RIYADH CABLES HIGH VOLTAGE

Riyadh CablesPOWER
Group CABLES
HV & EHV Cables Catalogue
 INTRODUCTION
Riyadh Cables started production of Medium voltage cables in 1986 and High Voltage
Cables in 1994 and has supplied huge quantities of Medium Voltage Cables while in the
High Voltage cables, the cumulative quantity exceeds 1000’s of kms in both 132 kV and
69 kV cables.

High and Extra High Voltage cables from 66 kV to 380 (420) kV with different constructions
and material manufactured by Riyadh Cables Group has been successfully type tested.

Long-term tests were also performed both at Riyadh Cables Laboratories and King Saud
University (6 months, 1 year, 2 years) to prove the high quality of RC&M manufactured
cables. Breakdown tests with different constant voltages and time gave the result that
cables designed at a stress of 13 kV/mm can survive more than 30 years which gives an
indication that RC&M high voltage cables can be designed at a stress level of 8 kV/mm
for High Voltage Cables and 12 kV/mm for Extra High Voltage Cables with a good safety
margin other than the values which were considered during evaluation.

Type tests and prequalification tests for 1x2500 mm² 230/380 (420) kV cable with BRUGG
accessories are finalized successfully in 2019.

Riyadh Cables have qualified engineers and the required software to design high voltage
circuits based on local conditions. Current rating, Induced voltage, Short circuit current for
conductor and screen are computed to meet customers’ requirements, positive, negative
and zero sequence impedance are computed for Engineering purposes and Network
protection.

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 RESEARCH AND DEVELOPMENT
The company has a realistic approach towards improvement and development of its
products, therefore, it has established a Research and Development team whose main
objectives are:

● Selection of the best raw material for cables after long term and short term testing and
after in-depth analysis and review.

● Co-ordinate with other research bodies both in the Kingdom and World, to study cable
phenomenon such as cable aging and insulation de-gradation and provide measures
to minimize this effect.

● Co-ordinate with the local electric utilities in order to optimize the most economical
cable construction taking into consideration their needs and local environment
conditions.

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 HIGH VOLTAGE & EXTRA HIGH VOLTAGE CABLES
The rapid development of the Solid Dielectric Cables manufacturing had lead to the
substitution of the traditional impregnated paper and oil filled cables almost entirely by
Cross-linked polyethylene (XLPE) Cables for voltages up to 380 kV or above due to the
great technical and economic advantages of XLPE cables. In comparison, XLPE Cables
have lower weight, better thermal properties and reduced installation and maintenance
costs. Environmentally, XLPE Cables have great advantage since the risk of oil leakage
in non-existent. The excellent electrical and mechanical properties of XLPE make it a
most suitable insulating material. Since the early 1960’s great quantities of XLPE Cables
have been installed around the world by virtue of its proven reliability, simplicity and
overall system economy.

Riyadh Cables (RCGC), a leader in Modern Cables Industry was the first cable
manufacturer to use the state-of-the-art “Dry Curing and Dry Cooling of Organic peroxide
XLPE” Cable production technology in the Middle East. RCGC started production of
Medium Voltage cables in 1986. Production of 69 kV cables began in 1991. The extensive
experience RCGC earned supported by the “Licensing Agreement for the Know-How and
Technical Assistance” with BRUGG KABEL AG lead to production of high voltage cables
greater than 69 kV in 1994 and Extra High Voltage XLPE cables “1x2500 mm² 380 kV”
in 2016.

In 2004, based on the cumulative experience gained by Riyadh Cables Group in High
Voltage Cable Production and System Installation and for more flexibility with accessory
suppliers, Riyadh Cables took the decision to continue High Voltage Cable Production
on its own. While in 2015, Riyadh Cables has signed with the same company “BRUGG
KABEL AG” an agreement for the production of 380 kV cables under their license with all
necessary know-how.

High Voltage and Extra High Voltage XLPE cables manufactured by Riyadh Cables meet
the standard specifications of Saudi Electric Companies and Electricity Corporation as
well as Saudi Arabian Standards and various other National & International Standards,
particularly standards of GCC Countries and other Arab Countries, to satisfy market
requirements both at home and abroad.

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 DESIGN PHILOSOPHY
High Voltage cables from 66 kV to 380 (420) kV with different constructions and material
manufactured by Riyadh Cables Group have been successfully type tested.

Long-term tests were also performed both at Riyadh Cables Laboratories and King Saud
University (6 months, 1 year, 2 years) to prove the high quality of RC&M manufactured
cables. Breakdown tests with different constant voltages and time gave the result that
cables designed at a stress of 13 kV/mm can survive more than 30 years which gives an
indication that RC&M high voltage cables can be designed at a stress level of 8 kV/mm
for High Voltage Cables and 12 kV/mm for Extra High Voltage Cables with a good safety
margin other than the values which were considered during evaluation.

Type tests and prequalification tests for 1x2500 mm² 230/380 (420) kV cable with BRUGG
accessories are finalized successfully in 2019 in KEMA.

Riyadh Cables have qualified engineers and the required software to design high voltage
circuits based on local conditions. Current rating, Induced voltage, Short circuit current
for conductor and screen are computed to meet customer requirement, positive, negative
and zero sequence impedances are computed for Engineering purposes and Network
protection.

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 SUPERVISION AND CERTIFIED
PROFESSIONAL JOINTERS
Experienced engineers provide supervision and certified professional jointers perform the
required cable laying and accessory installations. To cope with International awareness,
Riyadh Cables have purchased an HVAC site test systems, which provide more accurate
results about the installation and workmanship quality without affecting the system at any
point.

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 SPECIAL FEATURES OF HIGH & EXTRA HIGH
VOLTAGE CABLES MANUFACTURED BY
RIYADH CABLES GROUP

I. MATERIAL:
1) Super smooth inner semi-conducting layer where electrical stress is at its maximum
value. This shall improve the cable electrical characteristics, cable breaking strength
and extend the lifetime of cable..

2) Super-clean XLPE insulation material as contamination is one of the main cause of

water-tree initiation in the insulation material. The level of cleanliness is higher than
the requirements specified in AEIC CS9 and ICEA S-108-720..

3) For Watertight constructions, water swellable tapes shall be provided in the conductor
strand layers and over conductor to prevent ingress of water along the conductor
axis in case of cable failure due to any reason.

4) For watertight constructions, water swellable tapes under and over metallic screen
shall be used to prevent ingress of water longitudinally, in case of damage to the
outer sheath. Also, water swellable tapes shall keep the cable interior enough dry so
that triggering of water trees shall be considerably minimized.

5) For Radial Watertight constructions, Polyethylene Laminated Aluminium tape of

0.2 mm thickness is provided to prevent radial water penetration since polymeric
material might allow water to diffuse in very small quantities with the passage of time
and this shall affect the cable performance in the long run. The metal-copolymer
laminate consists of an aluminum tape with co-polymer lamination on both sides.
During extrusion of PE sheath the extruded sheath will fuse with the bonded PE
lamination of metal-polyethylene laminate to form one unit. This ensures 100%
radial watertight construction and shall effectively seal the underneath layers of the
cable perfectly preventing penetration of moisture into the cable. Up on request, lead
sheath is provided with smooth thickness to meet the short circuit requirements, or in
combination with copper wire screen for high short circuit levels.

6) Outer sheath of high-density polyethylene (HDPE), which can resist the force, applied
on the cable while pulling and it is also the best polymeric material as a radial water
barrier.

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 II. PROCESSING:
1) Clean Room, Material Handling and Conveying System:

Riyadh Cables Group uses the most sophisticated state of the art system available
in the world in the CCV lines to supply the materials to these lines. All CCV materials
are fed to extruders by gravitation. The connection between the material box and to
the extruder hopper is made in the clean room. The material is handled in completely
closed system where the cleanness level is as high as that of the materials’ supplier.
The surrounding area at the material connection with production equipement is very
clean. It is continuously monitored via particle counter, actual measurments show
that the area is at Class 100 of ASTM.

In addition, there is a high power magnet and a wind shifter above the insulation
extruder. The magnet (>15000 Gauss), stops any metallic steel contaminant
if present in the material. The wind shifter removes any powder in the granules,
possibly generated during shipment. This powder is collected in a bin and the content
is inspected at the end of each run.

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 2) Triple Extrusion:
Riyadh Cables employs state-of-the-art triple cross-head extrusion where the
conductor screen, insulation and insulation screen are extruded simultaneously by
means of a triple cross-head which has the following advantages:

● Uniform insulation structure.

● Ensures extremely accurate layer thickness
● Ensures high purity in the frontier limit between the semi-conductive layers and
insulation
● Provides optimal fusion of the individual layers without contamination.
● Ensures a firm bond and smooth interface between caech layer thus improving
electrical properties.
● Prevents unforeseen damage to the conductor or insulation screen during
manufacturing process.

ACTUAL CCV LINE TRIPLE CROSSHEAD & CONTROL UNITS

3) Dry Curing (Peroxide Curing):

The Insulated conductor is fed into the crosslinking zone where a computer calculated
and controlled heat treatment takes place in a dry inert gas (nitrogen) pressurized
atmosphere (dry curing).

Cross-linking is done by agent di-cumyl peroxide (DCP). Cross-linking takes place in

the CCV Tube under heated and pressurized Nitrogen where DCP decomposes into
two radicals which react with Polyethylene thereby causing cross linking.

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 Peroxide is already mixed at the material supplier’s plant with the proper balance of
Anti-oxidant and Peroxide to ensure the required thermal stability and optimum curing
level. Therefore, no mixing whatsoever is done at Riyadh Cables, this will prevent
any problems, which might occur due to the unbalanced mixing of the material in the
production stage as some other manufacturers do. Un-packing and handling of the
material is also done in similar super clean environment at RCGC details of which
are given in this catalogue.

The mixing ratio is about 1 to 1.5 PHR with very small amount of anti-oxidant.
The cross-link residual is gas, which defuses out of the insulation gradually. Other
residuals are Acetophone and Cumyl-alcohol, which are in very low ratio. Research
in this regard has proven that this material has very good effect on the insulation
such as:
a) It improves the breaking strength when inclusion occurs in XLPE material.
b) It slows water tree growth in the XLPE material under service.
c) Curing is done in heated and pressurized nitrogen which reduces micro voids and
moisture content in the insulation and ensures enhanced and stable breakdown
strength.

4) Dry Cooling/Water Cooling:

The hot cross-linked core passes into the cooling part of the line to be cooled in a dry
inert gas (Nitrogen) or pressurized water atmosphere.
Curing under pressure enhances elimination of micro voids and moisture content in
the insulation and ensures enhanced and stable breakdown strength and uniform
insulation structure.

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 5) Quality Control:
Performing very strict quality control during processing such as using X-ray unit for
thickness measurement in continuous mode for all extruded layers. This arrangement
also facilitates recording of the trend every two seconds. The unit continuously scans
360° geometry of the cable and displays maximum, minimum and eccentricity of all
three layers separately. Any deviation between specified values and measured values
are recorded and adjusted automatically.

Also included in the CCV line is the “Twin Rot System” one of the latest in manufacturing
technology, which ensures superior control of eccentricity and eliminates the possibility
of pear-drop as the cable rotates during manufacture.

Use of very sophisticated software for temperature adjustment in the curing zone of
CCV line ensures optimum XLPE characteristics.

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 TYPICAL HV/EHV CABLE DESIGN
High Voltage Cables and Extra High Voltage Cables are usually single core. The Basic Design
is shown below:

Conductor: Copper (Aluminum Optional)

Conductor Screen: Semi-conducting Thermosetting Compound
Insulation: Extruded Cross-linked Polyethylene (XLPE)
Insulation Screen: Semi-conducting Thermosetting Compound
Bedding Tape: Semi-Conducting Water Swellable Tape
Metallic Sheath: Copper Wire Screen &/or LEAD Sheath
Longitudinal Moisture Barrier: Water Swellable Tape
Radial Moisture Barrier: Laminated Aluminum Tape
Outer Sheath: Extruded HDPE (Graphite Coated)

Conductor water tightness is achieved by applying water swellable tapes between conductor
strand layers and a moisture impervious layer of semi-conducting water swellable tape over
conductor.

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 DESIGN PHILOSOPHY
Conductors:
Conductors are made of Copper or Aluminum. Conductors up to and including cross-
sectional areas of 1000 mm² are of round stranded compacted type. However 1000 mm²
conductor is provided in Milliken design as per some customers’ requests. Conductors
of cross-sectional areas 1200 mm² up to 3000 mm² are of Milliken design i.e. 4 or 5
segments with or without a central round conductor assembled together to form an overall
round section. This is in order to reduce the skin effect and ensure better compaction
and flexibility. Conductors comply in design and properties with IEC 60228. Conductor
formation comprises mainly of drawing and stranding. Wires of required diameter are
drawn in drawing machines and stranding is performed in stranding machines. In-
Process Quality Control monitors the specified requirements to ensure the quality of the
conductor.

Semi-Conductive Screens and Insulation:

The inner semi-conductive layer (conductor screen), XLPE insulation and the outer semi-
conductive layer (insulation screen) are applied simultaneously over the compacted
conductor by triple extrusion.

Extrusion of the above is performed in continuous caternary vulcanizing (CCV) line

specially designed to manufacture high and extra high voltage cables. Each component
of the line has been carefully selected to ensure the best quality product.

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 Material and Material Handling:
Specifically chosen, approved standard quality super clean material for high voltage
cables and ultra clean for extra high voltage cables from the world renowned leading
manufacturers of XLPE material is used along with super smooth material for
semiconductive screens as the compounds should meet strict standards of cleanliness.

Utmost precaution is taken to ensure cleanliness during handling and conveying of the
material. A clean room material handling and conveying system designed by German
companies specialized in clean room technology is installed which ensures a cleanliness
better than Class 100 of ASTM.

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 QUALITY CONTROL AND TESTING
High and Extra High voltage cables are subjected to continuous monitoring. Tests start
from the time of receiving the raw material right through various stages of production until
final testing.

Routine Tests, Sample tests and Type tests (when required) are carried out in accordance
with IEC, AEIC and other related International Standards.
Riyadh Cables has equipped itself with the most modern laboratories and equipment
including the following test fields:
● Routine test field with a large shielded enclosure for carrying out high voltage tests,
partial discharge measurements up to 500 kV at a noise level below 2 pC and for
measurements of tangent delta.
● High Voltage Laboratory containing basically a 2400 kV impulse generator, 400 kV AC
test system extendable up to 800 kV and heating equipment for conducting sample
tests, type tests on high voltage cables and accessories, long-term tests and tests to
determine breakdown data.
● Extra High Voltage Laboratory for electrical system type test which includes: AC test
system 800 kV, Impulse generator 2400 kV, Load cycle system 6000A to carry out
electrical type test for MV,HV & EHV cables system (up to 3000 mm²) in very large
shielded room to ensure high accuracy in cable system testing.

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 TECHNICAL INFORMATION:

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 Xm = x 0.2x ln x 10-3

Ui = Xm I L
Zm = +

Im =

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 The cyclic permutation of longitudinal sheath connections results in similar sheath over
voltage p roblems a t points where t he subdivided sheaths a re i nsulated as in single
grounded cable sheath. Therefore, these insulated points will have to be provided with
suitable over voltage protection (surge arrestors, non-linear silicon-carbide or zinc oxide
resistors)

Continuous Cross bonding system:

This is a type of cross bonding. It is applicable to circuits consisting of at least four minor
sections in which the cable metallic sheaths are successively cross-bonded at each joint.
At each end of the circuit the sheaths are solidly bonded and grounded (Figure c).

(c)

Mixed System:
Sometimes mixed system i.e., cross-boding and single point bonding in the same circuit
can be used where the number of minor sections cannot be divided over 3 such as 4 or
5 sections. H ere cross-bonding system can b e considered f or t he first 3 sections and
single point bonding used for the other section(s).

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 AL/XLPE/CUW/LAT/PE - 69 kV (72.5 kV) CABLE AS PER IEC 60840 &
NG SA 11-TMSS-01
Specification

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 CORRECTION FACTORS

Variation in Laying Depth of Cables

Soil Thermal Resistivity

Ground Temperature Ambient Air Temperature

Note: The overall accuracy of correction factors is within + 2%.

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 CORRECTION FACTORS

Variation in Phase Spacing of Cables*

Single circuit in flat formation in ground

Groups of Circuits in Ground in Trefoil Formation

Groups of Circuits in Ground in Flat Formation

Note: The overall accuracy of correction factors is within + 3%.

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