cs9+draft+g+june 2006id615ver26
TRANSCRIPT
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Specification for Extruded Insulation Power CablesAEIC CS9-06 1st Edition and their Accessories Rated aboe !6 "# throu$h %!& "#ac
SPECI'ICA(I)* ')R
E+(R,E I*S,.A(I)* P)/ER CA.ES
A* (EIR ACCESS)RIES
RA(E A)#E !6 "# (R),2 %!& "#ac
First Edition
(Draft G, June 4, 2006)
RA'( 2 - C)*'IE*(IA.
Association of Edison Illuminating Comanies600 !ort" #$t" %treet, &ost 'ffice o 264#
irming"am Ala*ama +2-#.0--2
Decem*er 200
http344www5aeic5or$
http://www.aeic.org/http://www.aeic.org/ -
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Specification for Extruded Insulation Power CablesAEIC CS9-06 1st Edition and their Accessories Rated aboe !6 "# throu$h %!& "#ac
Co/rig"t 2006 */ t"e Association of Edison Illuminating Comanies
!o art of t"is secification ma/ *e reroduced in an/ form it"out t"e rior ritten&ermission of t"e Association of Edison Illuminating Comanies1
All rig"ts resered1
&lease contact us at our e*site3
www5aeic5or$
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Specification for Extruded Insulation Power CablesAEIC CS9-06 1st Edition and their Accessories Rated aboe !6 "# throu$h %!& "#ac
(able of Contents
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Specification for Extruded Insulation Power CablesAEIC CS9-06 1st Edition and their Accessories Rated aboe !6 "# throu$h %!& "#ac
2112 edding and 7ongitudinal 5ater locBing1111111111111111111111111111111111111111111111111#$211+ %"ields111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111#$2114 %"eat"s1111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111#$211 adial 8oisture arrier11111111111111111111111111111111111111111111111111111111111111111111111111111#-
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Specification for Extruded Insulation Power CablesAEIC CS9-06 1st Edition and their Accessories Rated aboe !6 "# throu$h %!& "#ac
#01# CA7E EE7%1111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111+4#01#1# Ca*le eel &acBing, %ealing, and %"iing111111111111111111111111111111111111111111111+4#01#12 eel Dimensions11111111111111111111111111111111111111111111111111111111111111111111111111111111111111+#01#1+ 8arBing on eels1111111111111111111111111111111111111111111111111111111111111111111111111111111111111 +#01#14 Ca*le End Fittings11111111111111111111111111111111111111111111111111111111111111111111111111111111111+6
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Specification for Extruded Insulation Power CablesAEIC and their Accessories Rated !6 "# throu$h %!& "#ac
Vm: Maximum continuous phase-to-phase operating voltage (V+5%)
Vt: Phase-to-ground test voltage
Vented Water Tree: A water tree, which originates at the conductor shield or insulation
shield.
Void: Any cavity in a compound, either within or at the interface with
another extruded layer.
Wet Location: Installations underground or in concrete slabs or masonry in direct
contact with the earth; in locations subject to saturation with water
or other liquids and in unprotected locations exposed to weather.
XLPE Insulation Compound:Cross-linked polyethylene insulation.
15&58 efinition of (ests
The following additional definitions clarify the various testing terms used herein and in
documents referred to in this specification.
Production Tests: Tests made on each manufactured component (length of cable or
accessory), or samples thereof, to confirm compliance of the
finished product with this specification and other standards
referenced herein. They also verify that the delivered products
have at least the same quality as those having passed theQualification and Pre-qualification Tests. Production Tests are
sometimes variously referred to in other documents as factory
tests, routine tests and acceptance tests.
Qualification Tests: Tests made before supplying on a general commercial basis, a
type of cable, accessory or cable system (cable and accessories)
covered by this specification and referenced standards, in order to
demonstrate satisfactory performance characteristics for the
intended application. Once successfully completed, these tests
need not be repeated, unless changes are made in the cable or
accessory materials, or design, or manufacturing process, or
manufacturing plant, which might change the performance
characteristics. Qualification Tests are sometimes variously
referred to in other documents as prototype tests, type tests and
design tests.
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Specification for Extruded Insulation Power CablesAEIC and their Accessories Rated !6 "# throu$h %!& "#ac
Pre-qualification Tests: Tests made before supplying on a general commercial basis, a
type of cable system covered by this specification and referenced
standards, in order to demonstrate satisfactory long-term
performance of the complete cable system. The pre-qualification
test need only be carried out once, unless there is a substantial
change in the cable system with respect to materials, or design, or
manufacturing process, or manufacturing plant, which might
adversely affect the performance of the cable system.
Deeloment ;ests3 ;ests comleted */ t"e manufacturer during deeloment of t"eca*le s/stem *efore re.ualification tests1 ;"e recise natureand etent of deeloment orB and anal/ses s"all *e at t"ediscretion of t"e manufacturer, *ut ma/ include t"e folloing3
An ealuation of t"e materials and rocesses emlo/ed,
including leels of oids, contaminants, rotrusions, etc1
oltage.time endurance testing and 5ei*ull anal/sis of test
results, including determination of n>, t"e long term agingeonent
Development of compatible accessories, including factory tests
to assess aging effects related to electrical stress,
temperature, interface pressure, environmental conditions, etc.
erification tests on full sie ca*le s/stems,
Correlation of development test results with service reliability
requirements
156 RE'ERE*CES
The following standards and references form a part of this specification. The most recent
editions apply.
ASTM 1693 Tests for Environmental Stress Cracking of Ethylene Plastics
Electra No. 128 Article: Guide to the protection of specially bonded cable systems against
sheath over-voltages, January 1992
Electra No. 141 Article: Guidelines for Tests on High Voltage Cables with Extruded
Insulation and Laminated Protective Coverings, April 1992
Electra No. 151 Article: Earthing of GIS An Application Guide, December 1993
ICEA S-94-649 Standard for Concentric Neutral Cables Rated 5 through 46 kVICEA S-105-692 600 Volt Single Layer Thermoset Insulated Utility Underground
Distribution Cables
ICEA S-108-720 Standard for Extruded Insulation Power Cables Rated above 46 kV
through 345 kV
ICEA T-24-380 Guide for Partial Discharge Test Procedure
ICEA T-27-581 Standard Test Methods for Extruded Dielectric Power, Control,
Instrumentation & Portable Cables for Test
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Specification for Extruded Insulation Power CablesAEIC and their Accessories Rated !6 "# throu$h %!& "#ac
ICEA T-31-610 Guide for Conducting a Longitudinal Water Penetration Resistance Test
for Sealed Conductors
ICEA T-32-645 Guide for Establishing Compatibility of Sealed Conductor Filler
Compounds with Conductor Stress Control Materials
IEC 60228 Conductors of insulated cables
IEC 60229 Tests on cable oversheaths which have a special protective function
IEC 60287 Calculation of the continuous current rating of cables (100% load factor)
IEC 60853-2 Calculation of the cyclic and emergency current rating of cables
IEC 60529 Degrees of protection provided by enclosures (IP Code)
IEC 60840 Power cables with extruded insulation and their accessories for rated
voltages above 30 kV up to 150 kV Test methods and requirements
IEC 60859 Cable connections for gas-insulated metal-enclosed switchgear for rated
voltages of 72.5 kV and above
IEC 60855 Electrical test methods for power cables
IEC 62067 Power cables with extruded insulation and their accessories for rated
voltages above 150 kV up to 500 kV Test methods and requirementsIEEE 48 Standard Test Procedures and Requirements for Alternating Current
Cable Terminations 2.5 kV through 765 kV
IEEE C62.11 Standard for Metal-Oxide Surge Arresters for AC Power Circuits (> 1 kV)
IEEE 100 The Authoritative Dictionary of IEEE Standards Terms
IEEE 404 Standard for Extruded and Laminated Dielectric Shielded Cable Joints
Rated 2,500 500,000 V
IEEE 693 Recommended Practice for Seismic Design of Substations
ISO 9001 Quality Systems Model for quality assurance in design, development,
production, installation and servicing
NEMA WC26 Binational Wire and Cable Packaging
NEMA 250 Enclosures for Electrical Equipment
Other standards are in turn referenced from within the above documents.
15= R I*S,.A(I)*
Cable systems having cable insulation with nominal internal and external ac electrical stresses
greater than 100 V/mil (4.0 kV/mm) and 50 V/mil (2.0 kV/mm) respectively, shall be supplied with
a metallic moisture barrier to maintain dry insulation. Higher ac stresses may be applied to wet
design cable systems, if agreed to between the purchaser and manufacturer.
15> ESI2* .I'E A* RE.IAI.I(
Cable systems meeting the requirements of this specification are expected to have a minimum
design life of 40 years. The manufacturer shall supply test data and calculations supporting
these design and reliability requirements, if required by the purchasers specification (reference
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Specification for Extruded Insulation Power CablesAEIC and their Accessories Rated !6 "# throu$h %!& "#ac
Appendix 8, Item 25). The documentation shall include the electrical, thermal and mechanical
performance characteristics of the cable core, laminated metallic moisture barriers (if present),
solid metallic sheath, jacket and accessories.
Manufacturers shall take into account the Aging Factors, Design Life and Reliability
Considerations for Extruded Insulation Cables and Accessories in Appendix 2, to ensure that
the cable and accessory system performs reliably for the expected design life and intended
application. The design life shall also take into account the maximum operating temperature
considerations described in Appendix 4 and 1.9 below.
159 A+I, )PERA(I*2 (EPERA(,RES A* ,RA(I)*S
The design and construction of the cable and accessories shall be such that they perform
reliably together as a complete system, at conductor temperatures not exceeding those shown in
Table1.9-1.
Table1.9-1 Maximum Conductor Temperatures (C)
Type of Operation XLPEEPR
(to 138 kV max)
Normal Operation 90 90
Emergency Operation
(46 150 kV)105 105*
Emergency Operation
(>150 345 kV)105 Not applicable
Short Circuit Operation 250 250
*Emergency operation at conductor temperatures up to 130C may be used if mutually
agreed between purchaser and manufacturer and verified by qualification and pre-
qualification tests.
The temperatures identified for Emergency Operation apply for no more than 72 hours duration
on average per year during the design life of the cable system, without exceeding 216 hours in
any 12 month period. Users are referred to Appendix 4 for a description of the basis of these
emergency temperature/time requirements and an explanation of verification tests.
If emergency operation (for cables rated >150 to 345 kV) to 105C or higher is desired, the pre-
qualification tests in IEC 62067 shall include 90 additional load cycles to the maximum
emergency operation temperature, as described in Appendix 4. In addition, the qualification
tests (type tests) in IEC 62067 and IEC 60840 shall be performed at the maximum emergency
operation temperature, as described in Appendix 4.
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Specification for Extruded Insulation Power CablesAEIC and their Accessories Rated !6 "# throu$h %!& "#ac
The temperatures identified as for Normal Operation apply to operating load cycles typical of
electric utility systems (approximately 0.80 daily load factor for transmission lines; approximately
1.0 daily load factor for generating stations). Cable system designs shall assume that the
normal maximum operation temperatures can be applied continuously throughout the cable
systems design life, with corresponding load factors.
Designs for operation at the Table 1.9-1 maximum temperatures shall take into consideration
actual field-proven performance and design limits of transmission cable and accessories, as
relevant to the intended application. This shall include consideration of at least the factors
described in ICEA S-108-720 Appendix B, as well as the following:
the effects of high operating temperatures on radial expansion of XLPE insulation
possible degradation of stress relief cone interface pressure due to mechanical stress
relaxation, over the cable system design life
the temperature gradient across the cable core and the corresponding jacket temperature
limits, which could be excessive for some installation conditions
possible loss of adhesion at the overlap of laminated moisture barriers and loss of bondadhesion to the underside of the jacket
high axial thrust forces that can be transmitted to joints and terminations, especially for large
conductors
possible permanent distortion of the insulation due to high sidewall forces at bends, resulting
in a local reduction of insulation and jacket thickness
possible permanent distortion of the insulation due to radial expansion at clamps and
anchors, for some sheath/shield constructions
cyclic fatigue resistance of metal moisture barriers and corresponding value of the limiting
cyclic strain (see Appendix 2 references 17 42, and especially 20, 32, 35 and 37)
effective axial stiffness (longitudinal rigidity) of the cable (see Appendix 2 references 17
43) and the design of duct/pipe clearance, layouts in tunnels, manholes and approaching
terminations
effective bending stiffness (flexural rigidity) of the cable (see Appendix 2 references 17 - 43)
and the design of duct/pipe clearance, layouts in tunnels, manholes and approaching
terminations
The Table 1.9-1 maximum operating temperatures apply to the hottest portion of the cable
system at any time. They may be used in current rating calculations when adequate information
is known about the overall thermal characteristics of the cable system environment, to ensure
that these temperatures shall not be exceeded. In the absence of this information, the
maximum temperatures used in current rating calculations shall be reduced by 10C, or in
accordance with available data.
1510 C,RRE*( RA(I*2 A* CA.E (EPERA(,RE CA.C,.A(I)*S
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Specification for Extruded Insulation Power CablesAEIC and their Accessories Rated !6 "# throu$h %!& "#ac
Current ratings and cable temperatures shall be calculated in accordance with IEC 60287, or as
described in The Calculation of Temperature Rise and Load Capability of Cable Systems, J.H.
Neher, M.H. McGrath, AIEE Transactions on Power Apparatus and Systems, vol. 76, October
1957. Daily load factor effects shall be calculated in accordance with the latter reference or IEC
60853-2.
For conductors with large cross-sections, values for the skin effect factor (ks) and proximity effect
factor (kp) shall be in accordance with the recommendations of CIGRE Technical Brochure 272
Large Cross-sections and Composite Screen Designs, WG B1.03, June 2005, unless
otherwise agreed to between purchaser and manufacturer and verified by measurement of ac
resistance during qualification tests.
Emergency current ratings and cable temperatures shall be calculated in accordance with IEC
60853-2.
85 CA.ES
Cables shall comply with ICEA S-108-720 and as described herein.
An Insulation System Quality Assurance Plan shall be submitted with the Manufacturers
Technical Declaration File (reference Appendix 9, Item 24), if required by the purchasers
specification. The plan shall describe procedures to ensure that the cleanliness and smoothness
requirements of extruded insulation and semi-conducting shield materials are met throughout
the supply chain from compound supplier to the manufacturers extruders.
851 C)*,C()RS
85151 2eneral
The conductor material shall be copper or aluminum with circular cross-section.. If the area and
construction is not described by the purchasers specification, the manufacturer shall provide a
conductor with material, cross-sectional area and construction sufficient to meet the required
normal current carrying capacity, emergency current carrying capacity and short circuit fault
duty, without exceeding the temperature limits described in Table 1.9-1, in accordance with the
installation conditions and other information in the purchasers specification.
85158 Sealant for Stranded Conductors
If specified by the purchaser, a sealant designed as an impediment to longitudinal water
penetration shall be used to fill all the interstices of stranded conductors. Compatibility with the
conductor shield shall be determined in accordance with ICEA T-32-645. Longitudinal water
penetration resistance shall be determined in accordance with ICEA T-31-610 and shall meet a
minimum pressure requirement of 5 psig (35 kPa).
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Specification for Extruded Insulation Power CablesAEIC and their Accessories Rated !6 "# throu$h %!& "#ac
8515% Preferred Conductor Si?es
ICEA S-108-720 Tables 2-2 and 2-3 describe 31 possible conductor sizes ranging from 250
kcmil (127 mm2) to 4000 kcmil (2027 mm2), in copper and aluminum. Fewer standard sizes for
HV and EHV cable can result in lower tooling costs for manufacturers, smaller spare cable
inventories for purchasers and greater opportunities for sharing of spare cables between users.
Cables supplied under this specification shall therefore be limited to the conductor sizes shown
in Table 2.1-1, unless described otherwise in the purchasers specification, or proposed as an
alternative by the manufacturer.
Table 2.1-1 Standard Imperial Conductor Sizes (kcmil) and Nearest IEC 60228 SI Sizes
(mm2)
69 kV 115 kV 138 kV 161 kV 230 kV 345 kV
kcmil mm2
kcmil mm2
kcmil mm2
kcmil mm2
kcmil mm2
kcmil mm2
500 240
750 400 750 400 750 400 750 400
1000 500 1000 500 1000 500 1000 500 1000 500 1000 500
1250 630 1250 630 1250 630 1250 630 1250 630 1250 630
1500 800 1500 800 1500 800 1500 800 1500 800 1500 800
1750 800 1750 800 1750 800 1750 800 1750 800 1750 800
2000 1000 2000 1000 2000 1000 2000 1000 2000 1000 2000 1000
2500 1200 2500 1200 2500 1200 2500 1200 2500 1200 2500 1200
3000 1600 3000 1600 3000 1600 3000 1600 3000 1600 3000 1600
3500 1600 3500 1600 3500 1600 3500 1600 3500 1600 3500 1600
4000 2000 4000 2000 4000 2000 4000 2000 4000 2000 4000 2000
5000 2500 5000 2500
ICEA S-108-720 Tables 2-2 and 2-3 describe soft metric sizes, which are mathematically
correct conversions from Imperial to SI (1.000 kcmil = 0.507 mm2). The metric sizes shown in
the above Table 2.1-1 are hard conversions, complying with the closest standard sizes in IEC
60228 Conductors of insulated cables.
8515! Conductor Characteristics
The conductor characteristics, including dc resistances for the IEC 60228 SI conductor sizes,
shall comply with ICEA S-108-720.
858 C)*,C()R SIE.
85851 2eneral
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Specification for Extruded Insulation Power CablesAEIC and their Accessories Rated !6 "# throu$h %!& "#ac
The conductor shield shall provide a uniform, continuous, smooth, concentric, thermosetting,
semi-conducting, voltage stress control layer between the outer surface of the conductor and the
inner surface of the insulation. It shall be in direct contact with the conductor and adhere well to
the inner surface of the insulation under all operating conditions.
85858 aterial
The conductor shield material shall be as per ICEA S-108-720 except for XLPE insulations with
ac electrical stress at the conductor shield greater than 200 V/mil (8.0 kV/mm), the conductor
shield shall be formulated using acetylene black. The manufacturer shall verify with the
compound supplier that the sulfur and ash content is less than 0.005 % and 0.01 % respectively.
8585% Extruded Shield (hic"ness
The nominal thickness of the extruded conductor shield shall be as per ICEA S-108-720.
8585! #oids@ Protrusion and Irre$ularit< .i;its
The maximum allowable void, protrusion and irregularity limits for XLPE insulation cables shall
be as per ICEA S-108-720, except as modified in Table 2.2-1 for cables with nominal internal ac
stresses greater than 200 V/mil (8.0 kV/mm).
Voids are assumed to occur at the interface between the extruded conductor shield and the
insulation.
Protrusion and irregularity heights from the conductor shield into the insulation and from the
insulation into the conductor shield are one half the maximum allowable contaminant diameter,
which is less than described in ICEA S-108-720 for insulation internal stresses greater than 250
V/mil (10.0 kV/mm). (Refer to Appendix 1 for a description of the basis for these values.)
Table 2.2-1 Extruded Conductor Shield/Insulation Interface; Void, Protrusion and
Irregularity Limits vs Nominal Internal ac Stress (dimensions rounded to nearest 0.5 mil)
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Specification for Extruded Insulation Power CablesAEIC and their Accessories Rated !6 "# throu$h %!& "#ac
Nominal Internal ac Stress
at Vg
V/mil (kV/mm)
100
(4.0)
125
(5.0)
150
(6.0)
175
(7.0)
200
(8.0)
225
(9.0)
250
(10.0)
275
(11.0)
300
(12.0)
325
(13.0)
350
(14.0)
Maximum Void
Dimension
mils (m)
2.0
(50)
1
2.0
(50)
1
2.0
(50)
1
2.0
(50)
1
2.0
(50)
1
2.0
(50)
2
1.5
(38)
2
1.5
(38)
2
1.5
(38)
2
1.0
(25)
2
1.0
(25)
2
Maximum Protrusion and
Irregularity Height
mils (m)
3.0
(75)1
3.0
(75)1
3.0
(75)1
3.0
(75)1
3.0
(75)1
3.0
(75)1
3.0
(75)1
3.0
(75)2
2.5
(63)2
2.0
(50)2
2.0
(50)2
1reflect current practices and ICEA S-108-720 limits.2less than ICEA S-108-720 limits.
For EPR-insulated cable the void, protrusion and irregularity limits shall be as per Table 2.2-1,
but with nominal internal ac stress no greater than 200 V/mil (8.0 kV/mm).
8585& Ph
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Specification for Extruded Insulation Power CablesAEIC and their Accessories Rated !6 "# throu$h %!& "#ac
XLPE insulation shall be extruded together with the extruded conductor shield and extruded
insulation shield, in one common triple head extruder. The three layers shall be cross-linked in a
dry curing process.
XLPE insulation material shall be inspected for contaminants using a continuous sampling plan.
The plan must sample a minimum of 2 percent of the insulation material volume. Materialnot
inspected by the compound supplier must be inspected at the 2 percent rate by the cable
manufacturer. The material analysis shall be reported for engineering information and as a
minimum, provide a statistical analysis of the size and number of contaminants found per weight
of insulation inspected.
85%58 Insulation (hic"ness
For wet design cables without a metallic moisture barrier, insulation thickness shall be based
on the traditional values described in ICEA S-108-720, Appendix F.
For dry design cables, the insulation thickness shall be designed based on electrical stress, as
described in ICEA S-108-720 as well as the following, unless proposed otherwise by the
manufacturer or purchaser and supported by tests:
ac stresses at the conductor shield (internal stress) and over the insulation (external stress),
as calculated in 2.3.4, shall not exceed the limits described in Table 2.3-1 at the rated phase-
to-ground operating voltage Vg,
the ac and impulse stresses at the inner starting point of stress relief cones in accessories,
shall not exceed the limits defined by the manufacturer,
consideration of the Generic nominal thicknesses described in Appendix 5, which areintended to satisfy the nominal internal and external stress limit criteria over the standard
conductor size range and provide a degree of standardization.
Table 2.3-1 Rated Voltage, Conductor Size Range, Insulation Eccentricity Limits, Nominal
Internal ac Stress Limits and Nominal External ac Stress Limits
Rated
Voltage
kV
Conductor
Size
kcmil
Conductor
Size
mm2
Maximum
Insulation
Eccentricity
%
Nominal
Internal ac
Stress Limit
V/mil (kV/mm)
Nominal
External ac
Stress Limit
V/mil (kV/mm)69 wet 500-4000 240-2000 12 100 (4.0) 50 (2.0)
69 dry 500-4000 240-2000 12 150 (6.0) 75 (3.0)
115 750-4000 400-2000 12 200 (8.0) 100 (4.0)
138 750-4000 400-2000 12 200 (8.0) 100 (4.0)
161 750-4000 400-2000 10 225 (9.0) 100 (4.0)
230 1000-5000 500-2500 10 275 (11.0) 125 (5.0)
345 1000-5000 500-2500 10 350 (14.0) 150 (6.0)
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Notwithstanding the Table 2.3-1 values, for cables used with taped joints, the nominal internal
and external ac stresses shall be limited to 150 V/mil (6.0 kV/mm) and 75 V/mil (3.0 kV/mm)
respectively.
Insulation eccentricity shall not exceed the values in Table 2.3-1, as described in ICEA S-108-
720.
85%5% Insulation Reuire;ents
The insulation requirements shall comply with ICEA S-108-720 and as described herein.
The void, contaminant and amber limits for XLPE-insulated cables shall be as per Table 2.3-2
(see Appendix 1 for derivation). The applicable limits shall be based on the actual calculated
internal stress for the proposed cable system, which will vary with specific conductor size andinsulation thickness for each rated voltage level.
Table 2.3-2 Void, Contaminant and Amber Limits versus Nominal Internal ac Stress for
XLPE Insulation Cable3(dimensions rounded to nearest 0.5 mil)
Nominal
Internal ac
Stress at Vg
V/mil (kV/mm)
100
(4.0)
125
(5.0)
150
(6.0)
175
(7.0)
200
(8.0)
225
(9.0)
250
(10.0)
275
(11.0)
300
(12.0)
325
(13.0)
350
(14.0)
Maximum Void
Diameter
mils (m)
2.0
(50)1
2.0
(50)1
2.0
(50)1
2.0
(50)1
2.0
(50)1
2.0
(50)2
1.5
(38)2
1.5
(38)2
1.5
(38)2
1.0
(25)2
1.0
(25)2
Maximum
Contaminant
Dimension
mils (m)
5.0
(125)1
5.0
(125)1
5.0
(125)1
5.0
(125)1
5.0
(125)1
5.0
(125)1
5.0
(125)1
5.0
(125)1
5.0
(125)1
4.0
(100)2
4.0
(100)2
Maximum
Amber
Dimension
mils (m)
10.0
(250)1
10.0
(250)1
10.0
(250)1
10.0
(250)1
10.0
(250)1
10.0
(250)1
10.0
(250)1
10.0
(250)1
10.0
(250)1
8.0
(200)2
8.0
(200)2
1reflect current practices and ICEA S-108-720-2004 limits.2less than ICEA S-108-720 limits.3minimum point stresses could be higher. See 2.3.4.
85%5! Calculation of Insulation Electric Stress
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For cables with a semi-conducting conductor shield, the nominal ac electric stress at any point
in the insulation shall be calculated using the following formula:
rs
rir
VgGr
ln=
Where:
Gr= nominal ac voltage stress at radius r (kV/mm)
Vg= nominal phase to ground voltage (kV)
ri= nominal radius over the insulation (mm)
rs= nominal radius over the conductor shield (mm)
r= radius of a point of interest in the insulation (mm)
The nominal internal ac stress (Gmax) occurs at the interface between the conductor shield and
the insulation, whenr = r
s.
The nominal external ac stress (Gmin) occurs at the outside of the insulation, whenr = ri.
The average stress =rsri
Vg
For EPR cables with a non-conducting conductor shield, the nominal ac electric stress at any
point in the insulation shall be calculated using the following formula:
( )
+
=
Ki
rp
ri
kp
rc
rp
Kir
Vg
Grlnln
Where:
Gr= nominal ac voltage stress at radius r (kV/mm)
Vg= nominal phase to ground voltage (kV)
rc=nominal radius over the conductor (mm)
ri= nominal radius over the insulation (mm)
rp= nominal radius over the conductor shield (mm)
r= radius of a point of interest in the insulation (mm)
Ki= dielectric constant of the insulation
Kp= dielectric constant of the non-conducting insulation shield
The nominal internal ac stress (Gmax) occurs at the interface between the conductor shield and
the insulation, whenr = rs.
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Specification for Extruded Insulation Power CablesAEIC and their Accessories Rated !6 "# throu$h %!& "#ac
The nominal external ac stress (Gmin) occurs at the outside of the insulation, whenr = ri.
The average stress =rsri
Vg
Similar methods shall be used to determine the nominal impulse stresses, by substituting BIL for
Vg.
Informative Note: Users are reminded that ICEA S-108-720 allows a 5% continuous and
10% fifteen-minute over-voltage above the rated phase-to-ground voltage (Vg). In
addition, ICEA S-108-720 allows a minimum point insulation thickness 10% less than
nominal values. Conductor radii can also vary from nominal values. These effects can
lead to a lower value ofriand possibly higher actual stresses in cable and accessories
compared to those calculated above.
85!5 E+(R,E I*S,.A(I)* SIE.
85!51 2eneral
The extruded insulation shield shall provide a uniform, continuous, smooth, concentric,
thermosetting, semi-conducting, voltage stress control layer over the surface of the insulation. It
shall be in direct contact with and adhere well to the insulation under all operating conditions. It
shall be designed to conduct the insulation charging and leakage current to the overlying
bedding layer and metallic shield or sheath. It shall exhibit long-term chemical stability and
compatibility with adjacent cable components and its allowable operating temperature shall be
at least as high as the insulation.
85!58 aterial
The extruded insulation shield material shall be as per ICEA S-108-720.
85!5% (hic"ness Reuire;ents
The nominal thickness of the extruded insulation shield shall be as per ICEA S-108-720.
85!5! #oids@ Protrusions and Irre$ularit< .i;its
The maximum allowable void, protrusion and irregularity limits shall be as described in ICEA S-
108-720, repeated below.
Maximum void diameter 2.0 mils (50m)
Maximum protrusion height 5.0 mils (125m )
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If required by the purchasers specification, the manufacturer shall state the limitingalue of
s"eat" c/clic strain for 40./ear life () (referenceAppendix 8, Item 12 e)), to verify that cyclic
fatigue testing has been performed for the specific cable construction, and that it is adequate for
the intended application. Additional information is provided in Appendix 2.
85&5& Radial oisture arrier
XLPE-insulated cables shall incorporate a metallic, radial moisture barrier, unless a wet design
cable is specifically requested by the purchaser, and insulation electric stress limits are reduced
in compliance with 1.7 and 2.3.2. Radial moisture barriers can be a continuous metal sheath, as
described above, or a longitudinally applied metal foil layer bonded to the inside of the jacket.
Longitudinally applied metal foil moisture barriers shall meet the requirements of ICEA S-108-
720. When applied, they shall be in addition to an underlying shield, which is required to ensure
a satisfactory concentric conducting path for insulation charging and leakage current, as well as
neutral current, phase unbalance current, fault current, and surge current.
856 BAC7E(
85651 2eneral
The jacket shall comply with ICEA S-108-720 and as described herein.
Supplemental anti-corrosion protection shall be provided for aluminum sheaths, which are not
bonded to the inside of the jacket, by applying a continuous coating of waterproof compound
over the sheath immediately prior to extruding the jacket.
Users shall consider polyethylene jackets for cold-weather installation applications.
Jackets for wet design XLPE cables shall be polyethylene.
85658 Bac"et (hic"ness
The jacket thickness shall comply with ICEA S-108-720, or as modified in the purchasers
specification for the intended application (reference Appendix 6 Jacket Thickness
Considerations).
8565% Se;i-conductin$ Coatin$
Unless specifically excluded by the purchaser, a continuous graphite coating or extruded semi-
conducting layer shall be applied over the jacket to form an electrode for Production Tests, dc
testing during installation, and for periodic maintenance testing after commissioning.
85= PR),C(I)* (ES(S )* CA.E
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85=51 2eneral
The production tests shall comply with ICEA S-108-720, except as described herein.
85=58 Su;;ar< of ICEA S-10>-=80 Production (ests and 'reuenc1.5 Vgand duration < 10 hours.
3. There shall be no detectable discharge within the cable with a measurement sensitivity of 5 pC or
less.
4.Assumes cables are used on an effectively grounded system.
Table 2.7-2 Summary of ICEA S-108-720 and Supplementary Production Tests and
Frequency (* identifies variations from ICEA S-0108-720)
TestTest Method
ReferenceTest Frequency
Conductor
dc Resistance 9.3.1 1 test per each shipping length*
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ICEA T-27-581
Diameter ICEA T-27-581 1 sample from each end of each shipping
length*
Temper ASTM Manufacturer certification that values are met
Non-Metallic Conductor Shield
Elongation After Aging 9.4.14 Each lot of material used for extrusion onto
the cable
Volume Resistivity 9.8.1 Each lot of material used for extrusion onto
the cable
Note: This test is performed (in combination
with insulation shield volume resistivity) on a
sample of cable
Thickness 9.4.2 1 sample from each end of each shipping
length*
Voids, Protrusions & Irregularities 9.4.13 1 sample from each end of each shipping
length*
Wafer Boil 9.4.13 3 samples from each extruder run; near twoends & middle
Spark Test (non-conducting layer) ICEA T-27-581 100%
Insulation
Unaged & Aged Tensile & Elongation 9.4.8
9.4.9
1 test per 50,000 ft (15 km) or at least 1 per
extruder run
Hot Creep 9.4.10 and ICEA
T-28-562
3 samples from each extruder run; near two
ends & middle
Voids & Contaminants 9.4.13 1 sample from each end of each shipping
length*
Samples shall be prepared using a lathe, or
Owner-approved equivalent, to minimize
contamination of the surface of the samples
Diameter 9.6 1 sample from each end of each shipping
length*
Shrinkback (XLPE only) 9.9 For rated voltages 150 kV, 1 sample from
each 50,000 ft (15 km) or at least 1 per
extrusion run
For rated voltages > 150 kV, 1 sample from
each end of each extrusion run
Thickness & Eccentricity 9.4.2 1 sample from each end of each shipping
length*Non-Metallic Insulation Shield
Elongation After Aging 9.4.14.3 Each lot used for extrusion onto the cable
Volume Resistivity 9.8.2 Each lot used for extrusion onto the cable
Note: This test is performed (in combination
with insulation shield volume resistivity) on a
sample of cable
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Thickness 9.4.2 1 sample from each end of each shipping
length*
Voids & Protrusions 9.4.13 1 sample from each end of each shipping
length*
Wafer Boil 9.4.12 3 samples from each extrusionr run; near two
ends & middle
Diameter 9.6 1 sample from each end of each shippinglength*
Metallic Shields
Dimensional Measurements 9.5 1 sample from each end of each shipping
length*
Jackets
Unaged & Aged Tensile & Elongation 9.4.8
9.4.9
1 test per 50,000 ft (15 km) or at least 1 per
jacket extruder run
Thickness 9.4.2 1 sample from each end of each shipping
length*
Other Tests Applicable to JacketHeat Distortion 9.7.2
ICEA T-27-581
Each lot used for extrusion onto the cable
Heat Shock 9.7.1 Each lot used for extrusion onto the cable
Cold bend ICEA T-27-581 0 samples for -=80 Production (ests
Other additions and modifications to ICEA S-108-720 Production Tests shall be as follows:
2.7.3.1 Method for dc Resistance Determination (ICEA S-108-720 clause 9.3.1, ICEA T-27-581
clause 2.1)
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Clause 9.3.1 shall also include the following requirements:
The complete shipping length reel shall be placed in the test room, which shall be kept at a
reasonably constant temperature for at least 24 hours before the test. The temperature of the
cable (measured by placing a thermocouple one layer below the outer wrap) at the time of the
test shall be within 3 C compared with the testing room temperature.
The manufacturer shall report the following:
length of cable on the reel at the time of conductor dc resistance measurement
measured temperature of the cable and the test room, as well as the method of
measurement
measured conductor dc resistance, for each reel of cable
conductor dc resistance corrected to 25 C
2.7.3.2 Clarification and Extension of Shrinkback Test (ICEA S-108-720 clauses 9.9 and 9.15;
Table 4-8)
The clause 9.9 Shrinkback Test Procedure shall be modified to include a high temperature
heating-cooling cycle, to determine dimensional stability. The test shall be done following any of
the first three heating-cooling cycles which meets the acceptance limits of ICEA S-108-720
Table 4-8.
The additional heating-cooling cycle shall be to 105 C +/- 2 C for a period of 20 hours and then
cooled to room temperature.
The protrusion acceptance limit, at either end, shall be 175 mils (4.37 mm) for conductor shields
extruded directly over the conductor and 240 mils (6.00 mm) for conductor shields extruded over
semi-conducting tape shields.
2.7.3.3 Amber, Agglomerate, gel, Contaminant, Protrusion, Irrregularity and Void Tests (ICEA S-
108-720 clauses 9.4.13 and 9.15)
If either of the two samples from any shipping length fails, the shipping length shall be rejected.
2.7.3.4 Longitudinal Water Penetration
A longitudinal water penetration test shall be performed for sealed conductor cables, according
to the procedures in ICEA T-31-610. Tests shall be done on a sample of completed cable.
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2.7.3.5 Segmented Conductor Eccentricity
The eccentricity of cabled segmental conductors shall be determined from measurement of both
maximum callipered and circumference tape diameters taken at five locations spaced
approximately 1 foot (30 cm) apart along the conductor. The average of five maximum
callipered diameters shall not exceed the average of the five circumference tape diameters by
more than two percent (2%). At any one location, the maximum callipered diameter shall not
exceed the circumference tape diameter by more than three percent (3%).
85=5! Conditions Appl ,A.I'ICA(I)* (ES(S )* CA.E
The qualification tests shall comply with ICEA S-108-720 and as otherwise described herein.
859 CA.E IE*(I'ICA(I)*
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The cable identification shall comply with ICEA S-108-720 and as described herein.
The outer surface of each cable shall be durably marked throughout its length with the
manufacturers name, type of insulation, insulation thickness, conductor material and size,
sequential length indication, rated voltage and year of manufacture. Additional information may
be required by government and regulatory authorities.
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manufacturer for a period of not less than five years from shipping date, unless a longer period
is requested by the purchaser at the time of inquiry.
%50 (ERI*A(I)*S
%51 2E*ERA.
The cable system manufacturer shall provide terminations in accordance with the purchasers
custom project specification, suitable for terminating the cable described herein.
Terminations for use in air shall comply with IEEE 48. Terminations in gas insulated switchgear
(GIS) shall comply with IEC 60859, IEC 60840 and IEC 62067. Consideration shall also be
given to GIS grounding designs, as described in Electra No. 151 article Earthing of GIS An
application guide.
If required by the purchasers specification, the cable system manufacturer shall provide a copy
of representative qualification test reports for the proposed terminations with the proposal, or
include such testing with the proposal.
Each termination shall be packaged as a self-sufficient kit. It shall contain packing lists,
instructions and all permanent and consumable materials, as required for installation by
qualified Journeymen Cablemen, under the Supervision of a manufacturers representative.
Aerial connector lugs shall be provided for each air termination. The connectors shall have
NEMA four hole spacing and be capable of carrying the emergency operating current for 40 C
ambient air temperature, with sun and no wind.
%58 (ERI*A(I)* ),*(I*2 I*S,.A(I)*
Termination mounting assemblies shall be provided with electrical insulating systems to allow
temporary isolation of the shield/sheath circuit from ground for periodic maintenance testing of
the jacket with a dc test voltage. They shall also allow permanent isolation of the shield/sheath
circuit from ground, to implement special bonding systems, such as single point bonding, as
described in Electra No. 128 article Guide to the protection of specially bonded cable systems
to sheath over-voltages. The termination isolation systems shall withstand the same electrical
requirements as the external anti-corrosion serving for joint casings (see Table 4.2-1 Each partto Ground, below).
%5% PR),C(I)* (ES(S )* (ERI*A(I)*S
Production tests shall be done in accordance with the requirements of IEEE 48 or IEC 60859 for
installation in GIS, as applicable. In addition, the following tests shall be done on each of the
termination pre-molded or prefabricated stress relief cones and the housing:
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1.Partial Discharge Measurements The test shall be carried out in accordance with
ICEA T-24-380 or IEC 60885-2. The sensitivity of the partial discharge (PD)
measurements shall be 5 pC or better. The stress cone shall be installed on a length
of XLPE cable or a simulated accessory test mandrel, subject to agreement between
purchaser and manufacturer. The test voltage shall be raised gradually to and held
at 1.75 x Vgfor 10 seconds, and then slowly reduced to 1.5 x Vg. The magnitude of
the PD at 1.5 x Vgshall not exceed 5 pC.
2.Dimensional Checks The dimensions of the stress cone shall be measured and
checked against the tolerances established by the manufacturer. Checks shall
commence no earlier than the start of cable production.
3.Visual Inspection The bore of each stress cone shall be inspected with a fiber
scope or other suitable instrument to determine that there are no irregularities on the
surface of the bore. Each termination housing shall be visually inspected for the
presence of any defects prior to shipping.
%5! ,A.I'ICA(I)* (ES(S )* (ERI*A(I)*S
Qualification tests shall be done in accordance with IEEE 48 and IEC 60859 for installation in
GIS, as applicable, and as described herein.
Informative Note: Users are reminded that the IEEE 48 heating cycle voltage tests are
more severe than for IEC 60840 and 62067.
Terminations shall meet the qualification test requirements of IEEE 693 Recommended Practice
for Seismic Design of Substations, for Moderate Site, unless specifically excluded or moreonerous requirements are identified by the purchaser. IEEE 693 requires qualification by time-
history shaker table tests for voltage classifications 242 kV and static pull tests or time-history
shaker table tests for voltage classifications < 242 kV. The tests are done prior to the IEEE 48
qualification tests.
Static pull tests consist of pulling perpendicular to the top of the termination with a load twice the
operating weight of the termination. The load shall be applied for a minimum of 2 s. There shall
be no damage or cracks in any part, including the insulating housing, and no fluid leakage
before and after the static pull test.
Shaker table tests are described in IEEE 693.
%5!51 ualification (est for (er;ination ountin$ Insulators
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With the termination support structure connected to ground, 25 kVdc shall be maintained for one
minute across the termination mounting insulation, using the termination base plate for the
positive high voltage connection.
Having successfully withstood the application of dc voltage, the test assembly shall be submitted
to an impulse test. With the termination support structure grounded, ten positive, followed by
ten negative impulses shall be applied across the termination mounting insulation, using the
base plate for the high voltage connection. The magnitude of the impulses shall be in
accordance with Table 4.2-1 Each part to Ground.
Termination mounting insulators shall meet the requirements of IEEE 693, by being incorporated
into the termination assembly for the static pull tests or the time-history shaker table tests
described in 3.4.1.
!50 B)I*(S
!51 2E*ERA.
The manufacturer shall provide joints in accordance with the purchasers custom project
specification, suitable for jointing the cable supplied to the purchaser.
Joints shall comply with IEEE 404 and as described herein.
If required by the purchasers specification, manufacturers shall provide a copy of representative
qualification test reports for the proposed joints, with the proposal, or include such testing with
the proposal.
Each joint shall be packaged as a self-sufficient kit. It shall contain packing lists, instructions
and all permanent and consumable materials, as required for installation by qualified
Journeymen Cablemen, under the supervision of a manufacturers representative.
!58 SEA( SEC(I)*A.IDI*2 I*S,.A()RS A* B)I*( CASI*2 I*S,.A(I)*
Unless specifically excluded by the purchaser, joints shall be provided with a sheath
sectionalizing insulator with internal shield interrupt. The insulation of the two shall be
coordinated so that sectionalizing insulator voltage withstand is less than the internal shieldinterrupt. Both shall withstand the ac and transient over-voltages imposed on them during all
operating conditions, as described in the purchasers specification.
Joints supplied for use with dry insulation cables with a metallic moisture barrier, shall be
provided with a metallic casing enclosure to facilitate a continuous hermetic seal between the
two ends of the cable sheath.
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Joint casings shall be provided with an external anti-corrosion serving (jacket), to isolate the
metallic shield/sheath circuit from ground. It shall withstand the ac and transient over-voltages
induced onto it during all normal and abnormal operating conditions.
The sheath sectionalizing insulator and joint casing anti-corrosion covering designs shall ensure
long term ability to meet the above requirements and impulse withstand levels for 33 feet (10 m)
bonding leads, as described in Table 4.2-1 below. The table is derived from IEC 60840, IEC
62067 and the Electra No. 128 article Guide to the protection of specially bonded cable systems
to sheath over-voltages. It is also compatible with IEC 60229.
Table 4.2-1: Metallic Shield/Sheath Insulating Covering Impulse Withstand Voltage versus
BIL
Rated BIL for Main Insulation
kV
Impulse Test Level (1.2 x 50 sec)
Between Parts Each Part to Ground
Bonding
Cable Length
10
( 3m)
kV
Bonding
Cable Length
10 30
(3m 10m)
kV
Bonding
Cable Length
10
( 3m)
kV
Bonding
Cable Length
10 30
(3m 10m)
kV
250 to 325 60 60 30 30
550 to 750 60 75 30 37.5
1050 60 95 30 47.5
1175 to 1425 75 125 37.5 62.5
Notwithstanding the conservative assumption for testing based on 33 foot (10 m) bonding cable
length, connections shall be as short as possible to minimize surge voltage drop, especially
when exposed to high frequency transient over-voltages near GIS disconnects and breakers, or
near outdoor cable terminals exposed to lightning strikes.
The sheath sectionalizing insulators in joints shall withstand the Table 4.2-1 values Between
Parts. All other components, except link box insulation, shall withstand half these values.
The designs shall consider lifetime degradation due to repeated field voltage application,
moisture degradation, thermal degradation and a factor of safety.
Informative Note: The recommended approach is to design the insulating coverings for metallic
shield/sheath circuit components to withstand at least the Table 4.2-1 values throughout their
design life, but to also provide additional protection against transient over-voltages by applying
sheath voltage limiters (SVLs) with lower protective levels. (Reference Appendix 3)
!5% PR),C(I)* (ES(S )* B)I*(S
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Production tests shall be done in accordance with the requirements of IEEE 404. In addition,
the following tests shall be done on each of the joint pre-molded or prefabricated stress relief
cones:
1.Partial Discharge Measurements The test shall be carried out in accordance with
ICEA T-24-380 or IEC 60885-2. The sensitivity of the partial discharge (PD)
measurements shall be 5 pC or better. The stress cone shall be installed on a length
of XLPE cable or a simulated accessory test mandrel, subject to agreement between
purchaser and manufacturer. The test voltage shall be raised gradually to and held
at 1.75 x Vgfor 10 seconds, and then slowly reduced to 1.5 x Vg. The magnitude of
the PD at 1.5 x Vgshall not exceed 5 pC.
2.Dimensional Checks The dimensions of the stress cones shall be measured and
checked against the tolerances established by the manufacturer. Checks shall
commence no earlier than the start of cable production.
3.Visual Inspection The bore of each stress cone shall be inspected with a fiber
scope or other suitable instrument to determine that there are no irregularities on thesurface of the bore.
!5! ,A.I'ICA(I)* (ES(S )* B)I*(S
Qualification tests shall meet the requirements of IEEE 404 and as described herein. Users are
reminded that the IEEE 404 heating cycle voltage tests are more severe than for IEC 60840 and
62067.
IEC 60840 and 62067 impulse voltage tests for joints embodying sheath sectionalizing
insulation and insulating coverings are more severe than IEEE 404-2000 for main insulation BILgreater than 1050 kV. Therefore, for cables with main insulation BIL greater than 1050 kV, the
external insulation of sheath sectionalizing joints shall meet the test requirements described in
Table 4.2-1. The joint casing insulation shall also be proven to withstand at least 25 kVdc for
one minute, applied between the joint casing and the external electrode of the submerged joint.
&50 SEA( )*I*242R),*I*2 SS(ES
&51 2E*ERA.
Sheath Bonding/Grounding systems shall provide the sheath circuit interconnection andinsulation protection systems described in Electra No. 128 article Guide to the protection of
specially bonded cable systems to sheath over-voltages. The systems shall consist of bonding
cables, link boxes and sheath voltage surge arresters, as required for an insulated sheath
power cable system, as defined in the Electra No. 128 article.
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Over-voltage protection shall be used for GIS terminations to limit transient over-voltages
between the cable sheath and the GIS enclosure, as described in IEC 60859 and Electra No.
151 Article: Earthing of GIS An Application Guide.
If specified by the purchaser, the manufacturer shall provide drawings of the sheath
bonding/grounding system and calculations of expected sheath voltages and currents, done in
accordance with the Electra No. 128 article (reference Appendix 10 Information to be Submitted
After Award of Contract).
Ratings described below assume use on an effectively grounded system.
&5151 ondin$ Cables
Single conductor bonding cables shall meet the requirements of ICEA S-105-692, except that
the minimum average insulation thickness shall be 130 mils (3.3 mm).
Bonding cable connections to link boxes shall be as short as possible, but no greater than 33
feet (10 m) in total length to a ground point. They shall be single conductor construction,
provided the frequency of transient over-voltages is less than 25 kHz and the bonding cables
from adjacent phase connections are touching each other. For transient frequencies greater
than 25 kHz, the manufacturer shall provide concentric bonding cables, as agreed to with the
purchaser. Concentric bonding cables shall meet the requirements of ICEA S-94-649 except
that:
the minimum average central insulation thickness shall be 180 mils (4.6 mm)
the minimum average external insulation (jacket) thickness shall be 130 mils (3.3 mm) conductor and insulation shields shall be eliminated
the central concentric and conductors shall be identical in area and material (full neutral)
All conductors shall be designed to withstand the rated fault current and duration, as well as the
sheath currents corresponding to emergency loading. The insulation shall withstand the same
impulses as the main cable jacket and joint casing insulation, as described in Table 4.2-1.
Bonding cables used as a parallel earth continuity conductor (reference Electra No 128 article,
Fig. 4) shall be identical to those described in the foregoing, except that their conductors only
need to be designed to withstand the rated fault current and duration.
&5158 .in" oxes
Link boxes shall be designed for central water-tight interconnection of sheath cross-bonding,
single point bonding and grounding systems.
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Link boxes shall incorporate removable links, to easily isolate sections of sheath circuit for
maintenance dc testing of cable jackets, joint sectionalizing insulators, termination mounting
insulators, etc. The links shall also be designed to easily re-configure the bonding connection
system to solidly bonded.
At cross-bonding locations, or single point bonding open point locations, link boxes shall also
incorporate sheath voltage limiters (SVLs) to protect the sheath circuits insulation from transient
over-voltages.
Link box conducting components shall be designed to withstand the rated fault current and
duration.
The insulation between the links in all link boxes, including those without SVLs, shall be capable
of withstanding the following voltages, with an additional 25% margin to allow for variability in
service:
i) The dc voltage used for qualification tests (25 kV + 25% for one minute), initial
commissioning tests (24 kV maximum +25% for one minute) and maintenance testing of
the sheath insulation circuit (5 kV dc maximum for 1 minute)
ii) The highest power frequency voltage arising between sheaths during an external system
fault + 25%
iii) A 1.2/50 microsecond impulse voltage with a maximum value equal to the protective
level as defined in the referenced Electra No. 128 article, paragraphs 5.1.4 and 5.2.3, +
25%, noting that if the SVLs are connected in star, the protective level must be doubled
to allow for the fact that two SVLs are connected in series between each pair of sheaths.
Water-tightness of the link box enclosures shall meet the requirements of IEC 60529, with the
specific IP Code classification as agreed to between the manufacturer and purchaser,
depending on location of the installation (in manholes periodically submerged, in dry manholes
or tunnels, above ground outdoors, above ground indoors, etc.). Alternatively, they shall meet
the requirements of NEMA 250, based on agreement between the purchaser and manufacturer.
(Users are reminded that NEMA 250 Appendix A contains an equivalency conversion from
NEMA to IEC classifications.)
&515% Sheath #olta$e .i;iters
Sheath voltage limiters (SVLs) shall meet the requirements of IEEE C62.11 Standard for Metal-
Oxide Surge Arresters for AC Power Circuits (> 1 kV).
The metal oxide component of the SVLs shall be encased in a waterproof material to prevent
absorption of moisture.
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The SVLs shall be capable of withstanding continuously the sheath standing voltage applied to
them during full load or emergency overload.
The SVLs shall be capable of withstanding the highest power frequency voltage applied to them
during system faults, for the maximum fault current duration specified by the purchaser.
The residual voltage protective level of each SVL shall be less than the impulse withstand levels
of the sheath insulating circuit, taking into account surge voltage drop in bonding cable leads
and SVL connection methods.
&58 PR),C(I)* (ES(S )* SEA( )*I*242R),*I*2 SS(ES
Production tests on single conductor bonding cables shall meet the requirements of ICEA S-
105-692.
Production tests on SVLs shall meet the requirements of IEEE C62.11.
Production tests on link box water-tightness shall meet the requirements of IEC 60529 or NEMA
250. They shall also demonstrate the ability to withstand a dc test voltage of 25 kV +25% for
one minute, between the conducting components and ground.
&5% ,A.I'ICA(I)* (ES(S )* SEA( )*I*242R),*I*2 SS(ES
Qualification tests on single conductor bonding cables shall meet the requirements of ICEA S-
105-692 and as described herein. They shall also demonstrate the ability to withstand the
impulse test voltages described in Table 4.2-1.
Qualification tests on SVLs shall meet the requirements of IEEE C62.11.
Qualification tests on link box water-tightness shall meet the requirements of IEC 60529 or
NEMA 250.
In addition, link boxes shall withstand a water immersion test followed by an impulse voltage test
carried out on one assembly, as described in the Electra No. 75 article: Recommendations for
tests on anti-corrosion coverings of self contained pressure cables and accessories and
equipment for specially bonded circuits. The test voltages shall be in accordance with section5.1.2 above.
650 ,A.I'ICA(I)* (ES(S )* C)P.E(E CA.E SS(E
For rated voltages >46 kV to 150 kV, if required by the purchasers specification, the
manufacturer shall demonstrate satisfactory performance of a complete system comprised of
cable and at least one of each type of accessory to be provided. Demonstration shall consist of
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meeting the requirements of IEC 62067 Section 12. Type tests on cable systems, with the
Voltage Test done at 2.5 x Uo (Vg) for 30 minutes (as described in IEC 60840).
For rated voltages > 150 kV to 345 kV, the manufacturer shall demonstrate satisfactory
performance of a complete system comprised of cable and at least one of each type of
accessory to be provided. Demonstration shall consist of meeting the requirements of IEC
62067 Section 12. Type tests on cable systems.
651 RA*2E )' APPR)#A.
IEC 62067 Section 12.2 describes the Range of type approval and the validity of type, or
qualification, tests done on other similar cables and accessories, with respect to the purchasers
intended application. The same provisions shall apply equally to this specification,except for the
specific additions shown in brackets and underlined below.
When the type tests have been successfully performed on one cable system of specific cross-section, rated voltage and construction, the type approval shall be accepted as valid for cable
systems within the scope of this standard with other cross-sections, rated voltages and
constructions if the following conditions are met:
a)the voltage group is not higher than that of the tested cable system;
NOTE In this context, cable systems of the same rated voltage group are those of rated voltages
having a common value of Um[Vm], highest voltage for equipment, and the same test voltage values.
b)the conductor cross-section is not larger than that of the tested cable;
c)the cable and the accessories have the same or a similar construction as that of the tested
cable system;NOTE Cable and accessories of similar construction are those of the same type and manufacturing
process of insulation and semi-conducting screens. Repetition of the electrical type tests is not
necessary on account of the differences in the conductor type or material or of the protective layers
applied over the screened cores or over the main insulation part of the accessory, unless these are
likely to have a significant effect on the results of the test. In some instances, it may be appropriate to
repeat one or more of the type tests (e.g. bending test, heating cycle test and/or compatibility test).
d)calculated maximum electrical stresses on the conductor and insulation screens, in the main
insulation part(s) of the accessory and in boundaries [or interfaces] are equal to or lower
than for the tested accessory.
NOTE If the voltage group is the same, if the cable conductor cross-section is smaller and if the
insulation thickness is not less than that of the tested cable, calculated maximum stress on the
conductor may be 10% higher than that of the tested cable.
e) [material compositions, manufacturing processes, manufacturing plants, and equipment
used for making the cable and accessories subjected to the tests, have not significantly
changed].
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The type tests on cable components (see IEC 62067 clause 12.5) need not be carried out on
samples from cables of different voltage ratings and/or conductor cross-sectional areas unless
different materials are used to produce them. However, repetition of the aging tests on pieces of
complete cable to check compatibility of materials (see IEC 62067 clause 12.5.4), may be
required if the combination of materials applied over the screened core is different from that of
the cable on which the type tests have been previously carried out.
A type test certificate signed by the representative of a competent witnessing body, or a
[notarized] report by the manufacturer giving the test results and signed by the appropriate
qualified officer, or a test certificate issued by an independent test laboratory, shall be
acceptable as evidence of type testing.
=50 PRE-,A.I'ICA(I)* (ES(S )* C)P.E(E CA.E SS(E
For applications with a rated voltage greater than 150 kV, the manufacturer shall demonstrate
satisfactory, long-term performance of a complete system, comprised of cable and at least oneof each type of accessory to be provided. Demonstration shall consist of meeting the 365 day
test requirements of IEC 62067 Section 13. Pre-qualification test of the cable system, with
modifications to demonstrate performance at emergency conductor temperatures, as described
in section 1.9 preceding. Alternative long term tests may be accepted, as agreed to between the
purchaser and manufacturer, and provided they are applicable to the specific installation
conditions.
The above tests shall also be done for applications with a rated voltage above 46 kV to 150 kV,
with stresses greater than 200 V/mil (8.0 kV/mm) at the cable conductor shield, or greater than
100 V/mil (4.0 kV/mm) over the cable insulation, subject to agreement between the purchaserand the manufacturer.
=51 RA*2E )' APPR)#A.
IEC 62067 Section 13.1 describes the Range of pre-qualification test approval and the validity
of tests done on other similar cables and accessories, with respect to the purchasers intended
application. The same provisions shall apply equally to this specification,except for the specific
additions shown in brackets and underlined below.
When a pre-qualification test has been successfully performed on a cable system, it qualifies themanufacturer as a supplier of [similarly constructed] cable systems with the same or lower
voltage ratings, as long as the calculated electrical stresses at the insulation screen are equal to
or lower than for the system tested [and material compositions, manufacturing processes,
manufacturing plants, and equipment used for the cable system subjected to the tests, have not
significantly changed].
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A pre-qualification test certificate signed by the representative of a competent [independent]
witnessing body, or a [notarized] report by the manufacturer giving the test results and signed by
the appropriate qualified officer, or a test certificate issued by an independent test laboratory
shall be acceptable as evidence of pre-qualification testing.
>50 E.EC(RICA. (ES(S A'(ER I*S(A..A(I)*
Installation of cable systems is not included in this specification and therefore Electrical Tests
After Installation do not form a direct part of it. However, testing of the completed cable system
after installation shall be subject to mutual agreement between the purchaser and manufacturer
prior to testing. For information purposes, general recommendations are described in Appendix
7 and in ICEA S-108-720.
950 ,A.I( ASS,RA*CE
951 ,A.I( SS(E RE,IREE*(S
The manufacturer shall have a current quality assurance program and manual in place, for each
factory engaged in the work. It shall conform to ISO 9001 or equivalent, as acceptable to the
purchaser and registered by an accredited agency.
If required by the purchasers specification, the manufacturer shall submit a copy of their quality
assurance plans with their proposal (reference Appendix 9 Manufacturers Technical Declaration
File).
958 A*,'AC(,RI*2 I*SPEC(I)* A* (ES( P.A*
If required by the purchasers specification, within two weeks after a contract is awarded, the
manufacturer shall submit to the purchaser for acceptance, a final Inspection and Test Plan,
conforming to the requirements of ISO 9001 or equivalent (reference Appendix 10 Information to
be Submitted after Award of Contract). The Inspection and Test Plan shall be detailed and shall
include at least the following categories: Material or Parameter to be controlled; Method of
Inspection/Tests and Equipment Used; Frequency of the Inspection/Test; Reference Documents
Governing the QA Activity; QA Record Form; agreed Review/Witness/Hold points, etc.
The Inspection and Test Plan shall contain details of quality assurance activities to be performedfor all materials, manufacturing and handling processes. Inspection and test review/witness/hold
points shall be jointly established between the manufacturer and purchaser. If sub-contractors
are employed, the Inspection and Test Plan shall indicate the portion of the work that will be
undertaken by them, including their inspection and testing.
95% 'AC()R I*SPEC(I)*
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The manufacturer shall carry out such inspections and tests, in accordance with the accepted
Inspection and Test Plan to verify the conformity of each part of the work in accordance with
this specification. At least 7 working days written notice, prior to each established witness/hold
point, shall be given to the purchaser to allow for arrangements to be made for his attendance.
95! I*SPEC(I)* A* A,I( (E P,RCASER
Any quality assurance inspection carried out by the purchaser shall in no way relieve the
manufacturer of full responsibility for the quality, character or performance of the completed
work.
95& ACCESS () ,A.I( ASS,RA*CE A* (ES( )C,E*(S
When requested, the manufacturer shall provide timely access to, and copies of, the following
documents: shop travelers, detailed shop inspection procedures, certifications, qualifications,
inspection and test results, production records, process control charts, calibration certification
records and other quality assurance documents, compiled during the work.
956 *)*-C)*')RA*CE REP)R(S
The manufacturer shall provide non-conformance reports (NCRs) to the purchaser, for review
and acceptance, in accordance with ISO 9001 paragraph 4.13, or equivalent, for all major
factory non-conformances to this specification. The requirement for NCRs includes work by
sub-contractors. All NCRs shall include the manufacturers proposed disposition and/or
corrective action. The manufacturer shall establish criteria for submission of NCRs to the
purchaser, including the definition of major and minor non-conformances, with submission of the
Inspection and Test Plan. Unless otherwise agreed to between purchaser and manufacturer,
NCRs shall be submitted within 24 hours of the manufacturers discovery of the non-
conformance.
The above requirement is limited to only products which the manufacturer plans to supply to the
purchaser.
95= 'I*A. ,A.I( ASS,RA*CE REP)R(
If specified by the purchaser, the manufacturer shall submit three certified copies of the finalquality assurance reports, to the purchaser, certifying the compliance of the work to this
specification, including all assembly and test data required in the Inspection and Test Plan,
within one week of completion of final inspection and testing. The final quality assurance report
shall be a bound collection of relevant quality assurance documents as listed below, compiled
during the manufacture of the work.
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Unless limited by the purchasers specification, the final quality assurance report shall include at
least:
Sub-contractor inspection reports
Receiving inspection reports
Mill test certificates
Cable insulation quality reports
Material qualification reports
Component dimensional inspection data reports
Instrument and Gauge calibration certificates and records
Component test reports
Accepted non-conformance reports
Certified Test Reports in accordance with the specification
1050 SIPPI*2
1051 CA.E REE.S
105151 Cable Reel Pac"in$@ Sealin$@ and Shippin$
The cables shall be placed on reels so that they are protected from damage during shipment.
Each end of the cable shall be firmly and properly secured to the reel. Care shall be taken to
ensure that the cable is tightly wrapped to prevent movement during transportation.
There shall be no water in the completed cable when the reel is shipped.
Each length of cable listed on the purchaser's order or detail list shall be shipped on a separate
reel unless specifically agreed to between the purchaser and manufacturer.
The reels shall be lagged or covered with suitable material to provide physical protection for the
cables during transit and during ordinary storage and handling operations.
105158 Reel i;ensions
The minimum drum diameters for shipping reels shall be determined by the manufacturer. Reel
construction and dimensions shall comply with NEMA WC 26.
If the cable has a metallic sheath, the minimum drum diameter of the reels shall be in
accordance with the following Table 10.1-1, or as otherwise agreed to between the purchaser
and manufacturer.
Table 10.1-1 Minimum Drum Diameter for Various Metallic Sheath Types
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Sheath TypeInsulation Thickness
mils (mm)
Ratio of Outside Diameter of Reel
Drum to Cable Outside Diameter
Lead < 500 (12.7) 14
Lead 500 to 800 (12.7 to 20.3) 18
Lead > 800 (20.3) 22
Aluminum (smooth
tubular)30
Aluminum (smooth
tubular, bonded to
jacket)
18
Corrugated Metallic
(copper or aluminum)< 800 mils (20.3 mm) 18
Corrugated Metallic
(copper or aluminum)
> 800 mils (20.3 mm) 22
The inner or drum end of the cable, when allowed to project through the flange of the reel, shall
be protected to avoid damage to the cable or seal.
10515% ar"in$ on Reels
Each reel shall be marked with a durable label securely attached to the outside of a flange. The
label shall plainly state all the identification information described in section 2.9, as well as the
following:
manufacturers name and address
purchaser's order and contract number
destination
shipping length of cable on reel
reel identification number
conductor size
type of cable
thickness and type of insulation
voltage rating
gross, tare and net weight
Each reel shall be marked with an arrow on the flange indicating the direction the reel is to be
turned to unwind the cable.
Each reel shall be identified with a number permanently attached to the outside of a reel flange.
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Shipping reels shall be free of any information not pertaining to the order.
10515! Cable End 'ittin$s
Cables with a metallic moisture barrier shall have their ends hermetically sealed from moisture
entry with durable and effective metallic end caps. Special consideration shall be given to
effectively sealing cables with longitudinally applied metal foil moisture barriers.
A pulling eye, approved by the purchaser, shall be attached at the outside end of each shipping
length. The pulling eye shall be suitable for pulling the cable through wet or dry ducts or pipes,
tr