Ducab Powerplus Introduction & Tables

Ducab Powerplus™

A d vDucab Powerplus

Powerplus™Medium Vo l t a g eCable Systems

C o n t e n t s

SECTION PAGE

1. About Ducab 1

2. Introduction 2

3. Ducab’s New HV Cables Facility 3 - 5

4. Testing and Quality 6 - 9

5. Cable Selection 10 - 13

6. Cable Data 14 - 67

Cable Data Look-up Table 16 - 17

7. Technical Data and Rating Factors 68 - 75

8. Ducab Connect Components & Accessories 76 - 93

9. Drum Handling Instructions 94 - 95

Ducab

1Advanced Cable Solutions Through Technology and Innovat ion

Ducab Powerplus™About Ducab

Ducab, (Dubai Cable Company (Pvt) Ltd.), is the leading

manufacturer of electric cables in the Middle East. Established in

1979, the company is owned by the Governments of Dubai and

Abu Dhabi (35 % each) and the BICC Group (30%).

Ducab produces Ducab Powerplus™ medium voltage

cables up to 33 kV, and plans to extend to 132 kV during 2000.

The Ducab product range also covers low voltage power cables,

control and auxiliary cables, wiring cables, as well as lead

sheathed cables for the oil, gas and petrochemical industry, and

Ducab Smokemaster™ Low Smoke and Fume cables for

projects where safety is paramount.

Ducab’s aim is to produce electric cables of the highest

quality and provide customer service that is unequalled in the

Gulf region. Quality and customer service are two of the main

obsessions of Ducab. Access to the leading edge technology in

processing, manufacturing, engineering and in materials,

available from the BICC Group, gives Ducab the ability to

maintain the highest standards of quality.

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2Ducab Powerplus

This brochure contains technical information covering the

Ducab Powerplus™ range of XLPE insulated medium

voltage cables rated up to U0/U = 18/30kV i.e., equivalent to

33kV rating of the BritishStandards. The applicable standards

are IEC 60502-2 and BS 6622. The latter part of this publication

provides details of suitable cable joints and accessories so that

a complete medium voltage cable system can be designed and

purchased.

The Ducab Powerplus™ cable range includes copper

and aluminium conductors in a range of voltages with a choice

of single or three core armoured and unarmoured, a range of

sheathing, screening, taping and armouring options. To locate

particular voltages and cable designs and eliminate errors a

look-up guide has been included (see pages 16 & 17). This acts

as a guide to the cable data for the Ducab Powerplus™ range

of cables set out in pages 14 - 67.

Technical Data is covered in pages 68 - 75 whilst cable

components and accessories are set out in pages 76 - 93, and

include a full range of joints, terminations, glands, connectors

and fixings which are available ex stock from Ducab Connect.

Cable handling instructions appear in pages 94 - 95.

The cable designs in this brochure are to IEC 60502-2 and

in most parts to BS 6622. Ducab can however also supply a

range of alternative designs to meet more specialised customer

needs including water blocking, Ducab Smokemaster™ to

BS 7835 and enhanced fire performance. Alternative sheathing

materials and colours can also be manufactured along with

cables to individual customer specifications.

I n t ro d u c t i o n

Ducab Powerplus™

3Advanced Cable Solutions Through Technology and Innovation

The Most Advanced High Vo l t a g eCable Manufacturing Facility

in The Middle East

The design of Ducab's new High Voltage cables facility, opened in 1999, draws on the experience of the BICC Group and the new

manufacturing plant comprises a new Nextrom completely dry nitrogen curing and cooling line, as well as new wire-drawing, stranding,

laying up, taping and armouring, and sheathing equipment.

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Material HandlingTo ensure a very high degree of cleanliness, Ducab

uses only ultra-clean insulation materials and has

installed a material handling system that provides a

completely sealed path from the container in which

the material is received from the supplier to the

extruder. The features include:

• Gravity feed: The material is directly delivered

from the supplier's box to the extruder

• Clean box system to ensure materials are

completely contamination free

• State-of-the-art pellet inspection system which

rejects contamination - one of the only lines in the

world to have this extra feature

Superior Product Quality t h rough Advanced Te c h n o l o g y

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Advanced Cable Solutions Through Technology and Innovat ion

Ducab HV Product Advantages• Minimal risk of water treeing and premature cable failure.

• Long service life and discharge free insulation.

• Superior insulation/screen interface.

• Precision control of product dimensions.

State of the Art CoreInsulating ProcessDucab’s new facility incorporates

• CDCC - Completely dry curing and cooling technology.

• Triple head extrusion to ensure smooth and uniform

interface between the insulation and screen layers

• X- ray measurement of the thickness and concentricity of

each extruded layer.

• Inline inspection of product quality .

• Advanced line control and process support systems

ensuring real time control of over 50 parameters

on the line

• Cure prediction programme using the latest computer

software to optimise the curing process.

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In addition to massive investment in world class production facilities for

high voltage cables, Ducab recognises the critical importance of cable

testing and has installed a new, state-of-the-art, testing facility.

All cables are electrically tested as per specified requirements in

accordance with IEC 60502 and other international standards. The new HV

facility, supplied by Haefely of Switzerland, can supply much higher

voltages than the standard norm of 4 times the rated voltage, for cables up

to 33kV.

To screen out electric interference from the factory, Ducab has installed

an electrostatically screened room in which discharge and other testing is

carried out. The new testing facility includes:

* A new 250 kV/5MVA resonance test set.

*A dedicated, separate power supply.

* Different terminating facilities.

* Partial discharge testing equipment, giving results normally less than

1 pico-Coulomb, the lowest levels achieved anywhere in the world.

Ducab supports its designs with short and long term testing and cables

are subjected to tests that simulate actual environmental conditions. For

example, accelerated ageing of cable is achieved by applying a cyclic

voltage, at several times the rated voltage at elevated temperatures.

The Most Advanced Testing Facility for HV Cables

Te s t i n g

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The definition of quality in Ducab goes far beyond the conformance of product to specified

requirements. Ducab is committed to providing the customer with total quality excellence of product and

service that fully meets expectations and is superior in value to that which can be obtained elsewhere.

Since its inception, Ducab has an unrivaled reputation for quality in the region. For many years the

company has worked to raise quality awareness in Dubai and throughout the Gulf. The company’s Quality

Management System was certified to ISO 9002 in 1993 and upgraded in 1995 to the new, more stringent

ISO 9001 : 1994 standard. Ducab was the first cable company in the Middle East to achieve this distinction.

In 1997, Ducab became the first manufacturing company in the Middle East to obtain the ISO 14001

environmental certification.

Ducab is also the only cable manufacturer in the Middle East to obtain product type approval of a range

of low voltage cables to British Standards by BASEC (The BritishApprovals Service for Cables). This

approval is only awarded to manufacturers who meet the requirements of BS ENISO 9000 Quality

Management Standard and certified by BASEC.

D u c a bW h e re Quality is a Way of Life

Q u a l i t y

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Advanced Cable Solutions Through Technology and Innovation

Quality AssuranceDucab’s quality management system is certified for conformance to ISO 9001 Standard by BASEC, a reputed UKAS

accredited certification body specialising in the cable industry.

Ducab’s medium voltage cables have been accepted as world class following the type testing and certification of

several products by the KEMAHigh Voltage Laboratory in the Netherlands. Type testing included the requirements of the

IEC 60502-2 standard and some of the stringent provisions of BS 6622: 1999 standard. 11kV and 33kV cables tested by

KEMA consistently exhibited discharge-free characteristics. These cables also withstood Basic Impulse Levels of 95kV

and 195kV respectively as against 75kV and 175kV specified in IEC 60502-2.

Ducab’s high voltage test facility includes modern, highly sensitive partial discharge test equipment, situated in a fully

screened room. For materials and in-process cable tests, well-equipped laboratories, manned by experienced and trained

personnel are available. A separate cable fire test facility exists for IEC 332 Pt. 3, smoke density and other tests.

Ducab’s excellence in quality was recognised when the company was awarded the Dubai Quality Award, in the very

first year of its inception, in 1994, and by Ducab winning the award again in 1998. In 1997, the Gulf Excellence Award was

presented toDucab and at the presentation ceremony, Ducab was referred to as “The University of Quality

Improvement in the Gulf Region” .

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Cable SelectionIt is essential that any design of a cable system selected for a particular project or a distribution system is suitable for its

intended use. Choice needs to be based on a range of factors including installation specifications, local regulations and the

required performance characteristics, some of which are shown below:

• normal current load

• maximum fault current and its duration under fault conditions

• voltage grade

• subsoil conditions for underground installations e.g., presence of water, soil temperature and thermal resistivity,

possible attack of rodents, termites etc.

• cable fire performance requirements

• compatibility with an existing distribution system

In the tables in the next section, cable constructions and performance features correspond to IEC 60502-2 Standard and

Ducab’s in-house quality norms.

Cable Design and Construction

CONDUCTORS

The conductors of all Ducab’s HVand MV cables, both copper and aluminium, with the exception of very large sizes of

800sq mm and above, are all HCC + ™ design.

These are highly compacted and concentric conductors and offer the following advantages:

* Smaller overall size

* Smoother conductor/conducting screen interface

Conductors of 800 sq mm and above, are plain stranded and wrapped with penetration resistant semi-conductive tape prior

to passage through the triple extrusion line.

All conductors comply with the requirements of IEC 228, Class 2.

CONDUCTOR SCREEN

This is a layer of crosslinkable semi-conducting compound extruded directly over the conductor during the XLPE insulation

extrusion.

INSULATION

All Ducab’s MV and HV cables feature DFI ™ XLPEinsulation which is virtually discharge free, ensuring a long and trouble-

free service life.

The insulation is extruded and dry cured to meet the requirements of the standards and/or customer specification. A high

degree of concentricity is assured through the use of x-ray monitoring device during extrusion. The XLPEinsulation is capable

of operation continuously at 90˚C.

INSULATION SCREEN

This is a layer of cross-linkable semi-conducting compound extruded directly over the insulation at the same time when

the conductor screen and XLPE insulation are extruded. This semi-conducting screen is cold strippable but fully bonded

screens may be provided, if specified.

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METALLIC SCREEN

The metallic screen can be a helically applied copper tape or a number of copper wires applied with a lay or a combination

of tape and wires applied over the semi-conducting screen. The metallic screen provides the earth fault current path and it is of

a cross section designed as per customer’s performance specification.

In case of three core cables, phase identification tapes (red/yellow/blue) are generally longitudinally applied under the

metallic screen.

LAYING UP

In the case of three core cables, the three cores identified as red, yellow and blue are laid up together with polypropylene

string fillers at the interstices between the three cores. A binder e.g., polyester tape is wrapped round the assembly to form a

compact circular cable during this process.

BEDDING SHEATH

Black polyvinyl chloride (PVC) or Polyethylene (PE) Compound is extruded over the laid up 3 core cable or on the screened

single core cables.

ARMOURING

This process is not applicable if an unarmoured cable is specified. If armour is required, then following variations are

possible:

• Single Core Cables:

Aluminium armour wires applied all round the cable with a lay.

• Three Core Cables:

a) Galvanised Steel Wires applied all round the cable with a lay.

b) Galvanised Steel Tapes applied helically to provide coverage all round the cable.

OVERSHEATH

This is an extruded layer of black PVC (Type ST2) or PE (Type ST 3 or ST7) as required by customer specification. The

oversheath has an embossed legend in two or more lines appropriate for the cable.

SPECIAL FEATURES

The cable as a whole or its specific cores or other design elements can vary in a number of ways to meet specific customer

needs. The following are some examples, and by no means an exhaustive list of special features possible:

• Longitudinal and radial water blocking of conductors, cores or complete cable.

• Extra water-tree retardant XLPE insulation

• Lead sheath construction

• PVC oversheath with:

a) reduced flame propagation (RP) and low HCL(LHCL) emission properties

b) anti-termite properties

• Ducab Smokemaster™ Low Smoke and Fume construction using zero-halogen bedding and oversheath

• Oversheath of red colour with sulphide-resistant and/or UV resistant properties

• Graphite coated oversheath

• Embossed legend as per customer specification

• Metre length marking

Cable Selection

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Cable Data

The following data sheets cover a range of cables based on the IEC Specification 60502-2. Cables to otherspecifications and with special features such as lead sheaths, water swelling fillers, water blocking tapes and graphitecoatings can also be supplied.

For all cables the maximum conductor operating temperature is 90˚C and the limiting conductor temperature after shortcircuit is 250˚C.

To locate a cable of a specific voltage rating and design, please refer to the look-up table on pages 16 & 17.

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Single Core Aluminium Wire Copper Armoured Steel Wire

Steel Tape3.6/6(7.2kV)

Single Core Aluminium Wire Aluminium Armoured Steel Wire

Steel Tape


Steel Tape6/10(12kV)

Single Core Aluminium Wire Aluminium Armoured Steel Wire

Steel Tape


Steel Tape

8.7/15(17.5kV)Single Core Aluminium Wire

Aluminium Armoured Steel WireSteel Tape


Steel Tape

12/20(24kV) Single Core Aluminium Wire Aluminium Armoured Steel Wire

Steel Tape


Steel Tape

18/30(36kV)Single Core Aluminium Wire

Aluminium Armoured Steel WireSteel Tape

Three Core

Three Core

Three Core

Three Core

Three Core

Three Core

Three Core

Three Core

Three Core

Three Core

Look-up Ta b l e

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Page 20 Single Core Page 21 Unarmoured Three Core Page 19Page 22

Page 45 Single Core Page 43Page 46 Unarmoured Three Core Page 44Page 47









Ducab Powerplus Introduction & Tables

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