HV Cable Detailed Design Package

Design Philosophy

Template Identifier 240-62170368 Rev 1

Document Identifier 240-65871838 Rev 1

Authorisation Date 01 July 2013

Review Date June 2016

Public When downloaded from the document management system, this document is uncontrolled and the responsibility rests with

the user to ensure it is in line with the authorised version on the system.

No part of this document may be reproduced without the expressed consent of the copyright holder, Eskom Holdings SOC Ltd, Reg No 2002/015527/30.

Hard copy printed on: 30 November 2016 Page 1 of 15

Project No: NW-RFM-1310-2356 Project Name: Simmerpan-Germiston Munic Oil Cables Refurbishment Job No: NW-RFM-1310-2356-00002 Job Name: Simmerpan Germiston Munic oil cables refurb: Lay 1x 2.65km 1000mm² Cu XLPE

cable on existing route

Contents 1. Electrical Design .............................................................................................................................. 2

1.1 Fault Levels ............................................................................................................................. 2

1.2 Conductor and Equipment Ratings ......................................................................................... 2

1.3 Conductor rating (with de-rating, if applicable) ....................................................................... 3

1.4 Performance and operability ................................................................................................... 4

1.5 Insulation Coordination ........................................................................................................... 4

1.6 HV Cable ................................................................................................................................. 8

1.7 HV Joints and Kiosks .............................................................................................................. 9

1.8 HV Cable terminations ............................................................................................................ 9

1.9 DCRS and DTS System ........................................................................................................ 10

1.10 DTS fibre and Diff. protection fibre ........................................................................................ 10

1.11 Bonding and Earthing ............................................................................................................ 10

1.12 Spares ................................................................................................................................... 13

1.13 Non-Eskom DX site HV cable connection ............................................................................. 14

2. Route Selection .............................................................................................................................. 14

3. Legal requirements ........................................................................................................................ 14

3.1 Statutory requirements .......................................................................................................... 14

3.2 Other Statutory bodies .......................................................................................................... 14

3.3 Environmental requirements ................................................................................................. 15

3.4 Servitude and wayleave agreements .................................................................................... 15

High Level Scope of Work:

Lay a set of 3 x 132kV 1C 1000mm2 Al XLPE cable in road on the proposed route for a total of length of 3.2km. The scope includes the installation of Sheath Interrupting joints, and manhole link boxes.

Revision Details: Rev. 0: Original Document

Job ID: NW-RFM-1310-2356-00002 Job Name: Simmerpan Germiston Munic oil cables refurb:Lay 1x 2.65km 1000mm² Cu XLPE cable on existing route

Template Identifier 240-62170368 Rev 1

Document Identifier 240-65871838 Rev 1

Public When downloaded from the document management system, this document is uncontrolled and the responsibility rests with

the user to ensure it is in line with the authorised version on the system.

No part of this document may be reproduced without the expressed consent of the copyright holder, Eskom Holdings SOC Ltd, Reg No 2002/015527/30.

Hard copy printed on: 30 November 2016 Page 2 of 15

1. Electrical Design

1.1 Fault Levels

The following table represents the fault levels considered in the design:

Substation Fault Level (kA) -

Existing Fault Level (kA) -

Future 1ø 3ø 1ø 3ø

Simmerpan MTS (Source) 88kV B/B

12.08 16.00 23.55 18.56

Germiston Munic (Supply) substation

88kV B/B

18.4 15.7 21.6 17.0

1.2 Conductor and Equipment Ratings

Parameter Value Voltage 132/76kV Circuit Single Core Installation Underground trench

Flat Cross Bonded

Temperature: Soil Air

25°C 30°C

Soil Thermal Resistivity 1.2Km/W Conductor Type Aluminium Conductor size 1000mm² Capacity Normal and Emergency 776A (177MVA) , 910A (208MVA) Insulation XLPE Metallic Sheath Corrugated Seamless Aluminium Outer Sheath Linear Low-density Polyethylene Screened Yes Peak impulse withstand voltage 650kV Power frequency withstand voltage 275kV Cable Markings “Manufacturer”

“Eskom Distribution” “132 kV” At intervals not exceeding 2m

Job ID: NW-RFM-1310-2356-00001 Job Name: Simmerpan Germiston Munic oil cables refurb: Lay 1x 2.65km 1000mm² Cu XLPE cable on existing route

Template Identifier 240-62170368 Rev 1

Document Identifier 240-65871838 Rev 1

Public When downloaded from the document management system, this document is uncontrolled and the responsibility rests with

the user to ensure it is in line with the authorised version on the system.

No part of this document may be reproduced without the expressed consent of the copyright holder, Eskom Holdings SOC Ltd, Reg No 2002/015527/30.

Hard copy printed on: 30 November 2016 Page 3 of 15

1.3 Conductor rating (with de-rating, if applicable )

Due to the HV cable being placed inside PVC pipes (for the road / rail way crossing) de-rating had to be considered. De-rating also had to be considered for the general installation and a section inside Simmerpan MTS, due to the installation depth. For general installation of the cable: Irated = Istandard x k1 x k2 x k3 x k4

Where k1= 1 (soil thermal resistivity 1.2K.m/W) k2= 1 (soil temperature 25⁰C) k3= 0.985 (depth of burial 1300mm) k4= 1 (flat formation laid in ground) Irated = 776 x1 x 1 x 0.985 x 1 = 764.4A

For installation at road/ rail crossings of the ca ble:

Irated = Istandard x k1 x k2 x k3 x k4

Where k1= 1 (soil thermal resistivity 1.2K.m/W) k2= 1 (soil temperature 25⁰C) k3= 0.96 (depth of burial 2300mm) k4= 1 (flat formation laid in ground) Irated = 776 x1 x 1 x 0.96 x 1 = 744.96A

For installation on a portion inside Simmerpan MTS: Irated = Istandard x k1 x k2 x k3 x k4

Where k1= 1 (soil thermal resistivity 1.2K.m/W) k2= 1 (soil temperature 25⁰C) k3= 0.925 (depth of burial 2300mm) k4= 1 (flat formation laid in ground) Irated = 776 x1 x 1 x 0.925 x 1 =717.8A

Job ID: NW-RFM-1310-2356-00001 Job Name: Simmerpan Germiston Munic oil cables refurb: Lay 1x 2.65km 1000mm² Cu XLPE cable on existing route

Template Identifier 240-62170368 Rev 1

Document Identifier 240-65871838 Rev 1

Public When downloaded from the document management system, this document is uncontrolled and the responsibility rests with

the user to ensure it is in line with the authorised version on the system.

No part of this document may be reproduced without the expressed consent of the copyright holder, Eskom Holdings SOC Ltd, Reg No 2002/015527/30.

Hard copy printed on: 30 November 2016 Page 4 of 15

1.4 Performance and operability

The HV cable system designed to ensure maximum system performance. This is achieved through the installation of:

• Optical fibre communication for current differential protection.

• Tele-control at substations to relay information back. • 1.2 Km/W soil to be imported for bedding and blanket to allow faster heat dissipation

around the cable and ultimately a lower de-rating such that the HV feeder can be utilised closer to its manufactured capabilities.

Although both circuits will be on the same route for the better part of the route, they will be installed in separate trenches and on either side of the road for the in road installations. This is to allow better identification for operability and maintenance

The cables being installed are XLPE insulated and will thus give much improved performance and reliability than the present oil filled cables installed between the existing Simmerpan substation and Germiston Munic substation, which are aged and older technology.

1.5 Insulation Coordination

SANS 1019 will apply on phase-to-phase and phase-to-earth insulation:

• Highest System Voltage – 145kV • Rating Lighting Impulse withstand Voltage peak – 650 kV • Rated Power-Frequency Short duration withstand Voltage (r.m.s) – 275 kV

The insulation level of the HV cable sheath, bonding leads and other ancillary equipment associated with the special bonding system shall be in accordance with Annex D of SANS 60840. SVL’s Surge Arrestor Characteristics will be as stated below:

Job ID: NW-RFM-1310-2356-00001 Job Name: Simmerpan Germiston Munic oil cables refurb: Lay 1x 2.65km 1000mm² Cu XLPE cable on existing route

Template Identifier 240-62170368 Rev 1

Document Identifier 240-65871838 Rev 1

Public When downloaded from the document management system, this document is uncontrolled and the responsibility rests with

the user to ensure it is in line with the authorised version on the system.

No part of this document may be reproduced without the expressed consent of the copyright holder, Eskom Holdings SOC Ltd, Reg No 2002/015527/30.

Hard copy printed on: 30 November 2016 Page 5 of 15

SVL calculations for the Simmerpan-Germiston Munic no. 2 Feeder:

SVL Single Phase to Ground:

Job ID: NW-RFM-1310-2356-00001 Job Name: Simmerpan Germiston Munic oil cables refurb: Lay 1x 2.65km 1000mm² Cu XLPE cable on existing route

Template Identifier 240-62170368 Rev 1

Document Identifier 240-65871838 Rev 1

Public When downloaded from the document management system, this document is uncontrolled and the responsibility rests with

the user to ensure it is in line with the authorised version on the system.

No part of this document may be reproduced without the expressed consent of the copyright holder, Eskom Holdings SOC Ltd, Reg No 2002/015527/30.

Hard copy printed on: 30 November 2016 Page 6 of 15

SVL Double Phase:

Job ID: NW-RFM-1310-2356-00001 Job Name: Simmerpan Germiston Munic oil cables refurb: Lay 1x 2.65km 1000mm² Cu XLPE cable on existing route

Template Identifier 240-62170368 Rev 1

Document Identifier 240-65871838 Rev 1

Public When downloaded from the document management system, this document is uncontrolled and the responsibility rests with

the user to ensure it is in line with the authorised version on the system.

No part of this document may be reproduced without the expressed consent of the copyright holder, Eskom Holdings SOC Ltd, Reg No 2002/015527/30.

Hard copy printed on: 30 November 2016 Page 7 of 15

SVL Double Phase to Ground:

Job ID: NW-RFM-1310-2356-00001 Job Name: Simmerpan Germiston Munic oil cables refurb: Lay 1x 2.65km 1000mm² Cu XLPE cable on existing route

Template Identifier 240-62170368 Rev 1

Document Identifier 240-65871838 Rev 1

Public When downloaded from the document management system, this document is uncontrolled and the responsibility rests with

the user to ensure it is in line with the authorised version on the system.

No part of this document may be reproduced without the expressed consent of the copyright holder, Eskom Holdings SOC Ltd, Reg No 2002/015527/30.

Hard copy printed on: 30 November 2016 Page 8 of 15

SVL Three Phase:

According to the calculations SVLs with an Uc of 2.55kV can be used. The SVLs to be installed in this project is 3kV Ur 25kA SVLs. The SVL’s in the link box used to protect the bonding system will be rated for 2,55kV MCOV, which is not adequate to withstand the sheath integrity testing applied voltage of 5kV. The link boxes will have to be disconnected when sheath integrity tests occur. For the HV terminations, the external insulation of outdoor terminations shall have a shed profile in accordance with SANS 60815. The specific creepage level shall be 20mm/kV.

1.6 HV Cable

The HV cable to be used is 132kV 1C 1000mm² Al XLPE cable which will be installed in flat formation, with a 300mm spacing between HV cables. In future, Simmerpan MTS will be upgraded from 88 kV to 132kV, thus the installation of the 132kV cable. The minimum cable bending radii will be as per the table below, extracted from the HV cable standard.

Job ID: NW-RFM-1310-2356-00001 Job Name: Simmerpan Germiston Munic oil cables refurb: Lay 1x 2.65km 1000mm² Cu XLPE cable on existing route

Template Identifier 240-62170368 Rev 1

Document Identifier 240-65871838 Rev 1

Public When downloaded from the document management system, this document is uncontrolled and the responsibility rests with

the user to ensure it is in line with the authorised version on the system.

No part of this document may be reproduced without the expressed consent of the copyright holder, Eskom Holdings SOC Ltd, Reg No 2002/015527/30.

Hard copy printed on: 30 November 2016 Page 9 of 15

1.7 HV Joints and Kiosks

Based on the earthing design, only sheath interrupting joints will be used to connect two 132kV 1C 1000mm² Al XLPE cables together. Earth-electrodes, clamps, earth loops, bonding leads, etc. will be installed at each joint bay, as per then design. The kiosks to be used include 1x 6L earth manhole, 4 x 6 L X-BND SVL earth manholes on the HV cable feeder as per the earthing design. One 3L earth kiosk will be installed at Simmerpan MTS as per the earthing design and one 3L earth kiosk will be installed at Germiston Munic sub.

All kiosks will be marked and warning/danger labels shall be installed.

Link disconnecting boxes (see D-DT-8074) and bonding leads (see D-DT-8075) will comply with 34-1625.

Bonding leads will be kept as short as possible and the Kiosk will be installed in-line with the joint bay.

1.8 HV Cable terminations

The 132kV 1C 1000mm² Al XLPE cables will be terminated onto an outdoor support structure at Simmerpan MTS and Germiston Munic sub. The termination to be used is TERM KIT 1C 88-132kV 1000SQ XLPE I/LD8072 SAP NO: 018690 7. Self-supporting outdoor cable terminations shall be suitable for mounting on the medium equipment support and cap shown in D-DT 5271 sheet 2 of 3, D-D 5271 sheet 3 of 3, D-DT-0890 sheet 1 of 4 and D-DT- 0890 sheet 2 of 4.

For the HV terminations, the external insulation of outdoor terminations shall have a shed profile in accordance with SANS 60815. The specific creepage level shall be 20mm/kV for inland.

Job ID: NW-RFM-1310-2356-00001 Job Name: Simmerpan Germiston Munic oil cables refurb: Lay 1x 2.65km 1000mm² Cu XLPE cable on existing route

Template Identifier 240-62170368 Rev 1

Document Identifier 240-65871838 Rev 1

Public When downloaded from the document management system, this document is uncontrolled and the responsibility rests with

the user to ensure it is in line with the authorised version on the system.

No part of this document may be reproduced without the expressed consent of the copyright holder, Eskom Holdings SOC Ltd, Reg No 2002/015527/30.

Hard copy printed on: 30 November 2016 Page 10 of 15

1.9 Dynamic Cable Rating System (DCRS) and Distribu ted Temperature Sensing (DTS) System

A twin fibre optic duct will be installed for DTS.

1.10 DTS fibre and Diff. protection fibre

Optic fibre cable is installed on the route of Simmerpan-Germiston Munic cable no1 only. This optic fibre cable will be used for current differential protection and for DTS in future.

1.11 Bonding and Earthing

The cross bonded system approach will be used to bond and earth the 132kV cable sheaths so as to minimise the induction effects on the cable sheaths, because the single core cables will be laid in flat formation.

Cross-bonding link boxes (D-DT 8074) shall be used and installed at all joints and terminations. The cross-bonding at all terminations and joint positions will be connected directly to earth and via Sheath Voltage limiters as per the cable electrical circuit diagram.

The link boxes shall be of sufficient size to easily disconnect links for testing purposes. Link boxes at joint positions shall be of stainless steel or robust cast iron construction. Lids shall be secured with wing nuts with a sealing gasket between the lid and body. The bonding leads between the cable sheaths and link boxes shall be of the concentric type and less than 10m long, with a voltage rating adequate to withstand outer sheath test voltages.

All link boxes shall be supplied with an earth bonding point and lead.

The cable joint positions will be designed to limit the open circuit sheath standing voltage at rated current to a maximum of 65V. Calculated standing voltages on the sheaths of the single core cables for each major section of cable are attached in Annexure A. In addition to the cross bonding, the cables will be transposed at every joint bay position to minimize the impedance of the circuit. The SVL’s in the link box used to protect the bonding system will be rated for 2,55kV MCOV, which is not adequate to withstand the sheath integrity testing applied voltage of 5kV. The link boxes will have to be disconnected when sheath integrity tests occur

Link disconnecting boxes shall be supplied and installed at all joints and terminations. Link boxes to be self-supporting and positioned at least 1m from the joint bay.

Job ID: NW-RFM-1310-2356-00001 Job Name: Simmerpan Germiston Munic oil cables refurb: Lay 1x 2.65km 1000mm² Cu XLPE cable on existing route

Template Identifier 240-62170368 Rev 1

Document Identifier 240-65871838 Rev 1

Public When downloaded from the document management system, this document is uncontrolled and the responsibility rests with

the user to ensure it is in line with the authorised version on the system.

No part of this document may be reproduced without the expressed consent of the copyright holder, Eskom Holdings SOC Ltd, Reg No 2002/015527/30.

Hard copy printed on: 30 November 2016 Page 11 of 15

The joint bay positions were chosen based on suitable geographical locations along the cable route as well as positions that would minimise sheath circulating currents and standing voltages to below 65V. Details of the circulating current and standing voltage calculations are shown in Annexure A.

The HV cable will be transposed at the positions shown on the cable electric diagram. The Induced Standing Voltage in the cables’ metallic sheath < 65 V as seen in Annexure A. Concentric bonding leads are used on all joints/kiosks, to be in-line with the number of holes on the outer-housing used on HV joints and the kiosks that are currently being manufactured. A 16mm² copper conductor will be used to connect the earth-electrodes to the casing of the link disconnecting boxes associated with the joints, according to D-DT 0891 sheet 3 rev 6.

Please see below calculations and outputs:

Job ID: NW-RFM-1310-2356-00001 Job Name: Simmerpan Germiston Munic oil cables refurb: Lay 1x 2.65km 1000mm² Cu XLPE cable on existing route

Template Identifier 240-62170368 Rev 1

Document Identifier 240-65871838 Rev 1

Public When downloaded from the document management system, this document is uncontrolled and the responsibility rests with

the user to ensure it is in line with the authorised version on the system.

No part of this document may be reproduced without the expressed consent of the copyright holder, Eskom Holdings SOC Ltd, Reg No 2002/015527/30.

Hard copy printed on: 30 November 2016 Page 12 of 15

Job ID: NW-RFM-1310-2356-00001 Job Name: Simmerpan Germiston Munic oil cables refurb: Lay 1x 2.65km 1000mm² Cu XLPE cable on existing route

Template Identifier 240-62170368 Rev 1

Document Identifier 240-65871838 Rev 1

Public When downloaded from the document management system, this document is uncontrolled and the responsibility rests with

the user to ensure it is in line with the authorised version on the system.

No part of this document may be reproduced without the expressed consent of the copyright holder, Eskom Holdings SOC Ltd, Reg No 2002/015527/30.

Hard copy printed on: 30 November 2016 Page 13 of 15

Please see attached final earthing design:

The GPS coordinates for the link boxes are given below:

Link box 1 and 7 will be installed on the O/D HV cable termination at Simmerpan MTS and Germiston Munic substation respectively.

1.12 Spares Only Standard material is used.

Job ID: NW-RFM-1310-2356-00001 Job Name: Simmerpan Germiston Munic oil cables refurb: Lay 1x 2.65km 1000mm² Cu XLPE cable on existing route

Template Identifier 240-62170368 Rev 1

Document Identifier 240-65871838 Rev 1

Public When downloaded from the document management system, this document is uncontrolled and the responsibility rests with

the user to ensure it is in line with the authorised version on the system.

No part of this document may be reproduced without the expressed consent of the copyright holder, Eskom Holdings SOC Ltd, Reg No 2002/015527/30.

Hard copy printed on: 30 November 2016 Page 14 of 15

1.13 Non-Eskom DX site HV cable connection

N/A

2. Route Selection The route selection was selected with the assistance of EMM roads & storm water department as previous routes submitted to them Eskom were not suitable to them. The route in principal is approved provided that the first section (from the Germiston Munic substation end) is installed before June 2017, as EMM is busy with a project to upgrade in the area. Please see A0 drawing for final route and design.

3. Legal requirements

3.1 Statutory requirements

The requirements of the Occupational Health and Safety act (Act 85 of 1993) will be observed and adhered to by the contractor during construction.

Requirements as described in SANS 10198-1 will be met.

A civil design package that includes a road reinstatement design and a traffic management plan must accompany the statutory approval application in order for EMM to give approval.

Statutory approval is required by Ekurhuleni Metro Municipality along the planned cable route for:

• Directional drilling under all road crossings. • Running the 132kV cable circuit in road.

Statutory approval is required by Transnet Freight Rail along the planned cable route for:

• Directional drilling under the Transnet rail track.

3.2 Other Statutory bodies

The EMM roads & storm water will only give their approval once way leave approval has been granted by the following other statutory bodies:

• MTN • Vodacom

Job ID: NW-RFM-1310-2356-00001 Job Name: Simmerpan Germiston Munic oil cables refurb: Lay 1x 2.65km 1000mm² Cu XLPE cable on existing route

Template Identifier 240-62170368 Rev 1

Document Identifier 240-65871838 Rev 1

Public When downloaded from the document management system, this document is uncontrolled and the responsibility rests with

the user to ensure it is in line with the authorised version on the system.

No part of this document may be reproduced without the expressed consent of the copyright holder, Eskom Holdings SOC Ltd, Reg No 2002/015527/30.

Hard copy printed on: 30 November 2016 Page 15 of 15

• Neotel • Telkom • Sasol gas • EMM Water and Sewerage • EMM Electricity • Rand Water • Dark Fibre Africa

All the requirements of the above bodies have been met and incorporated into the design where HV cable is to be installed in close proximity to these services. All the statutory bodies have indicated that they require a site visit to indicate their services prior to construction.

Due to the urgency of this project and the amount of existing service infrastructure installed in the Germiston area, way leaves from these institutions are only valid for six months, and thus have only recently been initiated. All Statutory approvals are planned to be obtained by January 2017. This is in line with the scheduled construction start date of February 2017.

3.3 Environmental requirements

The requirements of the National Environmental Management Act (Act 107 of 1998), Eskom’s own environmental policies and procedures and the compiled Environmental management Plan, will be adhered to by the contractor during construction. The Contractor is responsible for developing the Waste Management Plan. Waste disposal methods will depend upon the location of the construction camps. This entails that sufficient waste bins are available on site and in the construction camp. The waste must be disposed of at an appropriate licensed waste disposal site. No containers, scrap metal, conductor etc. may be left on site. Such scrap must be removed and taken to an appropriate disposal site. Temporary waste storage sites must prior consent from the landowner and are to be barricaded at all times.

3.4 Servitude and wayleave agreements

The special requirements of municipal wayleaves / approvals will be obtained where the HV cable runs in road, and in the road reserve. An approval from Transnet Freight Rail will be obtained where the cable crosses the railway track. Servitude application for the EMM owned park will be put forth to Ekurhuleni Municipality. A letter of occupation will issued to Eskom to proceed with the project once servitude registration is been finalised.