Materials System Specification

15-SAMSS-502 20 November 2017

Medium Voltage Power Cable 5 kV through 35 kV
Document Responsibility: Electrical Systems Designs and Automation Standards
Committee

Contents
1 Scope ..................................................................... 2
2 Conflicts and Deviations ......................................... 2
3 References ............................................................. 2
4 Field Experience..................................................... 3
5 General .................................................................. 3
6 Medium Voltage Power Cable per IEC 60502-2 ..... 4
7 Medium Voltage Power Cable per AEIC CS8 ........ 6
8 Other Requirements ............................................... 8
Revision Summary ........................................................ 9
Data Sheets ............................................................... 10

Previous Issue: 4 December 2012 Next Planned Update: 20 November 2020

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Contact: Bugshan, Jamal A. (bugshaja) on phone +966-13-8809650

©Saudi Aramco 2017. All rights reserved.

Document Responsibility: Electrical Systems Designs and Automation Standards Committee 15-SAMSS-502
Issue Date: 20 November 2017
Next Planned Update: 20 November 2020 Medium Voltage Power Cable 5 kV through 35 kV

1 Scope

This specification defines the mandatory requirements for dielectric insulated power
cables with rated voltages from 5 kV through 35 kV, 50 or 60 Hz. Submarine,
submersible pump (down hole), portable, and motor lead cables are outside the scope
of this specification.

2 Conflicts and Deviations

2.1 If there are any conflicts between this specification and associated purchasing,
project, or engineering documents, this specification shall take precedence.

2.2 Direct all requests to deviate from this specification in writing to the Company
or Buyer Representative, who shall follow internal company waiver procedure.

2.3 The designation “Commentary” is used to label a sub-paragraph that contains

comments that are explanatory or advisory. These comments are not mandatory,
except to the extent that they explain mandatory requirements contained in this
SAMSS.

3 References

The following is a summary of all the documents which have been mentioned within
this specification. The specific part(s) of these documents which are applicable have
been identified throughout this specification.

3.1 Saudi Aramco References

Saudi Aramco Inspection Requirements

Form 175-150200 Medium Voltage Power Cable 5 kV through 35 kV

3.2 Industry Codes and Standards

American Society for Testing and Materials

ASTM B8 Concentric-Lay-Stranded Copper Conductors,
Hard, Medium Hard, or Soft
ASTM B496 Compact Round Concentric-Lay-Stranded Copper
Conductors

Association of Edison Illuminating Companies

AEIC CS8 Specification for Extruded Dielectric, Shielded
Power Cables Rated 5 through 46 kV

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Document Responsibility: Electrical Systems Designs and Automation Standards Committee 15-SAMSS-502
Issue Date: 20 November 2017
Next Planned Update: 20 November 2020 Medium Voltage Power Cable 5 kV through 35 kV

Insulated Cable Engineers Association

ICEA S-94-649 Concentric Neutral Cables Rated 5,000 - 46,000 Volts
ICEA S-97-682 Utility Shielded Power Cables Rated 5,000 - 46,000
Volts

International Electrotechnical Commission

IEC 60038 IEC Standard Voltages
IEC 60228 Conductors of Insulated Cables
IEC 60332-3-23 Test for Vertical Flame Spread of Vertically-
Mounted Bunched Wires or Cables - Category B
IEC 60502-2 Power Cables with Extruded Insulation and their
Accessories for Rated Voltages from 1 kV
(Um = 1,2 kV) up to 30 kV (Um = 36 kV)

Underwriters Laboratories
UL 1072 Standard for Medium Voltage Power Cable

4 Field Experience

Designs, materials and methods of construction used in cable shall have a minimum of
6 years of verifiable, proven field experience. (Local manufacturer is exempted).
Vendor shall supply a User List indicating User company name, installation site, date of
installation, and characteristics similar to cable quoted.

5 General

Medium Voltage Power Cable shall be manufactured and tested in accordance with
International Electrotechnical Commission (IEC) 60502-2, or in accordance with
Association of Edison Illuminating Companies (AEIC) CS8, as specified in the
purchase order or in the Saudi Aramco Materials System Specification (SAMSS)
description, with additional requirements as outlined below:

5.1 Cable manufactured to IEC 60502-2 shall meet the requirements of Sections 6
and 8 below.

5.2 Cable manufactured to AEIC CS8 shall meet the requirements of Sections 7 and
8 below.

5.3 Substitution of IEC cable with AEIC cable, if IEC cable is specified, and vice
versa, is prohibited.

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Document Responsibility: Electrical Systems Designs and Automation Standards Committee 15-SAMSS-502
Issue Date: 20 November 2017
Next Planned Update: 20 November 2020 Medium Voltage Power Cable 5 kV through 35 kV

6 Medium Voltage Power Cable per IEC 60502-2

Cable shall be manufactured and tested in accordance with IEC 60502-2, with the
following additional requirements:

6.1 The conductors shall be of Class 2 annealed copper in accordance with

IEC 60228, plain or metal coated as specified. Conductor sizes shall be standard
metric IEC 60228 sizes.

6.2 Insulation material shall be crosslinked polyethylene (XLPE), Tree Retardant

XLPE (TRXLPE) or ethylene propylene rubber (EPR), as specified.
Thermoplastic insulating compounds are not acceptable.

6.3 The rated voltage, nominal insulation thickness (as defined in IEC 60502-2) and
field (commissioning) test voltage of the cable shall be in accordance with
Table 1.
Table 1

I II III
Buyer's System Voltage Nominal Insulation
Uo/U(Um)
Nominal/Class Thickness
kV
kV mm
Above 2 up to 4.16/5 6/10 (12) 3.4
Above 4.16/5 up to 13.8/15 12/20 (24) 5.5
Above 13.8/15 up to 34.5/35 18/30 (36)* 9.0

Note: * IEC standard rated voltage; cable shall be similar to 18/30 (36) kV, but with 9.0 mm
insulation thickness.

IEC Definitions:
Uo : rated phase to ground voltage for which the cable is designed
U : rated phase to phase voltage for which the cable is designed
Um : highest system voltage for which the cable may be used (IEC 60038)

6.4 Conductor and insulation screening is required for all cables.

6.5 Conductor shield shall be easily removable from the conductor (to be firmly
bondable to the insulation XLPE), and shall consist of either a layer of extruded
semiconducting compound, or a layer of extruded semiconducting compound
over a semiconducting tape.

6.6 The non-metallic part of the insulation screen (shield) shall consist of a layer of
extruded semiconducting compound or extruded thermosetting compound.
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Document Responsibility: Electrical Systems Designs and Automation Standards Committee 15-SAMSS-502
Issue Date: 20 November 2017
Next Planned Update: 20 November 2020 Medium Voltage Power Cable 5 kV through 35 kV

Semiconducting coatings (paints) are not allowed. The extruded compound

shall be removable (strippable) tested in accordance with IEC 60502-2.

6.7 The extruded semiconducting conductor shield, the insulation, and the
semiconducting insulation shield shall be applied by simultaneous triple
extrusion. Steam curing is not acceptable for XLPE insulated cable.

6.8 The metallic part of the insulation screen (shield) shall consist of copper tape(s),
and shall be applied separately over each of the semicon-shielded, insulated
conductors. Copper tape shall be a minimum of 0.1 mm thickness, applied with
a minimum of 10% overlap.

6.9 If a concentric neutral conductor is specified in the purchase order, it shall

consist of copper wires with the specified cross section, and shall be plain or
metal coated as specified. The concentric neutral conductor shall be under the
outer jacket. The concentric neutral wires may serve as, and take the place of
the copper tape screen (shield) specified in paragraph 6.8.
Commentary Note 6.9:

The manufacturer may elect to include a copper tape screen (shield) as a means to
improve the flame retardant characteristics of the cable, and meet the requirements
of paragraph 6.16. In this case, the manufacturer shall notify Saudi Aramco.

6.10 IEC 60228 Class 2, stranded copper ground conductor(s) shall be provided in
the interstices of the cable, if specified in the purchase order.

6.11 Fillers (extruded material or non-hygroscopic fibers) shall be used in order to

ensure the cable is compact and round in cross-section.

6.12 Metallic armor, when specified in the purchase order, shall be galvanized steel
double tape armor, or galvanized steel wire armor.
Exception:

For single conductor cables, material shall be aluminum instead of steel.

6.13 All cables shall have a continuous overall outer nonmetallic oversheath (outer
jacket).

6.14 The outer jacket (oversheath) shall be polyvinyl chloride (PVC), suitable for
90°C maximum rated conductor temperature.

6.15 The outer jacket (oversheath) shall be sunlight resistant and oil resistant.

6.16 The cable shall meet the retardant test when specified in the purchase order as
per IEC 60332-3-23, “Test for vertical flame spread of vertically-mounted

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Document Responsibility: Electrical Systems Designs and Automation Standards Committee 15-SAMSS-502
Issue Date: 20 November 2017
Next Planned Update: 20 November 2020 Medium Voltage Power Cable 5 kV through 35 kV

bunched wires or cables – Category B.” This is a type/qualification test – see

paragraph 8.5.

6.17 All routine and sample tests shall be according IEC-60502-2.

7 Medium Voltage Power Cable per AEIC CS8

Cable shall be manufactured and tested in accordance with AEIC CS8 and
ICEA S-97-682 (cable without concentric neutral), or in accordance with
AEIC CS8 and ICEA S-94-649 (concentric neutral cable), in both cases with the
following additional requirements:

7.1 Insulation material shall be XLPE or EPR, as specified. Thermoplastic insulating

compounds are not acceptable.

7.2 The rated voltage, nominal insulation thickness and field (commissioning) test
voltage of the cable shall be in accordance with Table 2.
Table 2
I II III IV
Buyer's System Voltage Rated Insulation Nominal *
Nominal/Class Voltage Level Insulation Thickness
kV kV % mm (mils)
Above 2 up to 4.16/5 5 133 2.92 (115)
Above 4.16/5 up to 13.8/15 15 133 5.59 (220)
Above 13.8/15 up to 34.5/35 35 100 8.76 (345)

Note: * ICEA S-94-649 and ICEA S-97-682 specify insulation thickness in terms of minimum
and maximum values.

7.3 The conductors shall be ASTM B8 Class B concentric-lay-stranded annealed

copper, or ASTM B496 compact round concentric-lay-stranded annealed
copper, plain or metal coated as specified in the purchase order.

7.4 Conductor and insulation shields are required for all cables, except 5 kV rated
cable type MC can be without insulation shield if specified.

7.5 Conductor shield shall be easily removable from the conductor, and shall consist
of either a layer of extruded semiconducting compound, or a layer of extruded
semiconducting compound over a semiconducting tape.

7.6 The non-metallic part of the insulation shield shall consist of a layer of extruded
semiconducting compound. Semiconducting coatings (paints) are not allowed.
The extruded compound shall be removable (strippable); the tension required to
remove 12.5 mm strips at room temperature shall not be less than 1.4 kg (3lbs)

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Document Responsibility: Electrical Systems Designs and Automation Standards Committee 15-SAMSS-502
Issue Date: 20 November 2017
Next Planned Update: 20 November 2020 Medium Voltage Power Cable 5 kV through 35 kV

nor more than 11 kg (24 lbs), when the stripping test of ICEA S-94-649 or
ICEA S-97-682 is performed.

7.7 The extruded semiconducting conductor shield, the insulation, and the
semiconducting insulation shield shall be applied by simultaneous triple dry
extrusion. Steam curing is not acceptable for XLPE insulated cable.

7.8 The metallic part of the insulation shield shall consist of copper tape(s), and
shall be applied separately over each of the semicon-shielded, insulated
conductors. Copper tape shall be a minimum of 0.1 mm thickness, applied with
a minimum of 10% overlap.

7.9 If a concentric neutral conductor is specified in the purchase order (occasionally

referred to by type URD or UD cable), it shall consist of copper wires with the
specified cross section, and shall be plain or metal coated as specified.
Applicable standards for cables with concentric neutral are ICEA S-94-649 and
AEIC CS8. The concentric neutral conductor shall be under the outer jacket.
The concentric neutral wires may serve as, and take the place of the copper tape
screen (shield) specified in paragraph 7.8.
Commentary Note 7.9:

The manufacturer may elect to include a copper tape screen (shield) as a means to
improve the flame retardant characteristics of the cable, and meet the requirements
of paragraph 7.16. In this case, the manufacturer shall notify Saudi Aramco.

7.10 ASTM B8 Class B concentric-lay-stranded annealed copper, or ASTM B496

compact round concentric-lay-stranded annealed copper ground conductor(s)
shall be provided in the interstices of the cable, if specified in the purchase
order.

7.11 Fillers (extruded material or non-hygroscopic fibers) shall be used in order to

ensure the cable is compact and round in cross-section.

7.12 Metallic cover, when specified in the purchase order, shall be corrugated
impervious aluminum sheath, or galvanized steel interlocked tape. The cable
shall be type MC (metal clad).
Exception:

Steel shall not be used for single conductor cables.

7.13 All cables shall have a continuous overall outer nonmetallic jacket.

7.14 The outer jacket shall be PVC, suitable for 90°C maximum rated conductor
temperature.

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Document Responsibility: Electrical Systems Designs and Automation Standards Committee 15-SAMSS-502
Issue Date: 20 November 2017
Next Planned Update: 20 November 2020 Medium Voltage Power Cable 5 kV through 35 kV

7.15 The outer jacket shall meet the sunlight resistance, and the oil resistance I or II
requirements of UL 1072. This is a type/qualification test – see paragraph 8.5.
A certificate from the manufacturer that the cable has been type tested by a third
party and that it meets these UL tests is acceptable in lieu of formal UL listing or
certification.

7.16 The cable shall meet the vertical tray flame test specified in UL 1072. This is a
type/qualification test – see paragraph 8.5. A certificate from the manufacturer
that the cable has been type tested by a third party and that it meets this UL test
is acceptable in lieu of formal UL listing or certification.

7.17 In addition to the marking requirements of paragraph 8.2, the cable outer jacket
shall have the following markings:
i) Insulation thickness (preferably), or % insulation level.
ii) TYPE MV-90, or, when applicable, TYPE MV-90 OR MC,
or TYPE URD, or TYPE UD.
iii) OIL RES I or OIL RES II.

8 Other Requirements

8.1 Each phase of multi-conductor cables shall be permanently identified.

8.2 Cables shall be marked by embossing in English on the outer non-metallic jacket
(oversheath) at intervals not exceeding 1 m with the following information:
1) Rated voltage
2) Insulating compound (XLPE, TRXLPE or EPR)
3) Number, size and material (“COPPER” or “CU”) of conductors
4) Manufacturer's name
5) Year of manufacture

8.3 Reels shall be made of steel, or, alternatively, shall be heavy duty wood reels.
Reels shall be lagged with wood, and shall be marked with a steel engrave
durable label securely attached to a flange of the reel and plainly stating Buyer's
Purchase Order number, length of cable on reel, number, type and size of
conductors, Gross weight of cable on reel , and voltage rating. All markings shall
appear on both sides of the reel. Cable ends shall be sealed and capped.

8.4 Water Protection Requirement, if the cable is buried under water table, sabkah
area, outdoor onshore locations within one kilometer from the shoreline of the
Arabian Gulf or outdoor onshore locations within three kilometers from the
shoreline of the Red Sea shall be apply following;

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Document Responsibility: Electrical Systems Designs and Automation Standards Committee 15-SAMSS-502
Issue Date: 20 November 2017
Next Planned Update: 20 November 2020 Medium Voltage Power Cable 5 kV through 35 kV

8.4.1 Longitudinal water protection, in the form of semiconducting

waterblocking swellable tapes applied under and over the metallic screen
or concentric neutral.

8.4.2 One of the following shall be added to 8.4.1:

1) Longitudinal water protection for the conductors, in the form of
synthetic super-absorbent polymer type water swellable tape or
yarns, to prevent ingress of water along the conductor.
2) Tree- Retardant XLPE (TRXLPE) instead of XLPE insulation.
3) Radial water ingress protection, in the form of plastic coated
laminated aluminum or copper tape immediately under the outer
jacket and firmly bonded to it.

8.5 Type/Qualification Tests

The manufacturer shall provide a certificate from a third party testing agency
acceptable to Saudi Aramco, proving that all type or qualification tests required
by applicable IEC, ICEA and AEIC standards have been successfully completed
(a) prior to the placement of the first order for the type of cable ordered, and (b)
prior to the placement of the first order after any major change in manufacturing
processes. The certificate shall be plant-specific and shall not be extended to
other plants of the same manufacturer.

8.6 Inspection

Inspection shall be in accordance with this specification and Form 175-150200.

Revision Summary
4 December 2012 Revised the Next Planned Update.” Reaffirmed the contents of the document, and
reissued with minor revision that includes deletion of few requirements related to
installation of the cables and also specific requirements on where to apply water protection
for the cable system.
20 November 2017 Major revision to incorporate various major comments generated during the workshop
attended by standard stakeholders such as CSD, Power Systems Engineering
Department, FPD, SAPMT and local manufacturers. The new revision will include
following main items which are: allow AC or DC high-potential tests with applied voltage
values as specified in the international standards lessons learned from mega projects and
operating facilities were explored to identify areas of improvements.

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Document Responsibility: Electrical Systems Designs and Automation Standards Committee 15-SAMSS-502
Issue Date: 20 November 2017
Next Planned Update: 20 November 2020 Medium Voltage Power Cable 5 kV through 35 kV

Data Sheets

Data Sheet - Power Conductor

Item To be completed
No Description Specified By Vendor
Reference manufacturing standard IEC 60502-2/ AEIC CS8 _______________

Units Specified
01 Power Conductor Size mm²/kcmil _________ _______________

02 Power Conductor Insulation - _________ _______________

Type (Either XLPE or EPR)

03 Number of Cores 1C/3C _________ _______________

04 Rated Operating Voltage (U) KV _________ _______________

05 Max. Continuous Voltage (Umax) KV _________ _______________

06 Max. 15 min Overvoltage KV _________ _______________

07 Frequency Hertz 60

08 Power Requirement KVA _________ _______________

09 Load Power Factor (lagging) - _________

10 Cable Ampacity at 90°C A _________ _______________

11 Max Cont. Conductor Temperature C _________ _______________

12 Max Short Circuit Temperature C _________ _______________

13 Required Voltage Regulation % _________

14 Design Load Factor % _________

15 System Fault Current:

Phase to Ground A _________
Three Phase Sym. A _________
Duration Cycles _________

16 Cable Operating Temperature °C _______________

at Design Load

17 Min. Insulation Resistance Ohm/km _______________

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Document Responsibility: Electrical Systems Designs and Automation Standards Committee 15-SAMSS-502
Issue Date: 20 November 2017
Next Planned Update: 20 November 2020 Medium Voltage Power Cable 5 kV through 35 kV

18 Max. Conductor Impedance at 60 Hertz Ohm/km _______________

19 D.C. Resistance at 20°C Ohm/km _______________

20 A.C. Resistance at 90°C, 60 Hz Ohm/km _______________

21 Lead Sheath 5 – 35 kV Cables Yes/No _______________

22 Inductive Reactance at 60 Hz Ohm/km _______________

23 Shunt Capacitance µF/km _______________

24 Conductor Impedance Ohm/km _______________

25 Zero Sequence Impedance at 60 Hz Ohm/km _______________

26 Positive Sequence Impedance at 60 Hz Ohm/km _______________

27 Charging Current A/km _______________

28 Water Protection Yes/No _______________

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Document Responsibility: Electrical Systems Designs and Automation Standards Committee 15-SAMSS-502
Issue Date: 20 November 2017
Next Planned Update: 20 November 2020 Medium Voltage Power Cable 5 kV through 35 kV

Data Sheet - Overall Cable

Item To be completed
No Description Units Specified By Vendor

29 Minimum Bending Radius mm _______________

a) With tension mm _______________
b) Without tension mm _______________

30 Ultimate Breaking Strength

a) Minimum kN _______________
b) Maximum kN _______________

31 Recommended Maximum Tensile

Loading for Installation/
Recovery of Completed Cable kN _______________

32 Minimum Design Tension kN _______________

33 Max Bending Radius m _______________

33 Cable Weight
a) Net (Cable) kg/km _______________
b) Gross (Cable + Reel) kg _______________

34 Approx. Diameter of Conductor mm _______________

35 Cable Overall Diameter mm _______________

36 Maximum Diameter over Splices mm _______________

37 Nominal Insulation Thickness mm _______________

38 Total Cable Length km _________ _______________

39 Armor type and thickness (double tape / wire armor) _______________

40 Cable Shipment Type _________ _______________

- Additional technical information or features specified by the COMPANY

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Document Responsibility: Electrical Systems Designs and Automation Standards Committee 15-SAMSS-502
Issue Date: 20 November 2017
Next Planned Update: 20 November 2020 Medium Voltage Power Cable 5 kV through 35 kV

Figure 1 - Cross Section of 3-core Cable (example)

Figure 2 - Cross Section of 3-core Cable (example of additional water protection)

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Document Responsibility: Electrical Systems Designs and Automation Standards Committee 15-SAMSS-502
Issue Date: 20 November 2017
Next Planned Update: 20 November 2020 Medium Voltage Power Cable 5 kV through 35 kV

Figure 3 - Cross Section of 1-core Cable (example of additional water protection)

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