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TYPE TEST CERTIFICATE OF COMPLETE TYPE TEST

OBJECT Single-core power cable

TYPE 19/33 kV 400 mm2 Cu/XLPE/AWA/PVC

Rated voltage 19/33(36) kV Conductor material Cu Conductor cross-section 400 mm2 Insulation material XLPE

MANUFACTURER El Sewedy Cables16 Baghdad Street, El Korba, Heliopolis – Cairo, Egypt

CLIENT El Sewedy Cables 16 Baghdad Street, El Korba, Heliopolis – Cairo, Egypt

TESTED BY KEMA HIGH-VOLTAGE LABORATORY Arnhem, the Netherlands

DATES OF TESTS 12 June 2007 up to and including 23 July 2007

The apparatus, constructed in accordance with the description, drawings and photographs incorporated in this Certificate, has been subjected to the series of proving tests in accordance with

IEC 60502-2

This Type Test Certificate has been issued by KEMA following exclusively the STL Guides. The results are shown in the record of Proving Tests and the oscillograms attached hereto. The values obtained and the general performance are considered to comply with the above Standard and to justify the ratings assigned by the manufacturer as listed on page 4.

The Certificate applies only to the object tested. The responsibility for conformity of any object having the same designations with that tested rests with the Manufacturer. This Certificate consists of 32 sheets in total. © Copyright: Only integral reproduction of this Certificate is permitted without written

permission from KEMA. Electronic copies in e.g. PDF-format or scanned version of this Certificate may be available and have the status “for information only”. The sealed and bound version of the Certificate is the only valid version.

KEMA Nederland B.V.

P.G.A. Bus KEMA T&D Testing Services Managing Director Arnhem, 13 September 2007

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TABLE OF CONTENTS

TABLE OF CONTENTS .......................................................................................................................... 2

1 Identification of the test object......................................................................................................4 1.1 Ratings assigned by the manufacturer ........................................................................................4 1.2 Description of the test object........................................................................................................4 1.3 List of drawings ............................................................................................................................5

2 General information......................................................................................................................5 2.1 The tests were carried out by.......................................................................................................5 2.2 The following tests were subcontracted to KEMA Quality B.V., ..................................................5 2.3 Purpose of the test .......................................................................................................................6 2.4 Measurement uncertainty.............................................................................................................6 2.5 Applicable standards....................................................................................................................6

3 Electrical Type Tests....................................................................................................................7 3.1 Bending tests................................................................................................................................7 3.2 Partial discharge test....................................................................................................................8 3.3 Tan δ measurement .....................................................................................................................9 3.4 Heating cycle test .......................................................................................................................10 3.5 Partial discharge test..................................................................................................................11 3.6 Impulse test followed by a voltage test ......................................................................................12 3.6.1 Impulse test ................................................................................................................................12 3.7 Voltage test for 4 hours ..............................................................................................................15 3.8 Resistivity of semi-conducting screens ......................................................................................16

4 Non-electrical type tests.............................................................................................................17 4.1 Measurement of thickness of insulation.....................................................................................17 4.2 Measurement of thickness of non-metallic sheaths ...................................................................17 4.3 Tests for determining the mechanical properties of the insulation before and after ageing ......18 4.4 Tests for determining the mechanical properties of non-metallic sheaths before and after

ageing.........................................................................................................................................19 4.5 Additional ageing test on pieces of completed cables ...............................................................20 4.6 Loss of mass test on PVC sheaths of type ST2 .........................................................................21 4.7 Pressure test at high temperature on non-metallic sheaths ......................................................22 4.8 Test on PVC sheaths at low temperatures ................................................................................23 4.9 Test for resistance of PVC sheaths to cracking (heat shock test) .............................................23 4.10 Hot set test for XLPE insulation .................................................................................................24 4.11 Water absorption test on insulation............................................................................................24 4.12 Shrinkage test for XLPE insulation.............................................................................................25

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5 Verification of cable construction ...............................................................................................26

APPENDIX A MEASUREMENT UNCERTAINTIES......................................................................... 28

APPENDIX B MANUFACTURER’S DRAWING(S)/DATA SHEET .................................................. 29

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1 IDENTIFICATION OF THE TEST OBJECT 1.1 Ratings assigned by the manufacturer Rated voltage 19/33 (36) kV Conductor cross-section 1x 400 mm2 Insulation material XLPE 1.2 Description of the test object Manufacturer El Sewedy Cables Type 19/33 kV 400 mm2 Cu/XLPE/AWA/PVC Drawing(s) see appendix B, drawing no. CX5-TZ01-X40-00-01 Year of manufacture 2007 Quantity submitted more than 40 m - quantity used for electrical type tests 30 m approximately - quantity used for non-electrical type tests 4 m approximately Rated voltage 19/33 (36) kV No. of cores 1 Conductor - material copper, stranded compacted - cross-section 400 mm2 - maximum rated temperature 90 °C Conductor screen extruded semicon (bonded) Insulation material extruded XLPE Insulation screen extruded semicon (bonded) Metallic screen - material one copper tape - cross-section 9,7 mm2 Separation sheath PVC (type ST2) Armour - material single layer of aluminium wires

and above double synthetic tape - cross-section 49,7 mm2 Oversheath - material PVC plus a layer of graphite coating (type ST2) - colour black Longitudinally water-tightness - along insulation screen not claimed - along the conductor not claimed Flame retardancy not claimed Standard IEC 60502-2 (2005)

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1.3 List of drawings The manufacturer has guaranteed that the object submitted for tests has been manufactured in accordance with the following drawings. The following drawings are included in this report or kept in KEMA’s file. KEMA has verified that these drawings adequately represent the object tested.

CX5-TZ01-X40-00-01 dated, 03 March, 2007, Rev. No. 0 - (cable constructional drawing) CX5-TZ01-X40-00-01 pages 1 and 2 - (technical specification of cable construction)

2 GENERAL INFORMATION 2.1 The tests were carried out by Name Company

J.J.M. Mooren KEMA Nederland B.V. W.J.W.M. Sloot P.H.W. Kuijpers P.J. Hülkenberg E. Pultrum H.J. Arnoldus A.P.M. Derksen A.B.G.M. ten Have 2.2 The following tests were subcontracted to KEMA Quality B.V., Test

- measurement of resistivity of semi- conductive screens in accordance with clause 18.1.9 of IEC 60502-2 - non-electrical type tests in accordance with clause19 of IEC 60502-2 - verification of cable construction in accordance with clauses 5 –14 of IEC 60502-2

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2.3 Purpose of the test Purpose of the test was to verify whether the material complies with the specified requirements. 2.4 Measurement uncertainty A table with measurement uncertainties is enclosed in appendix A. Unless otherwise indicated in the report, the measurement uncertainties of the results presented are as indicated in this table. 2.5 Applicable standards When reference is made to a standard and the date of issue is not stated, this applies to the latest issue, including amendments which have been officially published prior to the date of the tests.

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3 ELECTRICAL TYPE TESTS 3.1 Bending tests The bending test was carried out in accordance with clause 18.1.3 of IEC 60502-2. The results are presented below. Atmospheric conditions Ambient temperature 21 °C Temperature of test object 21 °C Date of test: 12 June 2007 outer diameter of cable D (mm)

diameter of cable conductor d (mm)

required bending diameter Dr =20(D+d) ± 5%(mm)

actual bending diameter Da

(mm)

observations

57,6 23,3 1537 ≤ Dr ≤ 1699 1640 3 cycles (wind/unwind and wind/unwindin opposite direction)

Procedure The test sample shall be bent around a test cylinder at ambient temperature for at least one complete turn. It shall then be unwound and repeated, except that the bending of the sample shall be in the reverse direction without axial rotation. This cycle of operation shall be carried out three times. Observation The test was carried out successfully.

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3.2 Partial discharge test On completion of the bending test, the partial discharge test was carried out in accordance with clause 18.1.4 of IEC 60502-2. The results are presented below. Atmospheric conditions Ambient temperature 23 °C Temperature of test object 23 °C Characteristic test data Circuit balanced Calibration 5 pC Noise 1 pC Bandwidth 40-400 kHz Power frequency 50 Hz Coupling capacitor 2600 pF Date of test: 4 July 2007 core voltage applied, 50 Hz duration partial discharge level ... x U0 (kV) (s) (pC) conductor 2 38 10 - 1,73 33 - ≤ 1

Requirement There shall be no detectable discharge exceeding the declared sensitivity from the test object at 1,73xU0. Result The test was passed.

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3.3 Tan δδδδ measurement The capacitance and tan δ measurement was carried out in accordance with clause 18.1.5 of IEC 60502-2. The results are presented below. Atmospheric conditions Ambient temperature 25 °C Temperature of test object 96 °C Characteristic test data Length of test object 13,4 m Standard capacitor 100 pF Date of test: 6 July 2007 core core capacitance * tan δ

voltage applied, 50 Hz (kV) (µF/km)

conductor 5 0,237 7,4 x 10-4 * for information only Requirement The measured value shall not be higher than 40x10-4. Result The test was passed.

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3.4 Heating cycle test The heating cycle test was carried out in accordance with clause 18.1.6 of IEC 60502-2. The results are presented below. Atmospheric conditions Ambient temperature 24-28 °C Temperature of test object ambient - 96 °C Date of test: 10 July 2007 until 17 July 2007 no. of heating-cycles

required stable conductor temperature

heating current heating per cycle cooling per cycle

(°C)

(A)

total duration (hours)

duration of conductor at stable temperature (hours)

total duration (hours)

20 95-100 1116 5 2 3

Result The test was carried out successfully.

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3.5 Partial discharge test On completion of the heating cycle test, the partial discharge test was carried out in accordance with clause 18.1.4 of IEC 60502-2. The results are presented below. Atmospheric conditions Ambient temperature 24 °C Temperature of test object 24 °C Characteristic test data Circuit balanced Calibration 5 pC Noise 1 pC Bandwidth 40-400 kHz Power frequency 50 Hz Coupling capacitor 2600 pF Date of test: 17 July 2007 core voltage applied, 50 Hz duration partial discharge level ... x U0 (kV) (s) (pC) conductor 2 38 10 - 1,73 33 - ≤ 1

Requirement There shall be no detectable discharge exceeding the declared sensitivity from the test object at 1,73xU0. Result The test was passed.

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3.6 Impulse test followed by a voltage test 3.6.1 Impulse test The impulse test was carried out in accordance with clause 18.1.7 of IEC 60502-2. In order to achieve the elevated temperature of the test object, current was induced in the cable. The impulse test was performed two hours after thermal equilibrium had been established. The wave shape of the impulse voltage was determined at approximately 50 percent of the specified test value (see figure). The results are presented below. Atmospheric conditions Ambient temperature 24 °C Temperature of test object 97 °C Date of test: 19 July 2007 Specified test voltage: 170 kV

Requirement No breakdown of the insulation shall occur. Result The test was passed.

testing arrangement voltage applied to

earthed polarity voltage applied

(% of test voltage) no. of impulses

see figure

conductor screen positive 50 1 1 65 1 2 80 1 2 100 10 3 and 4 conductor screen negative 50 1 5 65 1 6 80 1 6 100 10 7 and 8

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Voltage test The power frequency voltage test was carried out in accordance with clause 18.1.7 of IEC 60502-2. After the impulse test, the test object was subjected to a power frequency voltage test, at ambient temperature. The results are presented below. Atmospheric conditions Ambient temperature 24 °C Temperature of test object 24 °C Date of test: 20 July 2007 testing arrangement voltage applied, 50 Hz duration voltage applied to earth connected to ... x U0 (kV) (min) conductor metal screen 3,5 66,5 15

Requirement No breakdown of the insulation shall occur. Result The test was passed. 3.7 Voltage test for 4 hours The voltage test for four hours was carried out in accordance with clause 18.1.8 of IEC 60502-2. The results are presented below. Atmospheric conditions Ambient temperature 24 °C Temperature of test object 24 °C Date of test: 20 July 2007 testing arrangement voltage applied, 50 Hz duration voltage applied to earth connected to ... x U0 (kV) (hours) conductor metal screen 4 76 4

Requirement No breakdown of the insulation shall occur. Result The test was passed.

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3.8 Resistivity of semi-conducting screens The measurement of the resistivity of semi-conducting screens was carried out in accordance with clause 18.1.9 of IEC 60502-2. The results are presented below. item unit requirement measured/determined conductor screen - without ageing Ωm ≤ 1000 92,1 - after ageing Ωm ≤ 1000 11,6 insulation screen - without ageing Ωm ≤ 500 1,1 - after ageing Ωm ≤ 500 76,8 Result The test was passed.

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4 NON-ELECTRICAL TYPE TESTS The non-electrical type tests were carried out in the period from 4 July 2007 up to and including 23 July 2007. 4.1 Measurement of thickness of insulation The measurement of the thickness of insulation was carried out in accordance with clause 19.1 of IEC 60502-2. The results are presented below. thickness unit requirement specified measured/determined - nominal mm 8 - average mm - 8,3 - minimum mm ≥ 7,10 8,05 - maximum mm - 8,55 - (max-min)/max ≤ 0,15 0,06 Result The test was passed. 4.2 Measurement of thickness of non-metallic sheaths The measurement of the thickness of the non-metallic sheaths was carried out in accordance with clause 19.2 of IEC 60502-2. The results are presented below. Oversheath (type ST2) thickness unit requirement specified measured/determined - nominal mm 2,5 - average mm 3,1 - minimum mm ≥ 2,03 2,72 Separation sheath (type ST2) thickness unit requirement specified measured/determined - nominal mm 1,2 1,45 - average mm 1,7 - minimum mm ≥ 0,96 1,50 Result The test was passed.

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4.3 Tests for determining the mechanical properties of the insulation before and after ageing

The tests for determining the mechanical properties of the insulation before and after ageing were carried out in accordance with clause 19.3 of IEC 60502-2. The results are presented below. item unit requirement measured/determined without ageing

- tensile strength N/mm² ≥ 12,5 25,1 - elongation % ≥ 200 519 after ageing (135°C / 7days)

- tensile strength N/mm² - 28,8 - variation with samples without ageing

% ± 25 max. 15

- elongation % - 596 - variation with samples without ageing

% ± 25 max. 15

Result The test was passed.

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4.4 Tests for determining the mechanical properties of non-metallic sheaths before and after ageing

The tests for determining the mechanical properties of the non-metallic sheaths before and after ageing were carried out in accordance with clause 19.4 of IEC 60502-2. The results are presented below. Oversheath (type ST2) item unit requirement measured/determined without ageing

- tensile strength N/mm² ≥ 12,5 19,6 - elongation % ≥ 150 283 after ageing (100 °C / 7 days)

- tensile strength N/mm² ≥ 12,5 18,7 - variation with samples without ageing

% ± 25 max. -5

- elongation % ≥ 150 288 - variation with samples without ageing

% ± 25 max. 2

Separation sheath (type ST2) item unit requirement measured/determined without ageing

- tensile strength N/mm² ≥ 12,5 18,8 - elongation % ≥ 150 302 after ageing (100 °C / 7 days)

- tensile strength N/mm² ≥ 12,5 17,8 - variation with samples without ageing

% ± 25 max. -5

- elongation % ≥ 150 309 - variation with samples without ageing

% ± 25 max. 2

Result The test was passed.

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4.5 Additional ageing test on pieces of completed cables The additional ageing tests on pieces of completed cable were carried out in accordance with clause 19.5 of IEC 60502-2. The results are presented below. item unit requirement measured/determined insulation (100 °C / 7 days)

- tensile strength N/mm² - 27,4 - variation with samples without ageing

% ± 25 max. 9

- elongation % - 555 - variation with samples without ageing

% ± 25 max. 7

separation sheath (100 °C / 7 days)

- tensile strength N/mm² - 16,1 - variation with samples without ageing

% ± 25 max. -14

- elongation % - 325 - variation with samples without ageing

% ± 25 max. 8

oversheath (100 °C / 7 days)

- tensile strength N/mm² - 17,5 - variation with samples without ageing

% ± 25 max. -11

- elongation % - 310 - variation with samples without ageing

% ± 25 max. 10

Result The test was passed.

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4.6 Loss of mass test on PVC sheaths of type ST2 The loss of mass test was carried out in accordance with clause 19.6 of IEC 60502-2. The results are presented below. Characteristic test data Temperature 100 °C Duration 7 d Separation sheath item unit requirement measured/determined - loss of mass mg/cm2 ≤ 1,5 0,8 Oversheath item unit requirement measured/determined - loss of mass mg/cm2 ≤ 1,5 0,4 Result The test was passed.

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4.7 Pressure test at high temperature on non-metallic sheaths The pressure test was carried out in accordance with clause 19.7 of IEC 60502-2. The results are presented below. Characteristic test data (separation sheath) Temperature 90 °C Duration 6 h Load 8,7 N Separation sheath item unit requirement measured/determined - depth of indentation % ≤ 50 11 Characteristic test data (oversheath) Temperature 90 °C Duration 6 h Load 13,0 N Oversheath item unit requirement measured/determined - depth of indentation % ≤ 50 17 Result The test was passed.

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4.8 Test on PVC sheaths at low temperatures The test on PVC sheath(s) was carried out in accordance with clause 19.8 of IEC 60502-2. The results are presented below. Characteristic test data Temperature -15 °C Separation sheath item unit requirement measured/determined - elongation - cold impact test

% -

≥ 20 no cracks

210 no cracks

Oversheath item unit requirement measured/determined - elongation - cold impact test

% -

≥ 20 no cracks

185 no cracks

Result The test was passed. 4.9 Test for resistance of PVC sheaths to cracking (heat shock test) The heat shock test was carried out in accordance with clause 19.9 of IEC 60502-2. The results are presented below. Characteristic test data Temperature 150 °C Duration 1 h Separation sheath item unit requirement measured/determined - soundness - no cracks no cracks Oversheath item unit requirement measured/determined - soundness - no cracks no cracks Result The test was passed.

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4.10 Hot set test for XLPE insulation The hot set test was carried out in accordance with clause 19.11 of IEC 60502-2. The results are presented below. Characteristic test data Temperature 200 °C item unit requirement measured/determined - elongation under load - permanent elongation

% %

≤ 175 ≤ 15

70 5

Result The test was passed. 4.11 Water absorption test on insulation The water absorption test was carried out in accordance with clause 19.13 of IEC 60502-2. The results are presented below. Characteristic test data Temperature 85 °C Duration 14 d item unit requirement measured/determined - variation of mass mg/cm2 ≤ 1 ≤ 0,1 Result The test was passed.

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4.12 Shrinkage test for XLPE insulation The shrinkage test was carried out in accordance with clause 19.16 of IEC 60502-2. The results are presented below. Characteristic test data Temperature 130 °C Duration 1 h item unit requirement measured/determined - shrinkage % ≤ 4 2 Result The test was passed.

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5 VERIFICATION OF CABLE CONSTRUCTION Verification of cable construction was carried out in accordance with clauses 5-14 of IEC 60502-2. The results are presented below.

item required/specified measured/determined conductor (IEC 60228 Class 2)

material: stranded copper wires

circular compacted construction 1-6-11-16-21

- resistance at 20 °C (Ω/km) ≤ 0,047

0,047

- no. of wires ≥ 53 copper wires 55x Ø 3,0mm approx.

- diameter min-max (mm) 23,2 (datasheet) 23,3 22,3 ≤ d ≤ 24,6 screening conductor screen yes present, semi conducting

conductor screen - thickness, minimum (mm) 0,5 (datasheet) - insulation screen yes present, semi conducting

insulation screen - thickness, minimum (mm) 0,4 (datasheet) - metallic part

yes

present,

one copper tape 1 x 0,1 mm (datasheet)

one copper tape, thickness 0,1 mm approx.

- cross section 9,7 mm2 (datasheet) - insulation material: extruded XLPE see result of non-electrical type tests see results of non-

electrical type tests separation sheath material: PVC type ST2 see results of non-electrical type

tests see results of non-electrical type tests

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item required/specified measured/determined armour material: aluminium wires single layer of aluminium wires, wire

diameter 2,5 mm present, aluminium armour wires 53x Ø 2,5 mm approx. and above double synthetic tape

oversheath material: PVC type ST2 see results of non-electrical type

tests see results of non-electrical type tests

marking of the cable - ELSEWEDY CABLES

EGC 1x400mm² 19/33kV IEC 60502 CU/XLPE/AWA/PVC 2007 PEC

colour of the core - black colour of the oversheath black (datasheet) black outer diameter of the cable average (mm) 54.7 (datasheet) 57,6 (average) outer diameter of the core average (mm) 41,4 (datasheet) 42,4 (average)

Result The test was passed.

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APPENDIX A MEASUREMENT UNCERTAINTIES The measurement uncertainties in the results presented are as specified below unless otherwise indicated.

measurement measurement uncertainty dielectric tests and impulse current tests

peak value: ≤ 3% time parameters: ≤ 10%

capacitance measurement tan δ measurement

0,3% ± 0,5% ± 5x10-5

partial discharge measurement < 10 pC : 2 pC 10 - 100 pC : 5 pC > 100 pC : 20 %

measurement of impedance ac-resistance measurement

≤ 1%

measurement of losses ≤ 1% measurement of insulation resistance ≤ 10% measurement of dc resistance 1 µΩ - 5 µΩ : 1%

5 µΩ - 10 µΩ : 0,5% 10 µΩ - 200 µΩ : 0,2%

radio interference test 2 dB calibration of current transformers 2,2 x 10-4 Ii/Iu and 290 µrad calibration of voltage transformers 1,6 x 10-4 Ui/Uu en 510 µrad measurement of conductivity 5% measurement of temperature -50 °C - -40 °C : 3 K

-40 °C - 125 °C : 2 K 125 °C - 150 °C : 3 K

tensile test 1% sound level measurement type 1 meter as per IEC 651 and

ANSI S1.4.1971 measurement of voltage ratio 0,1%

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APPENDIX B MANUFACTURER’S DRAWING(S)/DATA SHEET 3 pages drawing no. description date rev. CX5-TZ01-X40-00-01 cable construction datasheet (page 1 and 2) - - CX5-TZ01-X40-00-01 cable constructional drawing (page 3) 3 March 2007 0

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