cable routes Administrative procedures to provide cable route
information to other parties (using a central office to coordinate)

• Extruded cables: Serving test Visual inspection of terminations Thermal monitoring Inspection of alarm
equipment (if installed in tunnel) Serving test Inspection of terminations Inspection of fluid equipment
(pressure, tank)Inspection of fluid alarm equipment

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Survey of presently used maintenance programs

• Test on specially bonded systems Inspection of link box Inspection of surge arrestor Current measurement To
collect statistical data Innovative actions Tan delta measurement measurement Advanced failure analysis

• Conclusions: Preventive maintenance rather than predictive maintenance Frequency of maintenance actions
decided by the utility involvedCBM not well applied Failure analysis Investigation of “coincidental” samples
Collecting information in data base

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Failure modes/detection methods /maintenance actions

• Damaged cable, over sheath, metal sheath by 3rd party Damaged metal sheath due to corrosion or fatigue
Ingress of water in cable accessory of link box External mechanical stress due to ground changes, thermal
expansion / contraction (snaking) and improper clamping Thermal ageing of insulation Assembly errors
Movement of cable due to thermal cycling or poor clamping

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Available tools for Extruded cables

• Cable route inspection Serving test Tan delta measurement Temperature measurement Thermal backfill
surveyed measurement Chemical / physical analysis of fluid in termination-ray of accessories Inspection of
cable systemSVL test Bonding system test

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Serving test procedure

• Purpose of the oversheath: To protect the cable against mechanical forces during installation To protect the
metallic sheath against corrosion To isolate the metallic sheath from earth potential for cross bonding To
protect the insulation against ingress of water
• Voltage between sheath and earth If there is a defect, a high leakage current will flow (>10mA)The fault is
pinpointed using fault localization techniques After repair the test will be repeated

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Recommendations for extruded cables

• Ensure that cable rout information is available and procedures are in place to exchange information Periodic
inspections along the cable route to check 3rd party activities Periodic serving test Periodic inspection of out
door terminations Periodic visual inspection of link boxes Data base including failure events and causes
Continuous measurements of pressure in terminations and/or low pressure alarms Periodic inspection of
forced cooling system

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PARTIAL DISCHARGE
• Partial discharge is best described as a failure of part of an insulation system to withstand the electrical field
applied to it.
• This can be a result of poor design, poor workmanship, defective materials, contamination, or aging
• The result of this failure is a high-frequency, unipolar discharge and accompanying current that flows through
and on the insulation from the conductor to ground.
• This current pulse is low energy due to its short (microsecond) duration, but it can negatively affect the
insulation and eventually cause catastrophic failure
• The discharge spark erodes the insulation from within through its heat and ionization. If occurring on the surface,
the discharge also causes the breakdown of air molecules into oxygen (ozone) and nitrogen (nitric oxide).
• The nitric oxide forms nitric acid, which erodes the insulation from the outside.

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Glimpse of HV Cable Site Installation and Civil Works

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Setting out

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TRENCH EXCAVATION

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TRENCHER USED FOR NON UTILITY AREA

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FTB-INSTALLATION

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CABLE LAYING

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CBS installation

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Tiles installation

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COMPACTION

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COMPACTION TEST

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Joint Bay WORK

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JOINTING CONTAINER AND SHELTER

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JOINTING WORK IN PROGRESS

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JOINTING WORK & JOINTING COMPLETED

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FOC Termination photographs (PSS5) for
66kV Diyar Al Muharraq BSP-1 – Ajirah (PSS 5) CCT-3

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WATER PROOFING DONE

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BORING WORK FOR EARTHING

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Preparation, Plug in & Termination in BSP-1
66KV Diyar Al Muharraq BSP1 – Al Bareh (PSS 9)

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LINK BOX
CONNECTION

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Road crossing-HDD

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STRUCTURE WORK-TRIFOIL FORMATION
FIRE REDRANT PAINTING DONE OVER THE CABLE

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FIRE SHEET INSTALLED UNDER GIS WATER PROOFING AND FIRE PROOFING
DONE AT DUCT ENTRY

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FO CABLE BLOWING

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DTS PANEL AND FO CABLE TERMINATION BOX (OTB)

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HVAC Testing End to End Testing

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132KV
11KV 66KV

33KV

LV

152