ICEA S-94-649-2004

STANDARD FOR CONCENTRIC NEUTRAL CABLES

Approved by AMERICAN NATIONAL STANDARDS INSTITUTE

0 2 0 0 4 by

S TA N D A R D F O R

Standard

Approved by Insulated Cable Engineers Association, Inc.: August 31, 2004 Accepted by IEEEíICC2-A 14: September 9,2004 Accepted by AEIC: Cable Engineering Committee: September 13, 2004 Approved by ANSI: September 20,2005

including translation into other languages, reserved under the Universal Copyright and the international and Pan American Copyright Conventions.

NOTICE AND DISCLAIMER The information in this publication was considered technically sound by the consensus of persons not necessarily mean that there is unanimous agreement among every person participating in the development of this document. The Insulated Cable Engineers Association, Inc. (ICEA) standards and guideline publications, of which the document contained herein is one, are developed through a voluntary consensus standards development process. This process brings together persons who have an interest in the topic covered by this publication. While ICEA administers the process and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or verify the accuracy or completeness of any ICEA disclaims liability for personal injury, property, or other damages of any nature whatsoever, whether application, or reliance on this document. ICEA disclaims and makes no guaranty or warranty, expressed or implied, as to the accuracy or completeness of any information published herein, and disclaims and makes no warranty that the information in this document will fulfill any of your particular purposes or needs. ICEA does not undertake to guarantee the performance of any individual manufacturer or seller's products or services by virtue of this standard or guide. other services for or on behalf of any person or entity, nor is ICEA undertaking to perform any duty owed by reasonable care in any given circumstances. Information and other standards on the topic covered by this publication may be available from other sources, which the user may wish to consult for additional views or information not covered by this publication. document. ICEA does not certify, test, or inspect products, designs, or installations for safety or health purposes. Any certification or other statement of compliance with any health or safety-related information in statement.

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DATE: 10/14/04

FOREWORD

developed by the Insulated Cable Engineers Association Inc. (ICEA). for his particular need. Existence of an ICEA standard does not in any respect preclude the manufacture or conformity with this Standard. be provided. Suggestions for improvements gained in the use of this Standard will be welcomed by the Association.

and Electronics Engineers, Insulated Conductors Committee, Subcommittee A, Discussion Group A-1 4 for following:

F. Kuchta, Chairman

P. Cinquemani

D. Fox B. Temple

N. Ware

I

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S. Campbell R. Fleming

A. Pack B. Vaughn

ICEA S-94-649-2004

DATE: 10/14/04

1.2 GENERAL INFORMATION ...................................................................................................................1 1.3 INFORMATION TO BE SUPPLIED BY PURCHASER ........................................................................ 1 2 2

5 2.1.1 Copper Conductors ................................................................................................................... 2.1.2 5 2.2 OPTIONAL SEALANT FOR STRANDED CONDUCTORS ................................................................. 2.3 CONDUCTOR SIZE UNITS ................................................................................................................... 6 6 6 2.4.1 2.4.2

13 3.2 EXTRUDED SHIELD THICKNESS ..................................................................................................... 13 3.2.1 3.3 PROTRUSIONS AND CONVOLUTIONS ...........................................................................................13 3.4 VOIDS ................................................................................................................................................... 14 3.6.1 3.6.2 Extruded Nonconducting Material (For EPR Insulation Only) ................................................ 3.6.3 Semiconducting Tape ............................................................................................................. 14

Part 4 INSULATION........................................................................................................................................ 4.2.1 4.2.1.1 4.2.1.2 4.2.1.3

14

15 16 16 16

For Delta Systems Where One Phase May Be Grounded For Periods Over One Hour ..........................................................................................................

16 16

16

4.3.1 4.3.2 Electrical Requirements .......................................................................................................... 17 Partial-DischargeExtinction Level for Discharge-Free Designs Only ...................... 17 4.3.2.1 4.3.2.2 Voltage Tests ............................................................................................................. 18 4.3.2.3 Insulation Resistance Test ........................................................................................ 18 4.3.2.4 Dielectric Constant and Dissipation Factor ............................................................... 18 4.3.2.5 18

II

DATE: 10/14/04 4.3.3.1 4.3.3.2 4.3.4

Part 5.1 5.2 5.3 5.4

19

EXTRUDED INSULATION SHIELD ....................................................................................................22 THICKNESS AND INDENT REQUIREMENTS .................................................................................. 22 PROTRUSIONS ................................................................................................................................... 23 INSULATION SHIELD REQUIREMENTS .......................................................................................... 23 23 5.4.1 Insulation Shield for DISCHARGE-FREE Cable Designs Only ............................................. Removability .............................................................................................................. 23 5.4.1.1 Voids .......................................................................................................................... 5.4.1.2 23 5.4.1.3 Electrical Requirements ............................................................................................ 24 5.4.1.4 Wafer Boil Test ........................................................................................................... 24 5.4.1.5 24 5.4.2 Insulation Shield for DISCHARGE-RESISTANTCable Designs Only .................................. .. .............................................................................................................. 24 Removability 5.4.2.1 5.4.2.2 Electrical Requirements ............................................................................................ 24 5.4.2.3 Wafer Boil Test .......................................................................................................... 24 5.4.2.4

Part 25 6.1 25 6.2 25 6.3 LAY LENGTH ....................................................................................................................................... 6.4 CONCENTRIC WIRES ......................................................................................................................... 25 6.4.1 Minimum Sizes ........................................................................................................................ 25 6.4.2 Contrahelical Wire ................................................................................................................... 25 6.4.3 Diameter and Area .................................................................................................................. 25 6.5 FLAT STRAPS ..................................................................................................................................... 26 OPTIONAL WATER BLOCKING COMPONENTS FOR METALLIC SHIELD ................................. 6.6

26

28 Pari JACKETS ............................................................................................................................................. 28 7.1 7.1.1 Low and Linear Low Density Polyethylene, Black (LDPULLDPE) ........................................ 28 29 7.1.2 Medium Density Polyethylene, Black (MDPE) ........................................................................ High Density Polyethylene, Black (HDPE) .............................................................................. 30 7.1.3 31 7.1.4 Semiconducting Jacket Type II ............................................................................................... 32 7.1.5 7.1.6 Polyvinyl Chloride (PVC) ......................................................................................................... 33 7.1.7 Chlorinated Polyethylene (CPE) ............................................................................................. 34 7.1.8 Thermoplastic Elastomer (TPE) ............................................................................................. 35 7.1.9 Polypropylene, Black (PP) ...................................................................................................... 36 JACKET TYPES ................................................................................................................................... 37 7.2 7.2.1 Extruded-To-FillJacket ........................................................................................................... 37 7.2.2 Overlaying Jacket .................................................................................................................... 37 JACKET IRREGULARITY INSPECTION ........................................................................................... 37 7.3 7.3.1 Nonconducting Jackets ........................................................................................................... 37 7.3.2 Semiconducting Jackets ......................................................................................................... 37

Part 8.1

...

III

DATE: 10/14/04 8.2.1 Jacketed Cable ....................................................................................................................... 39 39 8.2.2 Unjacketed Cable .................................................................................................................... 39 8.2.3 8.2.4

Part 9.1 TESTING .............................................................................................................................................. 41 9.2 9.3 CONDUCTOR TEST METHODS ........................................................................................................ 41 9.3.1 41 Cross-Sectional Area Determination ...................................................................................... 41 9.3.2 9.3.3 9.4 9.4.2 Measurement of Thickness .................................................................................................... 41 9.4.2.1 9.4.2.2 42 9.4.3 Size of Specimens .................................................................................................................. 42 9.4.4 9.4.5 9.4.6 43 9.4.7 Calculation of Area of Test Specimens .................................................................................. 43 9.4.8 Test Temperature ...................................................................................................... 43 9.4.8.1 Type of Testing Machine ........................................................................................... 44 9.4.8.2 Tensile Strength Test ................................................................................................ 44 9.4.8.3 Elongation Test .......................................................................................................... 44 9.4.8.4 Aging Tests ............................................................................................................................. 44 9.4.9 Aging Test Specimens .............................................................................................. 44 9.4.9.1 Air Oven Test ............................................................................................................. 45 9.4.9.2 45 9.4.9.3 45 9.4.1 1 Solvent Extraction ................................................................................................................... 45 45 9.4.12.1 9.4.1 3 Amber, Agglomerate, Gel, Contaminant, Protrusion, Indent, Convolutions and Void Test ................................................................................................................................. 46 Sample Preparation ................................................................................................... 46 9.4.1 3.1 9.4.1 3.2 Resampling for Amber, Agglomerate, Gel, Contaminant, 9.4.1 3.3 Protrusion, Convolutions and Void Test .................................................................... 46 Protrusion, Indentation and Convolutions Measurement Procedure ....................... 9.4.1 3.4 46 9.4.1 4 Internal Irregularity Test Procedure for Crosslinked Polyethylene Insulation 9.4.1 4.1 9.4.14.2 9.4.14.3

Sample Preparation ...................................................................................................

47

Resampling for Internal Irregularity Test ................................................................... 48

Test Sample .............................................................................................................. 48 9.4.1 5.1 48 9.4.1 5.2 9.4.1 5.3 48 9.4.16 Retests for Physical and Aging Properties and Thickness ....................................................... 48

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ICEA 5-94-649-2004

49 49

9.6

9.7.1 Heat Shock .............................................................................................................................. 49 9.7.2 50 9.7.3 50 9.8 VOLUME RESISTIVITY .................................................................................................... 50 9.8.1 Conductor Shield (Stress Control) .......................................................................................... 9.8.2 Insulation Shield ...................................................................................................................... 50 9.8.3 Test Equipment ....................................................................................................................... 51 9.8.4.1 9.8.4.2 9.8.4.3 51 9.8.5 Semiconducting Jacket Radial Resistivity Test ...................................................................... 9.8.5.1 52 Test Equipment Setup ............................................................................................... 52 9.8.5.2 Calculation ................................................................................................................. 53 9.8.5.3 9.9 ADHESION (Insulation Shield Removability) TEST ........................................................................ 54 9.10 SHRINKBACK TEST PROCEDURE ............................................................................................. 54 9.10.1 Sample Preparation ................................................................................................................ 54 54 9.1 0.2 54 9.11 54 AC VOLTAGE TEST ....................................................................................................................... 55

9.1

55 9.1 .2 AC Voltage Test ...................................................................................................................... PARTIAL-DISCHARGETEST PROCEDURE ............................................................................... 55

DIELECTRIC STRENGTH OF EXTRUDED NONCONDUCTING POLYMERIC STRESS CONTROL LAYERS ................................................................................ 55 55 9.1 5.1 Water Under the Jacket .......................................................................................................... 55 9.1 5.2 Water in the Conductor ...........................................................................................................56 9.1 5.3 Water Expulsion Procedure.................................................................................................... 56 9.1 5.4 Presence of Water Test .......................................................................................................... 56 9.16 PRODUCTION TEST SAMPLING PLANS .................................................................................... 57 Part 10 10.0 GENERAL ....................................................................................................................................... 60 10.1 CORE QUALIFICATIONTESTS .................................................................................................... 60 10.1.1 Material Qualification Requirements ....................................................................................... 60 Conductor Shield/lnsulation Qualification ................................................................. 60 10.1.1.1 10.1.1.2 61 Manufacturing Qualification Requirements ............................................................................ 61 10.1.2 Conductor Shield/lnsulation Test ..............................................................................61 10.1.2.1 Insulation/lnsulation Shield Test ................................................................................61 10.1.2.2

10.1.4 Hot Impulse Test Procedure ................................................................................................... 64 10.1.5 Cyclic Aging ............................................................................................................................. 64 Cable Length ............................................................................................................. 64 Sample Preparation ................................................................................................... 64 10.15.2 10.1.5.3

V

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ICEA S-94-649-2004

DATE: 10/14/04

Load Cycle ................................................................................................................. 10.1 5 4 65 65 10.1.6 Accelerated Water Treeing Test (AWTT) Procedure ............................................................ General ...................................................................................................................... 65 10.1.6.1 Quantity of Cable To Be Aged ................................................................................... 65 10.1.6.2 10.1.6.3 Conduit Fixture .......................................................................................................... 65 10.1.6.4 10.1.6.5 10.1.6.6 10.1.6.7 10.1.6.8 10.1.6.9 1 0.1.6.1

66 Water ......................................................................................................................... 66 Ambient Temperature ............................................................................................... 66 Test Procedure .......................................................................................................... 66 Water pH ................................................................................................................... 68 68 69

10.1.8 Qualification Test Physical Measurements ............................................................................ 10.2.1

Scope ......................................................................................................................................

10.2.2.1 10.2.2.2 10.2.2.3 10.2.2.4

Fixture ........................................................................................................................ Load Cycling ..............................................................................................................

70

70 70 70 70 71

JACKET MATERIAL QUALIFICATION TESTS ............................................................................ 72 10.3.1 Polyethylene And Polypropylene Jackets ............................................................................... 72 10.3.1.1 73 10.3.1.1.2 Test Procedure ................................................................................................... 73 Absorption Coefficient Test ....................................................................................... 73 10.3.1.2 10.3.2 SemiconductingJackets ......................................................................................................... 73 10.3.2.1 73 10.3.3 Polyvinyl Chloride and Chlorinated Polyethylene Jackets ...................................................... 73 10.3.3.1 73 10.3.3.1.1 Test Samples...................................................................................................... 73 10.3.3.1.2 Test Procedure ................................................................................................... 73 73 10.3.4 Extruded Red Stripe For Jackets ............................................................................................ 10.3.4.1 73 10.3.4.1.1 Test Samples ...................................................................................................... 74 10.3.4.1.2 Test Procedure ................................................................................................... 74 10.4 CV EXTRUSION QUALIFICATION TEST ..................................................................................... 74 10.4.1 Thermal Conditioning .............................................................................................................. 74 10.4.2 Dissipation Factor Verification ................................................................................................ 74 10.4.3 AC Withstand Verification ....................................................................................................... 74 10.5 OTHER QUALIFICATION TESTS .................................................................................................75 10.5.1 Insulation Resistance ..............................................................................................................75 10.5.2 Accelerated Water Absorption Tests ...................................................................................... 75 10.5.3 Resistance Stability Test ......................................................................................................... 76 10.5.4 Brittleness Temperature for Semiconducting Shields ............................................................ 76 76 Test Samples ............................................................................................................. 76 10.5.5.1 10.5.5.2 76 10.5.5.3 10.3

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ICEA S-94-649-2004

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10.5.6.1 Test Environment ...................................................................................................... 77 10.5.6.2 10.5.6.3 10.5.7 Dissipation Factor CharacterizationTest ................................................................................ 78 10.5.7.1 Thermal Conditioning ................................................................................................ 78 10.5.7.2 Dissipation Factor Testing ......................................................................................... 78 10.5.7.3 Part 11 APPENDICES ................................................................................................................................. 79 NEMA. ICEA. IEEE. ASTM AND ANSI STANDARDS (Normative) ....................... 79 APPENDIX A Al 79 A2 IEEE AND ANSI STANDARDS .............................................................................................. 79 A3 A4 79 EMERGENCY OVERLOADS (Normative) ............................................................. 82 APPENDIX APPENDIX C SHIELDING (Informative) ........................................................................................ 88 APPENDIX D DEFINITION OF SHIELDING................................................................................................. 88 Dl FUNCTIONS OF SHIELDING ................................................................................................ 88 D2 USE OF INSULATION SHIELDING ....................................................................................... 88 D3 D4 D5 89 SPLICES AND TERMINATIONS ........................................................................................... 89 D6 HANDLING AND INSTALLATION PARAMETERS (Informative) ......................... 90 90 El 90 E2 DRUM DIAMETERS OF REELS ............................................................................................ 90 E3 MAXIMUM TENSION AND SIDEWALL BEARING PRESSURES ....................................... 90 E4 90 E5 During Installation ...................................................................................................... 90 E5.1 E5.2 90 In Service ................................................................................................................... E5.3 90 OPTIONAL FACTORY DC TEST (Informative) ..................................................... 92 APPENDIX F REDUCED NEUTRAL DESIGNS (Informative) ..................................................... 93 APPENDIX G ADDITIONAL CONDUCTOR INFORMATION (Informative) ................................. 97 APPENDIX H ETHYLENE ALKENE COPOLYMER (EAM) (Informative) ................................. 100 APPENDIX REVISED AWTT CONDUIT FIXTURES (Informative) ......................................... 101 APPENDIX INSULATION COMPOUND INSPECTION (Normative) ...................................... 102 APPENDIX K SCOPE .................................................................................................................................. K1 102 PROCEDURE ....................................................................................................................... K2 102 Compound Tape Inspection Sampling Plan ........................................................... 102 K2.1 102 K2.2

Table 2-1 Table 2-2 Table 2-3

Weight Increment Factors ........................................................................................... 7 Schedule for Establishing Maximum Direct Current Resistance 7 of Solid and Concentric Lay Stranded Conductor ...................................................

8

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ICEA 5-94-649-2004

DATE: 10/14/04

Table 2-3 (Metric)

of Solid and Concentric Lay Stranded Conductor ................................................... Nominal Diametersfor Copper and Aluminum Conductors ................................. 10 Table 2-4 Table 2-4 (Metric) Nominal Diametersfor Copper and Aluminum Conductors ................................. 11 Factors for Determining Nominal Resistance of Stranded Conductors Table 2-5 Per 1000 Feet at 25 OC ................................................................................................ 12 Extruded Conductor Shield Thickness .................................................................... 13 Table 3-1 Extruded Conductor Shield Requirements ............................................................. 14 Table 3-2 Conductor Maximum Temperatures ........................................................................15 Table -1 Table 4-2 Dielectric Constant and Dissipation Factor ............................................................ 18 Table 4-3 Shrinkback Test Requirements Cables Having Sealed Strand Table 4-4 Conductors and/or a Tape Over the Conductor ..................................................... 19 Shrinkback Test Requirements All Cables Not Covered by Table 4-4 .................19 Table 4-5 Cable BIL Values ......................................................................................................... 20 Table 4-6 Conductor Sizes. Insulation Thicknesses and Test Voltages .............................. 20 Table 4-7 Conductor Sizes. Insulation Thicknesses and Test Voltages .............................. 21 Table 4-7 (Metric) Insulation Shield Thickness Cables With Wire Neutral ......................................... 22 Table 5-1 Extruded Insulation Shield Requirements Discharge-Free Designs ................... 23 Table 5-2 Table 5-3 Concentric Neutral Wire Size ....................................................................................26 Table 6-1 Full Neutral Concentric Copper Conductor ............................................................ 26 Table 6-2 One-third Neutral Concentric Copper Conductor .................................................. 27 Table 6-3 Table 7-1 Medium Density Polyethylene, Black (MDPE) ......................................................... 29 Table 7-2 Table 7-3 31 Table 7-4 Semiconducting Jacket Type II ................................................................................. 32 Table 7-5 Table 7-6 Chlorinated Polyethylene (CPE) ............................................................................... 34 Table 7-7 Thermoplastic Elastomer (TPE) ................................................................................ 35 Table 7-8 Polypropylene, Black (PP) ......................................................................................... 36 Table 7-9 Extruded-To-Fill Jacket Thickness and Test Voltage ............................................ Table 7-10 37 Table 8-1 Table 9-1 Table 9-2 Table 9-3 Table 9-4 Table 9-5 Table 9-6 Table 9-7 Table 10-1 Table 10-2 Table 10-3 Table 10-4 Table 10-5 Table C-1 Table C-3 Table C-5 Table E-1

40

Test Specimens for Physical and Aging Tests ....................................................... Insulation Shield Hot Creep Requirements ............................................................. 46 Bending Requirementsfor Heat Shock Test ........................................................... Bending Requirementsfor Cold Bend Test ............................................................ Plan E ...........................................................................................................................

42 49 50

59

Minimum ac Withstand Values ..................................................................................69 Maximum Temperature Gradient for Thermal Aging ............................................. 71 Generic Grouping of Cable Components ................................................................ 72 83 Insulation Shield Adders ............................................................................................ 84

DC Field Test Voltages ............................................................................................... 91

viii

DATE: 10114/04 Table F-1 Table Table G-2 Table G-3 Table G-4 Table G-5 Table G-6 Table H-1 Table H-2 Table H-3

DC Test Voltages ........................................................................................................ 92 One-sixth Neutral Concentric Conductor for Copper Center Conductor ............ 93 One-twelfth Neutral Concentric Conductor for Copper Center Conductor ........ 94 One-eighth Neutral Concentric Conductor for Aluminum Center Conductor ....95 One-twelfth Neutral Concentric Conductor for Aluminum Center Conductor ... 95 Solid Aluminum and Copper Conductors ............................................................... 97 98 Concentric Stranded Class C and D Aluminum and Copper Conductors ..........99

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1.1 SCOPE

Part 1 GENERAL

crosslinked polyethylene and ethylene propylene rubber insulated single conductor or multiplexed concentric

1.2GENERAL INFORMATION "DISCHARGE-FREE" and the other as "DISCHARGE-RESISTANT", as well as allowing for selection of those individual components (such as conductors, insulation type and thickness, concentric neutral sizes, optional jackets, etc.) as required for specific installation and service conditions.

Each of these parts designates the materials, material characteristics, dimensions, and tests applicable

to the particular component and, as applicable, to the design concept.

cables.

U.S. customary units, except for temperature, are specified throughout this standard. Approximate

possible misapplication of the cables, the purchaser should also furnish the following information:

a. Load current. d. Number of phases and conductors. e. Fault current and duration. f. Cable insulation level.

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DATE: 10/14/04 h. Description of installation. 2. Direct burial in ground. 3. Descriptions other than the foregoing. I.

Installation conditions.

conduits. 4. Method of bonding and grou ding of metallic neutral. 5. Wet or dry location. 6. Thermal resistivity (rho) of soil, concrete and/or thermal backfill. 1.3.2

Quantities and Description of Cable

a. Total number of feet, including test lengths, and lengths if specific lengths are required. b. etc.. C. Rated circuit voltage, phase-to-phase. d. e. complete description should be given. f. Type of insulation. g. Thickness of insulation in mils. h. Size of neutral. I. Type of jacket. 1.

restrict the overall diameter. k. Method of cable identification.

Active Length:

Length of cable covered by insulation shield and metallic shield.

Agglomerate:

A discernible area of compound constituents in ethylene propylene based

Amber:

which is dissimilar in color (ranging from bright yellow to dark red) from the surrounding insulation, which passes light and is not always readily removable -

which are normally associated with the extrusion process. AWG:

American Wire Gauge

BIL:

Basic Impulse Insulation Level.

Bowtie Water Tree:

A water tree which originates within the insulation (usually at a contaminant or other imperfection) and develops radially toward the insulation shield and the conductor shield.

2

Cable Core:

The portion of a cable which includes the conductor, the conductor shield, the insulation and the insulation shield.

Cable Core Extruder Run:

A continuous run of cable core with one conductor size, one conductor shield compound, one insulation compound and thickness, and one insulation shield compound.

requirements of this Standard. Contaminant: Dielectric Constant:

Discharge-Free Cable Design:

Any solid or liquid material which is not an intended ingredient. material as a dielectric to the capacitance of the same electrode configuration with a vacuum (or air for most practical purposes) as the dielectric. A cable designed to eliminate electrical discharge in the insulation at normal operating voltage.

Discharge-Resistant A cable design capable of withstanding electrical discharge. Cable Design: Dissipation 'Factor:

The cotangent of the dielectric phase angle of a dielectric material or the

EPR Insulating Compound: Filled Crosslinked Polyethylene Insulation: Gel:

A discernible region of compound constituents in ethylene propylene based insulation which is gelatinous, not readily removable from the insulation, and generally translucent.

High Dielectric An extruded compound used for the conductor shield which has a dielectric Constant Compound: Jacket Extruder Run: A cable with a jacket which was applied in one continuous run with one jacket compound and one jacket thickness. kcmil:

thousands of circular mils (formerly MCM)

Lot (Cable):

The quantity of cable requiring one test.

Lot (Material):

A quantity of material used in cable construction which is produced at the same location under the same manufacturing conditions during the same time period.

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Maximum Conductor Temperatures: Normal Operating:

The highest conductor temperature permissible for any part of the cable line under normal operating current load.

Emergency Overload:

The highest conductor temperature permissible for any part of the cable line during emergency overload of specified time, magnitude, and frequency of application.

Short Circuit:

The highest conductor temperature permissible for any part of the cable line during a circuit fault of specified time and magnitude.

Partial Discharge Level:

The maximum continuous or repetitious apparent charge transfer, measured in picocoulombs, occurring at the test voltage.

pc:

picocoulombs

Room Temperature (RT): Shipping Length:

A completed length of cable which has passed all test requirements. It may or customer.

Shipping Reel: Translucent:

A localized area in crosslinked polyethylene (XLPE or TRXLPE) insulation removable from the insulation matrix. translucents in this standard.

Tree Retardant XLPE Insulation:

There are no requirements for

A tree retardant crosslinked polyethylene (TRXLPE) insulation compound containing an additive, a polymer modification or filler that retards the development and growth of water trees in the insulation compound.

Unfilled Crosslinked Polyethylene: V:

phase-to-phasevoltage

V,: Vented Water Tree: Void: Water Tree:

layer. Microchannels in the insulation which develop in the presence of moisture, voltage stress and some type of catalyst such as a contaminant, a protrusion, space charge or ion(s).

XLPE Insulation:

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ICEA S-94-649-2004

Part CONDUCTOR 2.0 GENERAL Conductors shall meet the requirements of the appropriate ASTM standards referenced in this Standard except that resistance will determine cross-sectional area as noted in 2.4 and diameters will be in accordance with 2.5. Compliance with cross-sectional area is not required. Requirements of a referenced ASTM standard shall be determined in accordance with the procedure or method designated in the referenced ASTM standard unless otherwise specified in this Standard. The following technical information on typical conductors may be found in Appendix H: a. Approximate diameters of individual wires in stranded conductors.

The conductors used in the cable shall be copper in accordance with 2.1.1 or aluminum in accordance shall be no water in stranded conductors in accordance with 9.1 5.

2.1.1 Copper Conductors 1.

2. 3. 4. 5. 6. 7. 8. 9.

-

constructions.

2.1.2 Aluminum Conductors

constructions. constructions.

5

DATE: 10/14/04

2.2OPTIONAL SEALANT FOR STRANDED CONDUCTORS penetration may be incorporated in the interstices of the stranded conductor. Compatibility with the conductor shield shall be determined in accordance with ICEA Publication T-32-645. Longitudinal water

2.3CONDUCTOR SIZE UNITS equivalents for small sizes shall be found in Table 2-4. The metric equivalents for all sizes are found in Table 2-4 (Metric).

2.4CONDUCTOR DC RESISTANCE PER UNIT LENGTH

The dc resistance per unit length of each conductor in a production or shipping length of completed cable shall not exceed the value determined from the schedule of maximum dc resistances specified in Table 2-2 when using the appropriate nominal value specified in Table 2-3. The dc resistance shall be determined in accordance with 2.4.1 or 2.4.2. Where the outer layer of a stranded copper conductor is coated, the direct current resistance of the resulting conductor shall not exceed the value specified for an uncoated conductor of the same size. When a sample is taken from a multiple conductor cable, the resistance shall comply with the appropriate maximum resistance value specified for a single conductor cable.

other than 25 OC, the measured value shall be converted to resistance at 25 OC by using either of the following:

If verification

is

required for the direct-current resistance measurement made on an entire length of

current resistance of each conductor shall be measured using a Kelvin-type bridge or a potentiometer.

Where:

When the volume resistivity is expressed in nanoohm meter (nn.m) and area is expressed in square millimeters (mm') the resistance is expressed in milliohm per meter (mcdm).

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6

2.5 CONDUCTOR DIAMETER The conductor diameter shall be measured in accordance with 9.3.3. The diameter shall not differ from -

Table 2-1 Weight Increment Factors' ~~

r Il

Conductor TypdSize

Weight Factor (K)

Solid All Sizes

1

~~

~~~

~

Combination Unilay Strand All Sizes All Sizes

II

'

~

Table -2 Schedule for Establishing Maximum Direct Current Resistance Per Unit Length of Completed Cable Conductors listed in Table 2-4 Maximum dc Resistance

Cable Type Single Conductor Cables and Flat Parallel Cables

(Rmax=Rx1.02)

Twisted Assemblies of Single Conductor Cables

f o r m u la :

f

A Where:

See 9.3.2 for cross-sectional area determination

7

ICEA 5-94-649-2004

Table 2-3 Nominal Direct Current Resistance in Ohms Per 1000 Feet at 25 OC of Solid and Concentric L y Strand d Conductor

I Conductor Si ze

DATE: 10/14/04

I

Solid Copper

Aluminum

Aluminum

I

Class B,C,D

-

8

Class B,C,D

Coated Class

Class C

Class

0.652 0.519 0.41 1 0.325 0.258

0.678 0.538 0.427 0.338 0.269

0.678 0.538 0.427 0.339 0.269

0.680 0.538 0.427 0.339 0.269

0.205

0.21 3

0.213

0.129 0.102 0.0810

0.134 0.106 0.0842

0.134 0.106 0.0842

0.213 0.169 0.134 0.106 0.0842

0.105 0.0836 0.0707 0.0590 0.0505

0.0642 0.0510 0.0431 0.0360 0.0308

0.0667 0.0524 0.0448 0.0374 0.0320

0.0669 0.0530 0.0448 0.0374 0.0320

0.0669 0.0530 0.0448 0.0374 0.0320

0.0442 0.0393 0.0354 0.0321 0.0295

0.0269 0.0240 0.0216 0.01 80

0.0277 0.0246 0.0222 0.0204 0.0187

0.0280 0.0249 0.0224 0.0204 0.01 87

0.0280 0.0249 0.0224 0.0204 0.0187

0.0272 0.0253 0.0236 0.0221 0.01 96

0.0166 0.0154 0.0144 0.0135 0.0120

0.0171 0.01 59 0.0148 0.0139 0.0123

0.0172

0.0173 0.0160 0.0150 0.0140 0.0126

0.0177 0.0161 0.0147 0.01 41 0.0136

0.0108 0.00981 0.00899 0.00863 0.00830

0.0111 0.0101 0.00925 0.00888 0.00854

0.00897 0.00861

0,00934

0.01 12 0.0102 0.00934 0.00897 0.00862

0.0126 0.01 18

0.0101

0.00771 0.00719 0.00674 0.00634 0.0061

0.00793 0.00740 0.00694 0.00653 0.00634

0.00793 0.00740 0.00700 0.00659 0.00640

0.00801 0.00747 0.00700 0.00659 0.00640

0.00982 0.00931 0.00885 0.0071 5 0.00596

0.00599 0.00568 0.00539 0.00436 0.00363

0.0061

0.00616

0.00555 0.00448 0.00374

0.00555

0.00622 0.00589 0.00560

0.640 0.508 0.403 0.31 9 0.253

0.659 0.522 0.414 0.329 0.261

1 .O7 0.851

0.201

U0

0.329 0.261 0.207 0.1 64 0.130

0.126 0.100 0.0794

0.207 0.164 0.130 0.102 0.0813

0.334 0.266 0.21 1 0.168 0.133

310 410 250 300 350

0.103 0.081 9 0.0694 0.0578 0.0495

0.0630 0.0500

0.0645 0.051 1

...

...

400 450 500 550 600

0.0433 0.0385 0.0347

...

... ...

... ...

... ...

...

650 700 750 800 900

... ...

... ...

... ...

...

...

... ...

3 2

Uncoated

~

1 .O5 0.833 0.661 0.524 0.415

5 4

1

Concentric Lay Stranded'

...

... ...

...

...

...

...

...

... ... ...

...

... ...

...

...

...

0.424

0.0149 0.0140 0.0126 ~~

1100 1200 1250 1300 1400 1500 1600 1700 1750

2000 2500 3000

...

... ...

... ... ...

...

...

...

...

...

...

...

...

... ...

... ...

8 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

0.01 11 0.0102

...

...

ICEA S-94-649-2004

DATE: 10/14/04

Concentric Lay Stranded'

Solid ConductorSize

AWG

Or Kcmil

Aluminum

mm2

Aluminum

Copper

Coated

3.44 2.73 2.17 1.72 1.36

0.830

2.16 1.71 1.36 1 .O8 0.856

2/0

26.7 33.6 42.4 53.5 67.4

1 .O8 0.856 0.679 0.538 0.426

0.659 0.522 0.413 0.328 0.260

0.679 0.538 0.426 0.335 0.267

310 410 250 300 350

85.0 107 127 152 177

0.338 0.269 0.228 0.190 0.162

0.207 0.164

0.212 0.168

...

...

400 450 500 550 600

203 228 253 279 304

650 700 750 800 900

329 355 380 405 456

1100 1200 1250 1300

507 557 608 633 659

1400 1500 1600 1700 1750

709 760 81 1 86 1 887

1800 1900 2000 2500 3000

91 2 963 1013 1266 1520

5 4 3

~

t

Uncoated

8.37 10.6 13.3 16.8 21.1

8 7

... ...

... ... ... ...

... ...

...

...

... ... ...

...

-

...

...

...

... ...

...

Copper Coated

Class B,C,D

Class

0.344 0.274 0.232 0.194 0.166

0.145 0.129 0.1 16 0.105 0.0968

Class

0.846

2.22 1.76 1.40 1.11 0.882

2.22 1.76 1.40 1.11 0.882

2.23 1.76 1.40 1.11 0.882

0.672 0.531 0.423 0.335 0.266

0.699 0.554 0.440 0.348 0.276

0.699 0.554 0.440 0.348 0.276

0.699 0.554 0.440 0.348 0.276

0.21 1 0.167 0.141 0.118 0.101

0.219

0.219 0.174 0.123 O. 105

0.21 9 0.174 0.147 0.123 0.105

0.147 0.123

0.0882 0.0787 0.0708 0.0643 0.0590

0.0909 0.0807 0.0728 0.0669 0.0613

0.0918 0.0817 0.0735 0.0669 0.0613

0.0918 0.0817 0.0735 0.0669 0.0613

0.0892 0.0830 0.0774 0.0725 0.0643

0.0544 0.0505 0.0472 0.0443 0.0394

0.0561 0.0522 0.0485 0.0456 0.0403

0.0564 0.0525 0.0489 0.0459 0.0413

0.0567 0.0525 0.0492 0.0459 0.0413

0.0581 0.0528 0.0482 0.0462 0.0446

0.0354 0.0322 0.0295 0.0283 0.0272

0.0364 0.0331 0.0303 0.0291 0.0280

0.0364

0.0306 0.0294 0.0282

0.0367 0.0335 0.0306 0.0294 0.0283

0.0253 0.0236 0.0221 0.0208 0.0202

0.0260 0.0243 0.0228 0.021 4 0.0208

0.0260 0.0243 0.0230 0.0216 0.0210

0.0263 0.0245 0.0230 0.0216 0.0210

0.0196 0.0186 0.0177 0.014 3 0.01 1 9

0.0202 0.0192 0.0182 0.0147 0.0123

0.0202 0.0192 0.0182

0.0204 0.01 93 0.0184

... ... ... ...

0.0413 0.0387 0.0364 0.0341 0.0331

... ...

0.0322 0.0305 0.0290 0.0235 0.01 95

i

1

'

Concentric lay stranded includes compressed and compact conductors.

9 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

0.0335

... ...

...

...

DATE: 10/14/04 Table 2-4

I

Conductor Size

AWG

I

Nominal Diameters (Inches)

kcmil

Solid

16.51 20.82 26.24 33.09 41.74

0.1285 0.1443 0.1620 0.1819 0.2043

3 2 1

52.62 66.36 83.69 105.6 133.1

0.2294 0.2576 0.2893 0.3249 0.3648

310 40

167.8 211.6 250 300 350

0.4096 0.4600 0.5000 0.5477 0.5916

400 450 500 550 600

0.6325 0.6708 0.7071

8 7

6

5 4

650 700 750 800 900

...

... ...

... ... ...

...

...

Concentric Lay Stranded

0.141 0.158 0.178 0.200 0.225

0.146 0.164 0.184 0.206 0.232

0.148 0.166 0.186 0.208 0.234

0.148 0.166 0.186 0.208 0.235

0.143 0.160 0.179 0.202 0.226

0.252 0.283 0.322 0.362 0.406

0.260 0.292 0.332 0.373 0.419

0.263 0.296 0.333 0.374 0.420

0.264 0.297 0.333 0.374 0.420

0.254 0.286 0.321 0.360 0.404

0.313 0.352 0.395

0.570 0.616

0.456 0.512 0.558 0.61 1 0.661

0.470 0.528 0.575 0.630 0.681

0.471 0.529 0.576 0.631 0.681

0.472 0.530 0.576 0.631 0.682

0.454 0.510 0.554 0.607 0.656

0.443 0.498 0.542 0.594 0.641

0.659 0.700 0.736 0.775 0.813

0.706 0.749 0.789 0.829 0.866

0.728 0.772 0.813 0.855 0.893

0.729 0.773 0.814 0.855 0.893

0.729 0.773 0.815 0.855 0.893

0.701 0.744 0.784

0.685 0.727 0.766 0.804 0.840

0.845 0.877 0.908 0.938 0.999

0.901 0.935 0.968

0.930 0.965 0.999 1 .O32 1 .O93

0.930 0.965 0.998 1 .O32 1.095

...

1 .O61

0.929 0.964 0.998 1 .O31 1 .O94

1.117 1.173 1.225 1.251 1.276

1.152 1.209 1.263 1.289 1.315

1.153 1.210 1.264 1.290 1.316

1.153 1.211 1.264 1.290 1.316

...

...

1.137 1.187 1.212 1.236

1.323 1.370 1.415 1.459 1.480

1.364 1.412 1.459 1.504 1.526

1.365 1.413 1.460 1.504 1.527

1.365 1.413 1.460 1.504 1.527

... ... ... ... ...

1.282 1.327 1.371 1.413 1.434

1.502 1.542 1.583 1.769 1.938

1.548 1.590 1.632 1.824 1.998

1.548 1.590 1.632 1.824 1.999

1.549 1.591 1.632 1.824 1.999

...

1.454 1.494 1.533

0.169

.,.

0.213 0.238 0.268 0.336 0.376 0.423 0.475

...

...

... ...

... ...

1400 1500 1600 1700 1750

...

...

1800 1900 2000 2500 3000

... ...

...

...

...

... ...

...

... ...

...

...

...

...

...

Unilay Compressed

0.134

...

...

...

...

...

Class D

Combination Unilay

Compressed

1100 1200 1250 1300

...

Class

Compact'

compact round, compact modified concentric and compact single input wire. Diameters shown are for

* * Diameters shown are for concentric round and modified concentric.

10 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

...

...

...

...

... ...

... ...

...

...

... ...

...

... ...

...

...

...

...

...

0.907 0.939 0.969 1 .O28

... ...

ICEA S-94-649-2004

DATE: 10/14/04

Table 2-4 (Metric) Nominal Diameters for Copper and Aluminum Conductors Conductor Size

AWG

Or Kcmil

mm2

Nominal Diameters (mm)

Solid

Class C

Class

4.29 5.41

3.58 4.01 4.52 5.08 5.72

3.71 4.17 4.67 5.23 5.89

3.76 4.22 4.72 5.28 5.94

3.76 4.22 4.72 5.31 5.97

3.63 4.06 4.55 5.13 5.74 6.45 7.26 8.15 9.14 10.3

2lO

26.7 33.6 42.4 53.5 67.4

5.83 6.54 7.35 8.25 9.27

6.05 6.81 7.59 8.53 9.55

6.40 7.19 8.18 9.19 10.3

6.60 7.42 8.43 9.47 10.6

6.68 7.52 8.46 9.50 10.7

6.71 7.54 8.46 9.50 10.7

310 410 250 300 350

85.0 107 127 152 177

10.4 11.7 12.7 13.9 15.0

10.7 12.1 13.2 14.5 15.6

11.6 13.0 14.2 15.5 16.8

11.9 13.4 14.6 16.0 17.3

12.0 13.4 14.6 16.0 17.3

12.0 13.5 14.6 16.0 17.3

400 450

550 600

203 228 253 279 304

16.1 17.0 18.0

16.7 17.8 18.7 19.7 20.7

17.9 19.0 20.0 21.1 22.0

18.5 19.6 20.7 21.7 22.7

18.5 19.6 20.7 21.7 22.7

18.5 19.6 20.7 21.7 22.7

650 700 750 800 900

329 355 380 405 456

... ...

21.5 22.3 23.1 23.8 25.4

22.9 23.7 24.6 25.4 26.9

23.6 24.5 25.3 26.2 27.8

23.6 24.5 25.4 26.2 27.8

23.6 24.5 25.3 26.2 27.8

1100 1200 1250 1300

507 557 608 633 659

28.4 29.8 31.1 31.8 32.4

29.3 30.7 32.1 32.7 33.4

29.3 30.7 32.1 32.8 33.4

29.3 30.8 32.1 32.8 33.4

1400 1500 1600 1700 1750

709 760 811 861 887

33.6 34.8 35.9 37.1 37.6

34.6 35.9 37.1 38.2 38.8

35.9 37.1 38.2 38.8

34.7

34.7 35.9 37.1 38.2 38.8

1800 1900 2000 2500 3000

91 2 963 1013 1266 1520

38.2 39.2 40.2 44.9 49.2

39.3 40.4 41.5 46.3 50.7

39.3 40.4 41.5 46.3 50.8

39.3 40.4 41.5 46.3 50.8

...

...

...

...

...

...

1

...

... ... ...

q

...

...

Compressed

4.62 5.19

500

Unilay Compressed

Compact'

8.37 10.6 13.3 16.8 21.1 3

Combination Unilay

...

Diameter5 iown ar( )r compact round, como:modified conc tric and compactigle input wire. * * Diameters shown are for concentric round and modified concentric.

11

...

...

...

...

...

... ...

...

... ...

...

...

...

...

...

...

...

... ...

...

... ...

...

...

... ...

7.95 8.94

10.0

11.3 12.6 13.8 15.1 16.3 17.4 18.5 19.5 20.4 21.3 22.2 23.0 23.9 24.6 26.1 27.5 28.9 30.1 30.8 31.4

...

32.6 33.7 34.8 35.9 36.4

...

36.9 37.9 38.9

... ... ... ... ...

... ...

...

... ...

DATE: 10/14/04

for Stranded Conductors Conductor Size

Concentric Stranded

Conductivity utilized for above factors, Percent

Aluminum

Uncoated

0.460 t o 0.290, Inclusive

17692

10786

11045

17865

10892

61

copper

t o 0.103, Inclusive

to 0.0201,

Inclusive

11217

U n d e r 0.0201

to0.0111,

Inclusive

11456

to 0.0010, Inclusive

11580

11568

97.66

97.16

96.16

94.16

93.15

-

12

DATE: 10/14/04

ICEA S-94-649-2004

3.1 MATERIAL

Part 3 CONDUCTOR SHIELD (STRESS CONTROL LAYER)

The conductor shall be covered with an extruded thermosetting conductor shield material. The extruded material shall be either semiconducting or nonconducting for ethylene propylene rubber (EPR) type insulation and semiconducting only for crosslinked polyethylene (XLPE or TRXLPE) type insulation. The extruded shield shall be compatible with all cable component materials with which it is in contact. The allowable operating temperatures of the conductor shield shall be equal to or greater than those of the insulation. The conductor shield shall be easily removable from the conductor and the outer surface of the extruded shield shall be firmly bonded to the overlying insulation. shall not be considered as part of the extruded shield thickness.

(See 9.4.2). The extruded conductor shield thicknesses are given in Table 3-1. Minimum point thickness does not apply to points of protrusions or irregularities.

Table 3-1 Extruded Conductor Shield Thickness Conductor Size, AWG or kcmil (mm2)

1 1 1 1 1 1 1 1

Extruded Shield Thickness Minimum Point

1

1 1001 and larger (507 and larger)

1 1

mils 12 16 20

24

1 1 1 1

mm

0.30 0.41 0.51 0.61

3.2.1 Reduced Extruded Shield Thickness For compact round and solid conductors which have a diameter eccentricity less than or equal to 2 mils (0.051 mm) measured before the extruded shield is applied, the extruded shield thickness may be 50 percent noted, all other requirements remain unchanged. Diameter eccentricity is defined as the maximum diameter minus the minimum diameter of a given cross section.

3.3 PROTRUSIONS AND CONVOLUTIONS (See 9.4.13). The contact surface between the extruded conductor shield and the insulation shall be

insulations. Strand convolutions (the tendency of the conductor shield to follow the contour of a stranded

13 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

DATE: 10114/04 conductor shields with reduced thickness, protrusions and convolutions into the conductor shield shall not

3.4VOIDS -

voids larger than 3 mils (0.076 mm).

3.5 PHYSICAL REQUIREMENTS The crosslinked material intended for extrusion as a conductor shield shall meet the following requirements: Table 3-2 Extruded Conductor Shield Requirements

Physical Requirements

'

at 121OC11 OC(forinsulationsrated90OC)or

at 136 OC 11

minimum percent -25

3.6 ELECTRICAL REQUIREMENTS 3.6.1

Extruded Semiconducting Material

(See 9.8.1). The volume resistivity of the extruded semiconducting conductor shield shall not exceed 3.6.2

Extruded Nonconducting Material (For EPR Insulation Only)

see Table 9-5, and meet the following requirements at room temperature, at the maximum normal operating temperature, and emergency operating temperature: Dielectric Constant, range 60

3.6.3

dielectric constant

Semiconducting Tape

(See 9.4.12). The extruded conductor shield shall be effectively crosslinked.

14

DATE: 10/14/04

ICEA S-94-649-2004

Part -

4.1 MATERIAL The insulation shall be one of the following materials meeting the dimensional, electrical, and physical requirements specified in this section: Filled or unfilled tree retardant crosslinked polyethylene (TRXLPE) A filled crosslinked polyethylene or filled tree retardant crosslinked polyethylene insulation (XLPE, TRXLPE, XLPE Class III or TRXLPE Class Ill), meeting the requirements of this specification, is one that a compound containing the following: an additive, a polymer modification, or filler that retards the development and growth of water trees in the compound. These XLPE and TRXLPE insulations are intended for use only in cables of the "DISCHARGE-FREE'' design concept. crosslinked polyethylene or unfilled tree retardant crosslinked polyethylene insulation compound for contamination. See Appendix K. Ethylene propylene rubber insulation has four classifications: III can be used in either the "DISCHARGE-FREE design or the "DISCHARGE-RESISTANT"design; IV is for use only in cables of the "DISCHARGE-RESISTANT"design.

the following:

Table 4-1 Conductor Maximum Temperatures Insulation Materiait

Normal Operation

Emergency Overload*

Short Circuit"*

90 "C

130 "C

250 "C

XLPE, TRXLPE, and

105 OC**

*See Appendix **Lower temperatures for normal operation may be required because of the type of material used in the cable joints, terminations and separable connectors or because of cable environmental conditions. Cable users should be aware that ail of the jackets further information. tother insulation materials composed of Ethylene and Alkene units, which are designated as EAM, may be available and can contact the manufacturerfor further information.

15

ICEA S-94-649-2004

DATE 1 0/14/04

The insulation thicknesses given in Table 4-7 are based on the rated phase-to-phase circuit voltage, conductor size, and the cable insulation level. The minimum thickness and maximum thickness of the insulation shall be as specified in Table 4-7 (see 9.4.2 for method of measurement).

Use the thickness values given in the respective columns of Table 4-7.

See 173 percent level in Note c following Table 4-7.

4.2.1.3 For Single- and Two-Phase Systems with 100 Percent Insulation Level Multiply the voltage to ground by 1.73 and use the resulting voltage value or next higher rating to select

the corresponding insulation thickness in the 133 percent insulation level column of Table 4-7.

4.3.1

Physical and Aging Requirements

When tested in accordance with Part 9, the insulation shall meet the following physical requirements:

16

ICEA S-94-649-2004

DATE: 10/14/04 Table 4-2 Insulation Physical Requirements Insulation Type


TRXLPE

Tensile Strength, Minimum psi (MPa)

TRXLPE Class 111

1800 (1 2.5)

700 (4.8)

1200 (8.2)

250

Elongation at Rupture, Minimum Percent

550 (3.8)

250

136

121

136

Tensile Strength, Minimum Percentage

75

75

80

Elongation, Minimum Percentage of Unaged Value Minimum Percent at Rupture

75

75

80

--

Unfilled

700 (4.8)

--

121 75

75 --

__

__

175

Filled

175 10

5

1

5

*For XLPE and TRXLPE insulations if this value is exceeded, the Solvent Extraction Test may be

4.3.2 Electrical Requirements 4.3.2.1 Partial-Discharge Extinction Level for Discharge-Free Designs Only (See 9.13). Each shipping length of completed cable shall be subjected to a partial discharge test. The

4.3.2.2 Discharge (Corona) Resistance for Discharge-Resistant Designs Only

discharge measurements are not required for DISCHARGE-RESISTANTcables.

17

ICEA S-94-649-2004

DATE: 10/14/04

4.3.2.3 Voltage Tests (See 9.1 2). Each shipping length of completed cable shall withstand, without failure, the ac test voltages conductor. Factory dc testing is not required by this specification. However, a dc test may be performed with prior agreement between the manufacturer and the purchaser. Suggested dc test voltages are listed in Appendix F. withstand value for all cable designs shall be 800 V/mil (31.5 kV/mm) except for XLPE or TRXLPE insulated cable designs rated for 15 kV where the minimum impulse withstand value shall be 1200 V/mil (47.2 kV/mm).

4.3.2.4 Insulation Resistance Test

4.3.2.5 Dielectric Constant and Dissipation Factor dissipation factor at room temperature when tested in accordance with ICEA T-27-581/NEMA WC-53.

Table 4-3 Dielectric Constant and Dissipation Factor ~~~

Insulation Type TRXLPE

Properties XLPE Class 111 ir

Dielectric Constant

I

Dissipation Factor, Percent

TRXLPE Class 111

Class IV Class less

3.5

28

kV

4.0

o.

0.5

1.5

2.0

1.5 -

1) Any void larger than 3 mils (0.076 mm). The number of voids larger than 2 mils (0.051 mm) shall not exceed 30 per cubic inch (1.8 per cm3) of insulation. 2) Any contaminant larger than 5 mils (0.127 mm) in its greatest dimension and no more than 15 per cubic inch (0.9 per cm3) between 2 and 5 mils (0.051 and 0.127 mm).

18

DATE: 10/14/04

ICEA S-94-649-2004 4.3.3.2 Ethylene Propylene Rubber (EPR)

(See 9.4.13 and Table 9-5). The insulation of the sample examined shall be free from:

distinction between contaminants, gels, and agglomerates is not required.

(See 9.10). The conductor shall not protrude beyond the insulation (total of both ends) by more than the amounts shown in Table 4-4 or 4-5.

Table 4-4 Shrinkback Test Requirements Cables Having Sealed Strand Conductors andor a Tape Over the Conductor

I(

Oven Cycle 1

I

Action Pass: Terminate Test Record and Continue Cycling

2

Pass: Terminate Test

3

Pass: Terminate Test Fail: Terminate Test

Oven Cycle

Total Shrinkback mils (mm)

Action Pass: Terminate Test Record and Continue Cycling Fail: Terminate Test Pass: Terminate Test Record and Continue Cycling Fail: Terminate Test Pass: Terminate Test Fail: Terminate Test

19

-

DATE: 10/14/04

ICEA S-94-649-2004 Table 4-6 Cable BIL Values

5

60

8

95

15*

110

46

250

Table -7 Conductor Sizes, Insulation Thicknesses and Test Voltages

Rated Circuit Voltage, Phase-to-Phase Voltagea

Conductor Size, kcmiOb

cent In-

Point

Point

Point

Point

Level

Level

85

120

110

145

18

23

135

170

135

170

28

28

110

145

135

170

23

28

165

205

165

205

35

35

165

205

250

35

44

1O01-3000

210

250

210

250

44

44

15001-25000

1-3000

245

290

305

350

52

64

25001-28000

1-3000

265

31

330

375

56

69

28001-35000

110-3000

330

375

400

450

69

84

35001-46000

410-3000

425

485

550

89

116

2001-5000

1O01-3000

1O01-3000 8001-15000

~

cent In-

20

-

DATE: 10/14/04 Table 4-7 (Metric) Conductor Sizes, Insulation Thicknesses and Test Voltages insulation Leveic(mm)

Rated Circuit Voltage, Phase-to-Phase

ac Test Voltage, kVd

Conductor Size, (rnm2lb

Voltagea

Minimum Point

Maximum Point

Minimum Po i n t

cent In sulation Level

Maximum Point

cent Insulation Level

8.37-506.7e

2.16

3.05

2.79

3.68

18

23

506.8-1520

3.43

4.32

3.43

4.32

28

28

13.3-506.7

2.79

3.68

3.43

4.32

23

28

506.8-1520

4.19

5.21

4.19

5.21

35

35

33.6-506.7

4.19

5.21

5.33

6.35

35

44

506.8-1520

5.33

6.35

5.33

6.35

44

44

15001-25000

42.4-1520

6.22

7.37

7.75

8.89

52

64

25001-28000

42.4-1520

6.73

7.87

8.38

9.53

56

69

2001 -5000

5001-8000

8001 -15000

28001-35000 35001-46000

I

53.5-1520 107.2-1520

I

8.38 10.8

I

9.53 12.3

I

10.2 14.0

I

11.4

15.5

I

69 89

I

84 116

percent during emergencies lasting not more than 15 minutes. bTo limit the maximum voltage stress on the insulation at the conductor to a safe value, the conductor size shall not be less than the minimum size shown for each rated circuit voltage category. ‘Selection of the cable insulation level to be used in a particular installation shall be made on the basis of the applicable phase-to-phase voltage and the general system category as outlined below:

majority of cable installations that are on grounded systems, they may be used also on other systems for which the application of cable is acceptable provided the above clearing requirements are met in completely de-energizingthe faulting section. Where additional insulation thickness is desired, it shall be the same as for the 133 percent insulation level.

section is indefinite. Their use is recommended also for resonant grounded systems. Consult the manufacturer for insulation thicknesses.

thicknesses. When such conditions are anticipated, the user should consult with the cable supplier to determine the appropriate insulation thickness. In common with other electrical equipment, the use of cables is not recommended o n systems where the ratio of the zero to positive phase case of ground faults.

21 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

ICEA S-94-649-2004

DATE: 10/14/04

Part

EXTRUDED INSULATION SHIELD 5.1 MATERIAL The insulation shield shall be an extruded semiconducting material compatible with all cable components with which it is in contact. The extruded shield shall be readily distinguishable from the insulation and plainly identified as semiconducting. Cables of the DISCHARGE-FREE design shall use a thermosetting material. (See 5.4.1) Cables of the DISCHARGE-RESISTANT design shall use either a thermoplastic or a thermosetting material. (See 5.4.2)

5.2THICKNESS AND INDENT REQUIREMENTS (See 9.4.2). The thickness and concentric neutral indent requirements for the insulation shield are as indicated in the tables below. The thickness requirements for the extruded insulation shield for cables with a wire neutral are as indicated in the Table 5-1. The thickness requirements for the extruded insulation shield For cables with wire neutral, the minimum point thickness does not apply to locations under the concentric neutral indent. For jacketed cable, the indent shall be measured after the application of the jacket. For cables with flat strap neutral, the minimum point thickness is applicable at all locations. Indent measurement is not required.

Table 5-1 Insulation Shield Thickness Cables With Wire Neutral Calculated Minimum Diameter Over the Insulation inches (mm)

2.001 and larger (50.83 and larger)

Insulation Shield Thickness Minimum Point

Maximum Point

Maximum Concentric Neutral Indent

mils

mm

mils

mm

mils

mm

30

0.76

60

1.52

15

0.38

1 1 11 1.40

22

1 2.29

0.51

2.67

0.51

ICEA S-94-649-2004

DATE: 10/14/04

5.3 PROTRUSIONS (See 9.4.13). The contact surface between the extruded insulation shield and the insulation shall be indent.

Insulation shields used in DISCHARGE-FREEcable designs are described in 5.4.1.

5.4.1.1 Removability

residual conductive material on the insulation surface which is not removable with light rubbing. Sanding At the option/approval of the purchaser, an insulation shield which is bonded may be supplied. In this

5.4.1.2 Voids (See 9.4.13). The interface between the insulation and the extruded insulation shield shall be free of any

5.4.1.3 Physical Requirements The material(s) intended for extrusion as an insulation shield shall meet the following requirements:

Table 5-2 Extruded Insulation Shield Requirements Discharge-Free Designs

Il


Material

Elongation after air oven test for 168 hours at 121 OC 11 OC (for insulations rated 90 OC) minimum percent Brittleness temperature not warmer than, OC

23

-25

ICEA S-94-649-2004

DATE: 10/14/04

5.4.1.4 Electrical Requirements

5.4.1.5 Wafer Boil Test

5.4.2

Insulation Shield for DISCHARGE-RESISTANT Cable Designs Only

5.4.2.1 Removability There is no minimum tension requirement for removing insulation shields used with discharge-resistant cables.

5.4.2.2 Physical Requirements The material intended for extrusion as an insulation shield shall meet the following requirements:

Table 5-3 Extruded Insulation Shield Requirements Discharge-Resistant Designs Thermoset Material


Thermoplastic Material

Elongation after air oven test at for 168 hours, minimum percent (for insulations rated 90 OC) Elongation after air oven test.at

N/A

Brittleness temperature not warmer than, OC

-25

-1

5.4.2.3 Electrical Requirements

5.4.2.4 Wafer Boil Test -

24

DATE: 10/14/04

ICEA S-94-649-2004

Part CONCENTRIC NEUTRAL CONDUCTOR 6.1 MATERIAL

coated neutrals. The wires or straps shall be applied helically over and in contact with the insulation shield.

6.2 CROSS-SECTIONAL AREA The cross-sectionalarea of the concentric neutral conductor shall be as follows: in Table 6-2 and the appropriate nominal circular mil area tabulated in Table 6-1. in Table 6-3 and the appropriate nominal circular mil area tabulated in Table 6-1. 3)

Other neutral cross-sectional areas based on specific fault-clearing requirements may be supplied with agreement between the manufacturer and the purchaser. ICEA Publication P-45-482 shall be -

Appendix G for typical reduced neutral constructions.

6.3 LAY LENGTH

The wires or straps of the concentric neutral shall be applied with a lay length not less than six nor more than ten times the diameter of the cable over the concentric neutral.

6.4 CONCENTRIC WIRES 6.4.1 Minimum Sizes

6.4.2 Contrahelical Wire

be applied over the other neutral wires in the opposite direction, but with the same lay length as the other neutral wires.

6.4.3 Diameter and Area

individual wires comprising a given concentric neutral may vary 15 percent in diameter from the appropriate nominal value, but the total circular mil area of the specified concentric neutral shall be in accordance with 6.2.

25

DATE: 10/14/04

6.5 FLAT STRAPS The minimum thickness of flat straps shall be 20 mils and the width of the strap shall not be less than specified for wires in 6.4.1.

6.6 OPTIONAL WATER BLOCKING COMPONENTS FOR METALLIC SHIELD

component is a tape and is applied under the metallic shield, it must be semiconducting and meet the requirements of 5.4. Longitudinal water penetration resistance shall be determined in accordance with ICEA Publication T-34-664 and shall meet minimum requirement of 5 psig.

AWG Size

II ~~~~~~

II

16

Nominal Diameter

Nominal Area (kcmil) 2.58

~

14

64.1

1.63

4.1

12

80.8

2.05

6.53

10

10.38

9

13.09

8

128.5

3.26

II II

II

16.51

Table 6-2

26 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

ICEA S-94-649-2004 Table 6-3 One-third Neutral Concentric Copper Conductor

WO

250

310 350

I

18

11

7*

...

...

...

20

13

8 '

...

...

...

22

14

9 '

6*

...

...

28'

18

11'

7*

6'

...

8=

7 '

...

25*

16

...

29'

18

12'

9*

8*

600

...

30'

19

12*

'

8=

750

...

...

24

15*

12*

'

500

...

...

26'

17

13*

lo*

600

...

...

31

20

16'

650

...

...

34*

21

17*

14'

1250

...

...

...

25*

20

16'

1500

...

...

...

30*

24

19'

...

...

...

51

41

500

350

750

2000

,

27

1

. .

ICEA S-94-649-2004

DATE: 10/14/04

Part JACKETS

The jacket, when supplied, shall consist of a nonconducting or semiconducting thermoplastic material depending upon installation requirements. The jacket material shall be compatible with all cable components accordance with Part 9, the jacket shall meet the applicable requirements. There shall be no water between

7.1.1

Low Density and Linear Low Density Polyethylene, Black (LDPE/LLDPE)

This jacket shall consist of a black, low density or linear low density polyethylene compound suitable for exposure to sunlight. The jacket shall meet the following requirements. Jacket irregularity inspection test shall

Table -1 Low Density and Linear Low Density Polyethylene, Black (LDPEILLDPE) Physical Requirements

I

Values

Tensile Strength, Minimum psi

1700

Elongation at Rupture Minimum Percent

350

(MW

Aging Requirements After Air Oven Aging at Tensile Strength, Minimum Percentage of Unaged Value

75

Elongation, Minimum Percentage of Unaged Value

75 30

Maximum Percent ~

~~

~

~~

~~

Environmental Stress Cracking* Absorption Coefficient Minimum 1OOO(absorbance/meter)

1

~~

320

Base Resin Density ( D 2 3 C , g / ~ m 3 p

polyethylenecompound that this requirementhas been complied with shall suffice.

28

-

7.1.2

Medium Density Polyethylene, Black (MDPE)

This jacket shall consist of a black, medium density polyethylene compound suitable for exposure to sunlight. The jacket shall meet the following requirements. Jacket irregularity inspection test shall be

Values


II Unaged Requirements Tensile Strength, Minimum psi (MPa)

2300

I

Elongation at Rupture

Requirements After Air Oven Aging at

(15.9)

350

75

Unaged Value

75

30

Maximum Percent

~~

Environmental Stress Cracking* Absorption Coefficient

320 ~

~~

** In lieu of testing finished cable jackets, a certification by the manufacturer of the

polyethylene compound that this requirement has been complied with shall suffice.

29 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

ICEA S-94-649-2004 7.1.3

High Density Polyethylene, Black (HDPE)

This jacket shall consist of a black, high density polyethylene compound suitable for exposure to sunlight. The jacket shall meet the following requirements. Jacket irregularity inspection test shall be performed in

Table -3 High Density Polyethylene, Black (HDPE) Values


Tensile Strength, Minimum


Aging Requirements After Air Oven Aging at Tensile Strength, Minimum Percentage of Elongation, Minimum

75 75

30

I

(I

Absorption Coefficient Minimum 1OOO absorbance/meter)

320

I

0.941 -0.965

** In lieu of testing finished cable jackets, a certification by the manufacturer of the

polyethylene compound that this requirement has been complied with shall suffice.

-

30

DATE: 10/14/04 7.1.4 Semiconducting Jacket Type This jacket shall consist of a black, thermoplastic, semiconducting compound suitable for exposure to sunlight. The semiconducting jacket shall be clearly identified as being semiconducting. The jacket shall meet the following requirements. Jacket irregularity inspection test shall be performed in accordance with 7.3.

Table 7-4 Semiconducting Jacket Type Physical Requirements

Tensile Strength, Minimum psi (MP4

~~~~

Values

1200

(8.27)

~~

Elongation at Rupture Minimum Percent ~~

Aging Requirements After Air Oven Aging at Tensile Strength, Minimum Percentage of Unaged Value

75

Elongation, Minimum Percentage 25

Maximum Percent ~~~

Radial Resistivity Maximum ohm-meter

Brittleness Temperature OC, not warmer th n

-1

31

--``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

DATE: 10/14/04

This jacket shall consist of a black, thermoplastic, semiconducting compound suitable for exposure to semiconducting jacket shall be clearly identified as being semiconducting. The jacket shall meet the following requirements. Jacket irregularity inspection test shall be performed in accordance with 7.3.

Table -5


Tensile Strength, Minimum psi (MPa)

Values

1500 (10.3)


150

Elongation, Minimum

75

Maximum Percent

Radial Resistivity At25"C15"C Maximum ohm-meter Brittleness Temperature

-1 5

-

32

ICEA S-94-649-2004 7.1.6 Polyvinyl Chloride (PVC) jacket shall meet the following requirements. Jacket irregularity inspection test shall be performed in

Table -6 Polyvinyl Chloride (PVC) ~


Values

Unaaed Requirements Tensile Strength, Minimum


Aging Requirements After Air Oven Aging at Tensile Strength, Minimum PercentageI of Unaged Value

85


60

Aging Requirements After Oil Immersion Test at Tensile Strength, Minimum Percentage of Unaged Value

80


60

50

Maximum Percent

No Cracks No Cracks

33

ICEA S-94-649-2004 7.1.7

Chlorinated Polyethylene (CPE)

This jacket shall consist of a black, thermoplastic, chlorinated polyethylene compound suitable for exposure to sunlight. The jacket shall meet the following requirements. Jacket irregularity inspection test shall

Table -7 Chlorinated Polyethylene (CPE) Physical Requirements

Values

Tensile Strength, Minimum psi (MW

1400 (9.65)

Elongation, Minimum psi (MPa)

(6.89)


150

~


50

Aging Requirements After O il Immersion Test at Tensile Strength, Minimum Percentage of Unaged Value

60

Elongation, Minimum

60 25

34

-

ICEA S-94-649-2004

DATE: 10/14/04

,

to sunlight. The jacket shall meet the following requirements. Jacket irregularity inspection test shall be

Thermoplastic Elastomer (TPE) Phvsical Requirements

I

Values

Unaged Requirements Tensile Strength, Minimum psi (MPa)

1800

Tensile Stress at 200 percent Elongation, Minimum psi (MPa)

400

(2.76)

~~


Unaged Value ~

350

75 ~~

~

Elongation, Minimum

75

Tensile Strength, Minimum

75


75 -

25

Maximum Percent

35

DATE: 10/14/04 7.1.9

Polypropylene, Black (PP)

sunlight. The jacket shall meet the following requirements. Jacket irregularity inspection test shall be

Table 7-9 Polypropylene, Black (PP) -

Values


Tensile Strength, Minimum psi

2500 (17.2)

Elongation at Rupture

350

Tensile Strength, Minimum Percentage of Unaged Value

75

Elongation, Minimum

75 15

Maximum Percent

I

Absorption Coefficient

320

36

DATE: 10/14/04

ICEA S-94-649-2004

7.2 JACKET TYPES 7.2.1 Extruded-To-Fill Jacket ductor and fill the spaces between the wires or oncentric neutral cc The iacket material shall cover th When measured over the wires or straps, the jacket thickness shall be as specified in Table 7-10 (See 9.4.2).

is nonconducting, the tape shall be either nonconducting or semiconducting. Materials suitable for use as an overlaying jacket are specified in 7.1.1 through 7.1.9. When measured over the wires or straps, the jacket thickness shall be as specified in Table 7-11 (See 9.4.2).

7.3.1 Nonconducting Jackets A nonconducting jacket over the concentric neutral conductor shall withstand an alternating current spark test voltage. The test voltage for a given thickness and type of jacket shall not be less than indicated in voltage shall be applied between an electrode at the outside surface of the jacket and the concentric neutral conductor. The neutral conductor shall be connected to ground during the test. The spark test shall be conducted in accordance with ICEA T-27-581/NEMA WC-53.

7.3.2 Semiconducting Jackets

Table 7-1 Extruded-To-Fill Jacket Thickness and Test Voltage AC Spark Test Voltage for Nonconducting Jackets

Calculated Minimum Diameter Over the Concentric Neutral Inches (mm)

kV mils

mm

mils

mm

Level A

45

1.14

'80

2.03

2.0

Level

1

4.5 ~

1.501 and larger (38.13 and larger)

70

1.78

37 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

120

3.05

3.0

7.0

ICEA S-94-649-2004

DATE: 10114/04 Overlaying Jacket Thickness and Test Voltage

Calculated Minimum Diameter Over the Concentric Neutral Inches (mm)

Overlaying Jacket Thickness Minimum Point

Maximum Point

AC Spark Test Voltage for

Nonconducting Jackets kV

mils

mm

mils

mm

Level A

55

1.40

90

2.29

2.5

5.5

70

1.78

105

2.67

3.0

7.0

2.54

150

3.81

4.5

10.0

3.1 8

180

4.57

5.5

12.5

125

Level

-

38

DATE: 10/14/04

Part CABLE ASSEMBLY AND IDENTIFICATION 8.1 MULTIPLEX CABLE ASSEMBLIES The assembly of multiplex cables shall have a left-hand lay. A left-hand lay is defined as a counterclockwise twist away from the observer. The length of lay of the individual cables shall not exceed 60 times the largest cable diameter.

8.2.1

J cketed Cable

the cable shall be suitably marked throughout its length by surface and/or indent print, at regular intervals with information: Manufacturer's Identificationor trade name Size of Conductor Conductor Material Type of Insulation Voltage Rating Nominal Insulation Thickness (See Table 8-1) embossed only) Year of Manufacture Semiconducting Jacket (If Applicable) 8.2;l.l

ptional Cable Id ntification

Upon request of the purchaser and with the manufacturer's agreement, the cable jacket may incorporate longitudinal red stripe (Three stripes) identification. Color retention cannot be guaranteed for the life of the cable. The three stripes shall be extruded into the jacket. The stripe material shall be durable and compatible stripes shall be sunlight resistant. 8.2.2

Unj cketed C able

shield outer surface shall be suitably marked throughout the cable length by surface print only, at regular following information:

<

>

Manufacturer's Identification or trade name Size of Conductor Conductor Material Type of Insulation Voltage Rating Nominal Insulation Thickness (See Table 8-1)

39

DATE: 10114/04 8.2.3

ptional Center Strand Id ntification

When center strand identification is requested by the purchaser, the center strand of each conductor shall be indented with the manufacturer's name and year of manufacture. This information is to be marked at 8.2.4

ptional Sequ ntial Leng h Mark ng

When sequential length marking is requested by the purchaser, the information is to be marked at

Table 8-1 Nominal Insulation Thickness Rated Circuit Voltage, Phase-to-Phase Voltage 2001-5000

Conductor Size, AWG or kcmil (mm2)

1001

Nominal Insulation Thickness (mils)

-3000(507-1520)

5001 -8000

Level

133 Perc n Level

90

115

140

140

115

140 175

175

220

220

220 ~

15001 -25000

1-3000 (42.4-1 520)

260

320

25001-28000

1-3000 (42.4-1 520)

280

345

28001-35000

520)

345

420 ~~

35001-46000

445

40

580

-

DATE: 10/14/04

ICEA S-94-649-2004

Part 9 PRODUCTION TESTS 9.1 TESTING

or cable.

9.2SAMPLING FREQUENCY Frequency Requirements".

9.3CONDUCTOR TEST METHODS

Measurements shall be made on the entire length of completed cable.

9.3.2 Cross-sectional Area Determination Cross-sectionalarea shall be determined in accordance with ICEA T-27-581/NEMA WC-53.

9.3.3 Diameter Determination Diameter shall be determined in accordance with K E A T-27-581/NEMA WC-53.

9.4.1

General

9.4.2 Measurement of Thickness The measurement of thickness for components having no minimum removability tension requirements shall be made with either a micrometer or an optical measuring device. For all other extruded components, mm).

41

ICEA S-94-649-2004 9.4.2.1 Micrometer Measurements When a micrometer measuring device is used, the component shall be removed and the minimum and maximum thickness determined.

9.4.2.2 Optical Measuring Device Measurements When an optical measuring device is used, the maximum and minimum thickness shall be determined

From each of the samples selected, test specimens shall be prepared in accordance with Table 9-1.

Table 9-1 Test Specimens for Physical and Aging Tests Total Number of Test Specimens For determination of unaged properties Tensile strength and ultimate elongation Permanent set For accelerated aging tests

-

For oil immersion 1

Heat shock Heat distortion

1

Cold bend Stripping

selected, then ail three test specimens shall be tested and the average of the results reported.

9.4.4 Size of Specimens

cross-section is used, the specimens shall not be cut longitudinally. In the case of wire and cable size

segmental specimen.

42

ICEA S-94-649-2004

DATE: 10/14/04

axis of the cable. The test specimen shall be a segment cut with a sharp knife or a shaped specimen cut out irregularities, corrugations, and wires have been removed.

9.4.5

Preparation of Specimens of Insulation and Jacket

The test specimen shall have no surface incisions and shall be as free as possible from other minimum requirement with irregularities, then their removal is not required.

9.4.6 Specimen for Aging Test treatment not specifically described in this Standard.

9.4.7.1 Where the total cross-section of the insulation is used, the area shall be taken as the difference between the area of the circle whose diameter is the average outside diameter of the insulation and the area of the circle whose diameter is the average outside diameter of the conductor shield.

whose diameter is that of the insulation. The height of the segment is the wall of insulation on the side from which the slice is taken. When the cross-section of the slice is not a segment of a circle, the area shall be calculated from a direct measurement of the volume or from the specific gravity and the weight of a known length of the specimen having a uniform cross-section.

be taken, the area shall be calculated as the thickness times the width. corrugations have been removed. be taken, the area shall be calculated as the proportional part of the area of the total cross-section.

9.4.8 Unaged Test Procedures

-

9.4.8.1 Test Temperature

43

DATE: 10/14/04

ICEA S-94-649-2004

9.4.8.3 Tensile Strength Test The tensile strength test shall be made with specimens prepared in accordance with 9.4.3 and 9.4.4.

The tensile and elongation determinations for compounds for which the compound manufacturer certifies of 0.926 s/cm3 or greater), or total base polyethylene resin content (having a density of 0.926 g/cm3 or

calculated based on the area of the unstretched specimen. Specimen length, gauge mark distance, and jaw speed shall be recorded with the results.

9.4.8.4 Elongation Test Elongation at rupture shall be determined simultaneously with the test for tensile strength and on the same specimen. The elongation shall be taken as the distance between gauge marks at rupture less the original gauge be reported with results.

9.4.9 Aging Tests 9.4.9.1 Aging Test Specimens -

Test specimens of similar size and shape shall be prepared from each sample selected, three for the determination of the initial or unaged properties, and three for each aging test required for the insulation or jacket being tested. Simultaneous aging of different compounds should be avoided. One specimen of each three specimens shall be tested and the average of the results reported. mrn'). Die-cut specimens shall be smoothed before being subjected to the accelerated aging tests wherever the thickness of the specimen will be 90 mils (2.29 mm) or greater before smoothing. The test specimens shall be suspended vertically in such a manner that they are not in contact with each other or with the side of the oven. The aged specimens shall have a rest period of not less than 16 hours nor more than 96 hours between aged and unaged specimens shall be made at approximately the same time.

44

ICEA S-94-649-2004

DATE: 10/14/04

9.4.9.2 Air Oven Test The test specimens shall be heated at the required temperature for the specified period in an oven having forced circulation of fresh air. The oven temperature shall be controlled to 11 OC.

9.4.9.3 Oil Immersion Test for Polyvinyl Chloride Jacket

elongation of the specimens shall then be determined in accordance with 9.4.8 at the same time that the original properties are determined.

The hot creep test shall be determined in accordance with ICEA Publication T-28-562. The sample shall be taken from the inner 25 percent of the insulation.

9.4.1 1 Solvent Extraction

9.4.12 Wafer Boil Test for Conductor and Insulation Shields Any outer covering and the conductor shall be removed. A representative cross section containing the extruded conductor shield and insulation shield, shall be cut from the cable. The resulting wafer shall be at least 25 mils (0.64 mm) thick. The wafer may be further separated into concentric rings by careful separation of the shield from the insulation. This may include the use of a punch to separate the conductor shield or insulation shield from most of the insulation. The resulting wafer(s) or rings shall then be immersed in boiling decahydronaphthalene with 1 percent by works as effectively as a fresh solution). The wafer(s) shall then be removed from the solvent and examined Total or partial separation of the semiconducting shields from the insulation is permissible. Partial loss of the shields is also permissible provided each shield is a continuous ring. If the conductor shield dissolves or cracks such that it does not maintain a continuous ring, the cable lot shall be rejected. If the insulation shield the manufacturer or a sample of insulation shield from the same lot shall be subjected to the requirements of 9.4.12.1 as a referee test.

9.4.1 2.1 Insulation Shield Hot Creep Properties

elongation and set to the values in Table 9-2.

45 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

ICEA S-94-649-2004

Table 9-2 Insulation Shield Hot Creep Requirements

(I

Physical Requirements Maximum elongation Maximum set

Extruded Insulation Shield 100%

II

5%

9.4.13 Amber, Agglomerate, Gel, Contaminant, Protrusion, Indent, Convolution and Void Test 9.4.13.1 Sample Preparation Samples shall be prepared by cutting a suitable length of cable helically or in some other convenient produce wafers with uniform thickness and with very smooth surfaces. The sample shall be kept clean and

9.4.13.2Examination

-

and ambers, as applicable, in the insulation. They shall also be examined for voids and protrusions between the insulation and the conductor and insulation shields and conductor shield convolutions. Unfilled insulations shall be examined using transmitted light. An optical coupling agent such as mineral oil, glycerin cross-linked polyethylene insulation, EPR, and extruded shields, a reflected light method shall be used. For

Test agglomerates, gels, ambers, convolutions or protrusions exceeds the specified limits, the lot shall be divided samples from the shipping length fails, the shipping length shall be rejected.

9.4.13.4 Protrusion, Indentation and Convolutions Measurement Procedure To measure the size of protrusions, indentations and conductor shield convolutions in wafers examined

This procedure is used on cable wafers with the conductor, jacket and metallic shield removed.

46

DATE: 10/14/04

ICEA S-94-649-2004

Figure 9-1 Procedure to Measure Protrusions and Indentations

Concentric Neutral

-Co

Protrusion of insulation into shield

Protrusion of shield into insulation

Figure 9-2

Convolutions Insulation Shidd Insulation Conductor Shidd

TRXLPE) Only 9.4.14.1 Sample Preparation This test is conducted on a 24-inch (610-mm) long sample cut into convenient lengths for the test apparatus. The insulation shield shall be removed. The insulation shall be made transparent by heating the

The samples shall then be viewed for conductor shield smoothness and for contaminants.

47 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

flat glass

DATE: 10/14/04 irregularities. Further enhancement may be accomplished with a dark background or a darkened room. Care shall be used in making the insulation transparent to prevent overheating which may deform the cable or' create conditions, which did not already exist such as voids, protrusions, and cracks. This test method is not recommended for the detection of voids in the insulation. -

9.4.14.2 Detection of Irregularities Contaminants in the insulation and protrusions or deformations at the conductor shield shall be marked on the insulation surface. Wafers containing these irregularities shall be cut from the sample and viewed contained in the 24-inch (61O-mm) sample is used. The irregularities shall not exceed the specified limits. The results of this examination shall be recorded in the production test report.

9.4.14.3 Resampling for Internal Irregularity Test If the irregularity limits are exceeded, a second 24-inch (610-mm) long sample shall be taken from an

adjacent length of cable in the same master length as the first sample. If this sample fails, the master length shall be divided into shipping lengths. One sample shall be taken from the beginning and end of each

9.4.15 Physical Tests for Semiconducting Material Intended for Extrusion 9.4.15.1 Test Sample cable.

9.4.15.2Test Specimens

specimens shall be tested and the results averaged.

9.4.15.3 Elongation This test shall be conducted in accordance with 9.4.8 and 9.4.9.

9.4.16 Retests for Physical and Aging Properties and Thickness

that reel shall be considered as not conforming to this Standard, and a thickness measurement on each of the remaining reels shall be made. When ten or more samples are selected from any single lot, all reels shall be considered as not

48

ICEA S-94-649-2004

DATE: 10/14/04

individual tests.

9.5 DIMENSIONAL MEASUREMENTS OF THE METALLIC SHIELD insulated conductor. Measurements shall be made with a micrometer or other suitable instrument readable to at least 0.0001 inch (0.002 mm). the middle of the sample. The average of the three measurements shall be taken as the diameter. The minimum measured individual wire diameter and the averaged measured total wire diameter shall be reported in the production test report. shall be taken as the width and thickness. The minimum measured individual strap width and thickness and the averaged measured total strap width and thickness shall be reported in the production test report.

Measurement of the diameter over the insulation and the insulation shield shall be made with a diameter tape accurate to 0.01 inches (0.25 mm). When there are questions regarding compliance to this Standard, measurements shall be made with an

The diameter for the cross-section shall be the average of the four values. This average diameter value shall measurements shall be made on cable samples that contain the conductor. -

9.7.1 Heat Shock Samples of polyvinyl chloride jacketed cable shall be wound tightly around a mandrel having a diameter hour. At the end of the test period, the sample shall be examined without magnification.

Table 9-3 Bending Requirements for Heat Shock Test

Number of

Inches 0-0.750

0-1 9.05

6

0.751 -1 500 .1.501 and larger

Outside Diameter of Cable 3

180-degree bend 38.1 3 and larger

180-degree bend

49

12

II

DATE: 10/14/04

ICEA S-94-649-2004

9.7.2 Heat Distortion

9.7.3 Cold Bend shall have a diameter in accordance with the following table:

Table 9-4

Inches

mm

0-0.800

0-20.32

0.801 and larger

Outside Diameter of Cable

20.32 and larger

8 10

1

9.8.1 Conductor Shield (Stress Control) shall be applied to the conductor shield spaced at least 2 inches (50.8 mrn) apart.

p=

IOOL

Where:

9.8.2 Insulation Shield apart.

The volume resistivity shall be calculated as follows:

50

-

DATE: 10/14/04

ICEA S-94-649-2004

P=

100L

Where: -

9.8.3 Test Equipment

A.

9.8.4 Test Procedure 9.8.4.1 Two-electrode Method

9.8.4.2 Four-electrode Method The four-electrode method may be used as a referee method. Conductor shield: The samples shall be cut in half longitudinally and the conductor removed. Four silverpotential electrode. shall be placed at least

inch (25.4 mm) beyond each potential electrode.

9.8.4.3 Measurement The resistance of the conducting component between the electrodes shall be determined at the specified temperature.

with concentric wire neutrals. The resistance of the jacket is obtained from measuring the voltage drop across the sample at room

51

ICEA S-94-649-2004

DATE: 10/14/04

direction. The apparent resistivity of the jacket is calculated from the electrical measurement and geometry of the cable.

9.8.5.1 Sample Preparation

separated approximately 1/8 inch (3.2 mm) from the measuring electrode.

Electrode Semi-

G 2.0"

Concentric Neutral Electrode

E2

Figure 9-3 Sample Preparation for Radial Resistivity Measurement Legend:

The sample shall be tested in air at room temperature.

9.8.5.2 Test Equipment Setup voltmeters, an ammeter, an adjustable resistor and an adjustable voltage dc or 60 Hz ac power supply. The measuring circuit is connected as shown in Figure 9-4. This is done to prevent surface current from affecting the measurement. As it is adjusted, the measured

52 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

DATE: 10/14/04

ICEA S-94-649-2004

G

G

E2

-

Reiu Ammeter n

Guard

Figure 9-4 Circuit for Radial Resistivity Measurement of Semi-Conducting Jackets

9.8.5.3 Calculation

cable sample, calculate the apparent resistivity as follows:

P, ):n I(

Where:

diametrically opposite from each other.

53

vo It

Meters

DATE: 10/14/04

Adhesion test shall be performed in accordance with. ICEA T-27-58VNEMA WC-53 (Adhesion).

9.10 SHRINKBACK TEST PROCEDURE

Five samples, each 1.5 feet (0.45 m) are required for the test. A length of the specimen cable 17.5 feet

end pieces from the original cable length are to be discarded. 9.1 0.2

-

Test Procedure

performed three times, if required. At the end of each cooling period, the samples shall be measured for shrinkback using a micrometer, or

preferably an optical measuring device. The selected measuring device shall have a minimum resolution of

maximum.

The measured values shall be in accordance with Tables 4-5 or 4-6 of Part 4. Only consider the worst sample of the five using the total shrinkback of both ends.

9.1

RETESTS ON SAMPLES Except for physical and aging properties and thickness tests Except for Amber, Agglomerate, Gel, Contaminant, Protrusion, Indent,

See 9.4.1 6

See 9.4.13.3

Except for Internal Irregularity Test

See 9.4.1 4.3

they represent shall be considered as meeting the requirements of this Standard.

54

DATE: 10114/04 considered as meeting the requirements of this Standard. Failure of any sample shall not preclude resampling and retesting the length of cable from which the original sample was taken.

9.12 AC VOLTAGE TEST 9.12.1 General between the conductor and the metallic shield with the metallic shield grounded. The rate of increase from the initially applied voltage to the specified test voltage shall be approximately uniform and shall be not more

This test shall be made with an alternating potential from a transformer and generator of ample capacity and shall have a wave shape approximating a sine wave as closely as possible. The initially applied ac test voltage shall be not greater than the rated ac voltage of the cable under test.

9.13 PARTIAL-DISCHARGE TEST PROCEDURE Partial-discharge test shall be performed in accordance with ICEA Publication T-24-380. The manufacturer shall wait a minimum of 7 days after the insulation extrusion process before the tests are

discharge test.

CONTROL LAYERS Determination of dielectric constant and dielectric strength shall be peiformed in accordance with ICEA T-27-581/NEMA WC-53.

9.1

WATER CONTENT

and for water in the conductor (if cable does not have a sealant and is stranded).

9.15.1 Water Under the Jacket

cable containing water under the jacket is discarded.

55 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

on each end. The strands shall be individually separated and visually examined. If water is present, the

9.15.3 Water Expulsion Procedure of Water Test. As soon as possible after the procedure, both ends of the cable shall be sealed to prevent the ingress of water during shipment and storage.

To verify the presence of water in the conductor, the following steps shall be taken.

Each length of cable to be tested shall be sealed at one end over the insulation shield using a rubber cap filled with anhydrous calcium sulphate granules. The rubber cap shall be fitted with a valve. The valve on the rubber cap shall then be opened sufficiently to hear a flow of gas.

This procedure shall be repeated after placing new granules in the cap.

56

--``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

DATE: 10/14/04

STANDARD

TEST

MINIMUM

REFERENCE

REFERENCE

FREQUENCY

dc Resistance

Part

9.3.1 and ICEAT-27-581

100%

Diameter

Part 2

ICEA T-27-581

Plan A

Temper

Part

ASTM

Manufacturer certification that required values are met

ElongationAfter Aging

Part 3

9.4.15

Plan

Volume Resistivity

Part 3

9.8.1

Plan

Thickness

Part 3

9.4.2

Plan

Voids, Protrusions and Irregularities

Part 3

9.4.1 3

Plan A

Wafer Boil

Part 3

9.4.1 2

Plan

Spark Test (Non-conducting Layer Only)

Part

K E A T-27-581

100%

~~~

~

_

_

_

_

_

_

_

_

_

_

~

9.4.8 and 9.4.9

~

II

Hot Creep

Part 4

Voids and Contaminants

Part4

9.4.13

Internal Irregularity Test (XLPE/TRXLPE Only) Part 4

9.4.14

Diameter

Appendix C

9.6

Shrinkback Test (XLPW RXLPE Only)

Part

9.10

Plan C

Thickness

Part 4

9.4.2

Pian

II Non-Metallic nsulation Shield

II

Elongation Aiter Aging

Part 5

9.4.15

Plan

Volume Resistivity

Part 5

9.8.2

Plan

Thickness

Part 5

9.4.2

Plan

Indent (Under Concentric Neutrals)

Part5

9.4.13

Plan

Voids and Protrusions

Part

9.4.13

Plan A

Stripping Tension

Part

9.9

Plan

Part

9.4.12

Plan

Appendix

9.6

Plan

~~

~

~

II

1

~~~

57

Table 9-5

TEST

STANDARD REFERENCE

TEST METHOD REFERENCE

MINIMUM FREQUENCY

Dimensional Measurements

Part 6

9.5

Plan E

Unaged and Aged Tensile and Elongation

Part 7

9.4.8 and 9.4.9

Plan H

Thickness

Part 7

9.4.2

Plan E

Heat Distortion

Part 7

ICEA 1-27-581

Plan H

Heat Shock

Part 7

9.7.1

Plan H

Cold Bend

Part 7

ICEA T-27-581

Plan

Oil Immersion

Part 7

9.4.9.3

Plan H

Radial Resistivity

Part 7

9.8.3

Plan

ac Withstand Test

Part

9.12

Plan

Partial Discharge Test

Part 4

ICEA T-24-380

Plan

Jacket Spark Test

Part 7

100% ~

~~

Other Tests Part

Water in Conductor

Plan

9.15 I

I

Water Under Jacket

Part

Conductor Water Penetration Test, if applicable

Part

ICEA T-31-610

Part 6

ICEA T-34-664

9.15

~

~

~~

Plan

II

Plan C I

Plan

II

Plan

Plan Three samples shall be taken per cable core extruder run. The samples shall be taken near the beginning, near the middle and near the end of each extruder run. The middle sample shall be eliminated if the extruder run is to be shipped in one continuous length.

Plan

58 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

ICEA S-94-649-2004

DATE: 10/14/04

Plan D

Plan E -

Table 9-6 Plan E

II

Per Extruder Run each shipping length 2 10% of shipping lengths

20 and greater

next higher integer value)

Plan Table -7 Plan Jacket Extruder Run Length-feet (meters) ~

Samples

less than 250 (127) 250 (127) and larger 250 (127) and larger 250 (127) and larger

Plan One test per shipping length. For multiple conductor assemblies, each conductor of a shipping length shall be tested.

Plan Each lot of material used for extrusion on the cable.

59

DATE: 10/14/04

QUALIFICATION TESTS 10.0

GENERAL

Qualification tests included in this Standard are intended to demonstrate the capability of materials to be used in high quality cable with the desired performance characteristics. It is intended that the product furnished under this Standard shall consistently comply with all of the qualification test requirements. The tests are divided into five categories. A) Core Qualification i) Core Material Qualification Requirements ¡i) Manufacturing Qualification Requirements C) Jacket Material Qualification

D) CV Extrusion Qualification E) Other Qualification Tests

certified copy of the qualification test report that represents the cable being purchased. If a conductor shield/insulation combination, insulation shield or a completed cable design was qualified qualification tests, or thermomechanical qualification test, as applicable, in this standard.

Additional

Standard.

10.1

CORE QUALIFICATION TESTS

These tests evaluate core (conductor shield, insulation, and insulation shield) materials only. Unless otherwise noted, samples of unjacketed 15kV rated cable with a 100% insulation level wall thickness in conductor, and having a concentric wire neutral which successfully complete this qualification test program, Manufacturing Qualification Report will remain valid until any one of the compounds change (change in the compound composition). 10.1.1

Material Qualification Requirements

The Conductor Shield/lnsulation and Insulation/lnsulationShield material qualification requirements may

under Manufacturing Qualification Requirements. 10.1.1.1 Conductor Shield/lnculation Qualification

60

--``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

ICEA S-94-649-2004

DATE: 10/14/04

The results of all tests shall be provided in the qualification report.

10.1.1.2 Insulation/lnsulation Shield Qualification 120 days of testing (Tests 1-5). This test can be performed once and all cable manufacturers can use the

CS/I qualification test. The results of all tests shall be provided in the qualification report. shield without performing a separate insulation shield qualification test.

10.1.2 Manufacturing Qualification Requirements Once a set of cable core interfaces meet the Material Qualification Requirements, each cable Manufacturing Qualification Tests as outlined below. The Conductor Shield/lnsulation and Insulation/lnsulation Shield manufacturing qualification requirement may be met by conducting the appropriate tests on a single cable or on two different cables. The appropriate test must be repeated if any material is changed (change in compound name or number). indicate a slight change made only to improve compound handling or extrusion characteristics,do not require re-qualified by each manufacturer using the appropriate Manufacturing Qualification Requirements.

10.1.2.1 Conductor Shieldnnsulation Test All conductor shield/insulation (CS/¡) interfaces must meet the AWTT performance requirements out to Shield qualification test. The results of all tests, including those performed as a part of the material qualification, shall be provided in the qualification report.

10.1.2.2 Insulation/lnsulation Shield Test

The results of all tests, including those performed as a part of the material qualification, shall be provided in the qualification report.

-

61

ICEA S-94-649-2004

DATE: 10/14/04

FLOW CHART FOR CORE QUALIFICATION TESTS

I

I

21 Samples

I -

Test Number High Voltage Time Test

Electrical Measurements Para. 10.1.7 Sample 7

-

Para. 10.1.3

I

Physical Measurements

Hot Impulse Test

Test Number

Para. 10.1.4 Para. 10.1.4

120-Day Accelerated Water Treeing Test (Awn) Para. 10.1.6

I

180-Day Accelerated Water Treeing Test (AWTT) Para. 10.1.6

360-Day Accelerated Water Treeing Test (AWTT) Para. 10.1.6

I

Electrical Measurements Para. 10.1.7

I

Test Number High Voltage Time Test Para. 10.1.3

Physical Measurements Para. 10.1.8 Sample 13


Physical Measurements Para. 10.1.8 Sample 16

62


ICEA S-94-649-2004

DATE: 10/14/04

10.1.3 High Voltage Time Test (HVTT) Procedure A high voltage time test shall be made on samples of cable as shown in the Flow Chart (Test Numbers (3.9 kV/mm), based on the nominal insulation wall thickness of the sample, shall be applied under the will be reported for this test. Insulation Thickness at Failure

Measured insulation thickness immediately adjacent to the failure site.

AC Breakdown Step

The voltage step, calculated in V/mil (kV/mm) and based on the nominal insulation thickness of the sample, at which the sample failed.

AC Withstand Step

The highest voltage step, calculated in V/mil (kV/mm) and based on the nominal insulation thickness of the sample, that was maintained for an entire 5-minute period without the sample failing.

If a sample fails while the voltage is being increased from one step to the next, then both the ac added within the qualification report to clarify that the failure occurred during the voltage transition between steps. The minimum qualification ac withstand values are listed in Table 10-1. When samples are removed from the Accelerated Water-Treeing Test (AWTT), the HVTT shall be performed within 24 hours after completion of the AWTT. The water in the conductor shall not be drained samples shall be stored in water with the same characteristics as the water used during the test until the HVTT is not completed within 48 hours. -

depiction of the sample length is as follows. HV Term. Section

I

Air Section

I

Water Section

Lengthasneeded

I

Air Section

I

HV Term. Section

1' to

requirements have taken effect. been completed, the sample shall be re-terminated and re-tested. This procedure shall be repeated only reported, but the reported value shall be reported as a termination failure. To retest after a termination failure, the voltage shall be reapplied starting at 00 V/mil (3.9 kV/mm) and

63

DATE: 10/14/04

ICEA S-94-649-2004

held for 30 seconds. It shall then be increased in 40 V/mil (1.6 kV/mm) steps and held for 30 seconds at each step, continuing to the step at which the terminal failure occurred. The voltage shall be held for until breakdown occurs. It must be documented in the test report that a termination failure occurred along with the active length of cable that was tested after re-termination.

10.1.4 Hot Impulse Test Procedure To establish impulse performance characteristics, a hot impulse test shall be made in accordance with

horizontally mounted, 3-inch nominal diameter polyethylene or PVC conduit that is 6-feet (1.8m) in length. The conduit ends shall be closed to prevent air circulation into or out of the conduit. For hot impulse tests, the temperature of the conductor shall be equal to the rated emergency overload temperature of the cable +0/-5”C. The temperature shall be achieved by circulating current in the conductor with no current in the metallic shield. Ten impulses of positive polarity with a magnitude equal to the BIL shown in Table 4-6 shall be applied,

impulses of negative polarity applied at each step and continuing to cable breakdown outside the terminals. qualification test report. If a failure occurs outside of the active length of the sample, the value obtained shall be reported as a failure outside the active length. Samples must meet the minimum impulse withstand requirements provided in paragraph 4.3.2.3 of this standard.

10.1.5 Cyclic Aging Cyclic aging is conducted to provide thermal conditioning (to remove a large portion of the volatiles found in freshly manufactured cable) for Test Numbers 3 through 7 as listed in the Flow Chart. Cable samples the cable is insulated and when cyclic aging begins. The date when the cable core was extruded and the date when the cyclic aging begins must be recorded in the qualification report.

10.1.5.1 Cable Length Sufficient sample length is required to provide thermally conditioned cable for Test Numbers 3 through in the Flow Chart.

conducted on unjacketed cable only.

The cable shall be installed in a 3-inch nominal diameter polyethylene or PVC conduit with ends closed to prevent air from escaping or entering the conduit. The conduit may be smooth or corrugated. Elevated conductor temperatures are achieved by circulating ac current in the conductor with no current in the metallic shield.

64

DATE: 10/14/04

ICEA S-94-649-2004 10.1 5 4 Load Cycle

during which the current is on for the first 8 hours and off for the remaining 16 hours. The conductor voltage is applied during the load cycle. Temperatures shall be established before the test is performed by test sample.

10.1.6 Accelerated Water Treeing Test (AWTT) Procedure 10.1.6.1 General .placed in a 3-inch nominal diameter polyethylene or PVC conduit and with both the conductor interstices and the conduit filled with tap water throughout the test. The cables shall also be subjected to load cycles using induced current.

Flow Chart. The aging test may be conducted with individual samples or in one continuous length that is subsequently cut into individual samples.

10.1.6.3Aging Time

-

samples are aged for 180 days and subjected to a series of tests (Test Number 6). The remaining three samples are aged for 360 days and then subjected to a series of tests (Test Number ).

10.1.6.4Conduit Fixture The conduit fixture shall consist of a horizontally mounted, 3-inch diameter polyethylene or PVC conduit. Bends will be attached on each end of this conduit in order to maintain water within the fixture. The angle the cable from being bent tighter than its minimum bending radius. Short lengths of conduit may also be Figure 10-1 for an example of a typical conduit fixture. Multiple conduit installations positioned side-by-side must have a minimum of 1-inch separation between the conduits. Vertically stacked conduit fixtures are allowed if temperature profiles are conducted in each fixture layer and it is shown that the temperature of the cables in the upper conduits are not affected by the temperature of the cables in the lower conduits. When Water shall be maintained within 4 inches from the top of the conduits at all times throughout the test.

1

-

Figure 10-1 Conduit Fixture

65

Bend, selected by laboratory Floor

DATE: 10/14/04

ICEA S-94-649-2004 10.1.6.4.1 Structures Above Conduit Fixtures

Structures, such as platforms, walkways, etc., may be installed above the conduit fixtures if temperature profiles demonstrate that the structures do not affect the required temperatures of the cable.

10.1.6.4.2 Conduit Fixture Dimensions Conduit fixtures shall be constructed such that individual cable samples are produced that meet the within five years of the date of this standard.

10.1.6.5 Water maintained within .4 inches from the top of the conduits at all times throughout the test. Tap water shall also be maintained within the interstices of the conductors at all times throughout the test. Before each test begins, the water in each conduit fixture must be removed and the conduit cleaned such that a new test begins with fresh tap water. -

10.1.6.6Ambient Temperature

10.1.6.7Test Procedure The aging parameters for the accelerated water treeing test are outlined as follows: Test Voltage:

Test Frequency: 49-61 Hz (report nominal frequency utilized) Test Cycle:

that do not meet this requirement will not be considered a part of the aging time. Dummy Load Cycle: To

u

p

u

p

d

66

p

d

p

du

DATE: 10/14/04

in-water insulation shield temperature requirement, it may be necessary to use a thin blanket of thermal profile for the outermost conduits (conduits not bounded on both sides by other conduits containing similarly energized cables). If insulation is required, it must remain in place throughout the aging period conductor in air and water and the insulation shield in water shall be reported graphically in the qualification test report. The 24-hour load cycle temperature profile for the insulation shield in water determined by the dummy load cycle shall be followed during the cable aging load cycle. If a laboratory has more than one bank of conduit fixtures, temperature profiles must be established for each bank of fixtures. Temperature profiles must also be established for the outermost conduit fixtures (conduits not bounded on both sides by other conduits containing similarly energized cables) in a multiple

of the installation. Aging Load Cycle:

shall be induced 8 hours on and 16 hours off (one load cycle period) for the number of load cycles indicated below. During each load cycle, the in-water insulation shield temperature profile established for the dummy cable shall be followed. Generally, the current magnitude established during the dummy achieve the correct temperature if the thermal environment of the test facility changes during the test. If the cable insulation shield temperature exceeds 48"C, the qualification test report shall include the conductor or the conduit or for general maintenance. To monitor voltage aging time, a cumulative

120-Dav Samples

thermal load cycles followed by two consecutive days with no thermal load cycles.

However, when

so, the 86 days with thermal load cycles must be dispersed throughout the 120-day aging period There shall be no periods with more than eight consecutive days with thermal load cycles and no periods with more than four consecutive days with no thermal load cycles. If the maximum temperature during a thermal load cycle is below the required limit of 42"C, the load

the total number of voltage applied days in the qualification test report.

67

ICEA S-94-649-2004

DATE: 10/14/04

180-Dav Samples These samples must experience a cumulative total time of 180 days at the proper aging voltage. They must also experience 129 days with thermal load cycles at the required time and temperature values. The objective is to have repeating, seven-day load cycle periods consisting of 5 consecutive days with

shall be no periods with more than eight consecutive days with thermal load cycles and no periods with more than four consecutive days with no thermal load cycles. cycle must be repeated. There will be an exception to this for up to five load cycles that do not achieve this requirement, the total voltage aging time may exceed 180 days. When this occurs, report the total number of voltage applied days in the qualification test report. 360-Dav Samples These samples must experience a cumulative total time of 360 days at the proper aging voltage. They must also experience 257 days with thermal load cycles at the required time and temperature values. The objective is to have repeating, seven-day load cycle periods consisting of 5 consecutive days with so, the 257 days with thermal load cycles must be dispersed throughout the 360-day aging period There shall be no periods with more than eight consecutive days with thermal load cycles and no periods with more than four consecutive days with no thermal load cycles.

If the maximum temperature during a thermal load cycle is below the required limit of 42"C, the load cycle must be repeated. There will be an exception to this for up to ten load cycles that do not achieve must have continuous voltage applied. Therefore, if it is necessary to repeat load cycles in order to meet number of voltage applied days in the qualification test report.

shall be reported in the certified qualification report.

10.1.6.9High Voltage Time Test Requirements High Voltage Time Tests are required as a part of Tests 1, 3, 5, 6, and 7. The minimum acceptable ac withstand values at these aging periods are shown in Table 10-1. All High Voltage Time Test results shall be included in the qualification report. Any failures that occur outside the active cable length will not be considered as failures of the test cable, but these failures must be documented and reported in the certified qualification report along with the active identified.

68

DATE: 10/14/04

ICEA S-94-649-2004 Table 10-1 Minimum ac Withstand Values I

~~

Type Crosslinked Polyethylene

After Cyclic Aging

620 (24.4)

620 (24.4)

300 (1 1.8)

660 (26.0)

660 (26.0)

580 (22.8)

380 (15.0)

500 (19.7)

420 (16.5)

340 (13.4)

340 (13.4)

Tree Retardant 620 (24.4) Crosslinked Polyethylene Ethylene Propylene Rubber

After 120 Days After 180 Days After 360 Days of AWTT Aging of AWTT Aging of AWTT Aging

Prior To Cyclic Aging

500 (19.7)

Not Required

Not Required

minimum agreed upon expectations at the time this standard was balloted. Industry organizations, The ICEA will evaluate future proposals that try to better define the generic insulation materials. Note2: The minimum ac withstand values shown above for ethylene propylene rubber compounds are lower than the corresponding values for polyethylene compounds. This does not indicate that these insulations are inferior or that their long term reliability will not be good. The lower values are simply a function of the composition of EPR material.

For the occasional situation where cable samples fail during aging, or cases where cables fail the ac or impulse test requirements, and where the failure is demonstrated to have occurred as a result of manufacturing imperfections (such as contamination, voids, protrusions, or conductor shield skip), retesting is allowed. To conduct the retest, all three samples in the three-sample set that contains the failed sample shall be retested. The retest samples shall come from the same length of cables a s the original samples. The entire test protocol shall be conducted on these samples. If they meet all test requirements, along with all other If more than one sample (including any one of the retest samples) fails during aging or does not meet the

requirements.

10.1.7 Qualification Test Electrical Measurements To monitor changes in the electrical characteristics of the cable during aging, partial discharge (for discharge free cable designs only), capacitance and dissipation factor shall be measured. The capacitance and dissipation factor test shall be made at rated voltage at room temperature. These tests shall be

qualification test report for engineering information only.

69 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

ICEA S-94-649-2004

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10.1.8 Qualification Test Physical Measurements To monitor changes in the insulation shield stripping tension and to document the conductor shield thickness, insulation thickness, insulation shield thickness, these values shall be measured on Samples 1, 7, qualification report for engineering information only.

operate near the rated emergency overload conductor temperature.

10.2.1 Scope The manufacturer shall conduct the test on a generic cable design in accordance with Tables 10-2 and necessary to demonstrate the desired performance results.

10.2.2 Procedure 10.2.2.1 Fixture 4-inch nominal diameter conduit shall be used for cables larger than 1.5 inches (38.1 mm) in diameter. The mm) for the 4-inch nominal conduit.

10.2.2.2 Load Cycling The cable shall be subjected to 14 load cycles. Each load cycle is defined as a 24-hour time span with a current-on period and a current-off period. During the current-on period, sufficient alternating current shall be Voltage on the conductor is not required during load cycling. When the conductor is at the required temperature, the temperature gradient shall be within the limits outlined in Table 10-2. The reference location for all conductor temperature requirements is the longitudinal center of the cable inside the conduit (in center of U-bend). These temperatures shall be established before the test is performed by placing a thermocouple on the conductor of a "dummy" cable which is load cycled in a manner similar to a test sample. air temperature. If this condition cannot be met, the test shall be interrupted at the end of the fifth and tenth cycle. During this interruption, the current shall remain off for a period of at least 24 hours to allow the cables interrupted procedure may also be followed even if the temperature drop requirement during the current-off period can be met. part of a load cycle. If, for any reason, the temperature falls below the specified level during any given load cycle, that load cycle must be repeated. Load cycles may be contiguous or there may be periods with no current between

70

ICEA S-94-649-2004

DATE: 10/14/04

10.2.2.3 Electrical Measurements Initially and after 14 test cycles partial discharge (unless otherwise specified) and dissipation factor measurements shall be made with the cable conductor at room temperature and at the emergency overload Unless there is specific agreement by purchaser and manufacturer on other values, the dissipation factor at room temperature and partial discharge shall meet the limits in the appropriate Parts of this Standard and shall be reported. If the partial discharge or the dissipation factor limits are exceeded, the test shall be terminated and the cable design rejected.

10.2.2.4Physical Measurements Before and After the Thermomechanical Design Test At the end of the test, a sample of cable from the center of the bend will be removed for measuring.

Measure the thickness of the conductor shield, insulation, insulation shield, and jacket as outlined in 9.4.2.2. These measurements shall also be made on an unaged sample of the same cable. If the jacket cracks or develops holes during the test, the cable design shall be rejected.

Table 10-2 Maximum Temperature Gradient for Thermal Aging Conductor Size, kcmil (mm2)

Insulation Thickness mils (mm)

Maximum Temperature Gradient between

Voltages Qualified

Outer Surface

500 (253) or 345 (8.76) or more larger

all

40 OC

345 (8.76) or more

all

40°C

less than

500 (253)

500 (253) or less than larger 345 (8.76) less than 500 (253)

that voltage class

less than that voltage class 345 (8.76)

71

30

C

Conductor Sizes Qualified

I I

all

Il Il

that size and all smaller sizes

that size and all smaller sizes

insulations: ~

~~

a)

Crosslinked polyethylene

b)

Ethylene propylene rubber

The addition of tree retardant compounds does not add to the categories.

Extruded Shielding: ~

a)

Thermoplastic

b)

Thermoset

Metallic Shielding: a)

Round wire

b)

Flat strap

Non-conducting Jackets:

-

b)

Low, medium and linear low density polyethylene

c)

High density polyethylene

f)

PP

SemiconductingJackets: a)

Notes: 1)

2)

and vice versa. qualification test.

The following qualification tests are for specific types of jacketing materials and shall be performed on each compound. The jacket material tests or certification from the material supplier can be used by all cable producers who propose to use the material. The material qualification is valid until the compound is changed. 10.3.1 Polyethylene and Polypropylene Jackets

72

DATE 10/14/04

ICEA S-94-649-2004 10.3.1.1.1 Test Specimen

(3.18 mm) thick from the sample shall be molded from material intended for extrusion. The temperature of the molded specimens shall be lowered at any suitable rate. A slit made with a razor blade, approximately -

one of the 1.5 inch by 0.5 inch (38.1 mm by 12.7 mm) surfaces.

10.3.1.1.2 Test Procedure

equivalent) shall be added to completely cover the specimen. The test tube, suitably closed by means such

The absorption coefficient of polyethylene jacket compound shall be determined in accordance with

10.3.2 Semiconducting Jackets 10.3.2.1 Brittleness Temperature (See 10.5.4) 10.3.3 Polyvinyl Chloride and Chlorinated Polyethylene Jackets 10.3.3.1 Sunlight Resistance 10.3.3.1.1 Test Samples Five samples shall be prepared from material intended for extrusion or from completed cable.

10.3.3.1.2 Test Procedure The test may be performed using either a carbon-arc or xenon-arc apparatus. For a carbon-arc apparatus, five samples shall be mounted vertically in the specimen drum of the carbon-arc-radiation and water-spray exposure equipment per ASTM G-153. For the xenon-arc apparatus, five samples shall be mounted, top and bottom, on a rack of the xenon-arc-radiation and water-spray exposure equipment per ASTM G-155. The test method shall also be in accordance with ASTM G-153 or ASTM G-155 respectively prepared and tested for tensile and elongation from (1) unaged section of the cable jacket and (2) the conditioned samples, one specimen from each sample. The respective averages shall be calculated from the five tensile strength and elongation values obtained for the conditioned samples. These averages shall be divided by the equivalent averages of the five tensile and elongation values obtained for the unaged specimens. This provides the tensile and elongation ratios for the jacket. The jacket is not sunlight resistant if maintained.

10.3.4 Extruded Red Stripe For Jackets 10.3.4.1 Sunlight Resistance

73

DATE: 1 0/14/04 10.3.4.1.1 Test Samples Five samples shall be prepared from material intended for extrusion.

10.3.4.1.2 Test Procedure The test may be performed using a xenon-arc apparatus. Five samples shall be mounted, top and bottom, on a rack of the xenon-arc-radiation and water-spray exposure equipment per ASTM G-155. The test unaged molded plaque and (2) the conditioned samples, one specimen from each sample. The respective averages shall be calculated from the five tensile strength and elongation values obtained for the conditioned samples. These averages shall be divided by the equivalent averages of the five tensile and elongation values obtained for the unaged specimens. This provides the tensile and elongation ratios for the stripe

followed by a High Voltage Time Test. If an extrusion line did not produce any cable for a shipping length during a calendar month, a test is not required. If a Core Material Qualification Report on cable not produced by the manufacturer is used in accordance

10.4.1 Thermal Conditioning

applied. additional length to apply terminations for the High Voltage Time Test.

10.4.2 Dissipation Factor Verification ground voltage. Any appropriate metallic shield may be used for this test. The dissipation factor shall meet the requirements of Part 4. The actual value shall be recorded.

After the thermal conditioning is complete, the sample shall be subjected to the High Voltage Time Test (kV/mm) step increases are calculated based on the nominal thickness in Table 8-1. The CV Extrusion Qualification Test report shall indicate the appropriate minimum withstand value for the -

only.

74

.

DATE: 10/14/04

Table 70-4 AC Withstand Voltage Requirements 15-35 kV Rated Cables ~

Insulation Type

Insulation Thickness (nominal)

XLPE

II

Filled XLPE or TRXLPE EPR

420 (16.5)

460 (18.1)

I

460 (18.1) 340 (13.4)

I

300 (1 1.8)

Il

10.5 OTHER QUALIFICATION TESTS These tests shall be performed once for each material, as applicable. The results shall be on file with the manufacturer and provided on qualification test reports as requested.

Test 10.5.6 shall be performed on EPR Class IV insulations. The Resistance Stability Test 10.5.3 and the Brittleness Test 10.5.4 shall be performed on every shield material. 10.5.1

Insulation Resistance

Insulation resistance test shall be performed in accordance with ICEA T-27-58UNEMA WC-53.

Accelerated water absorption test shall be performed in accordance with ICEA T-27-581NEMA WC-53. The insulation shall meet the requirements in Table 10-5.

75 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

DATE: 10/14/04 Accelerated Water Absorption Properties Insulation Type I

Accelerated Water Absorption Properties (Electrical Method)

XLPE and TRXLPE

XLPE Class 111 and TRXLPE Class 111

75

90

Dielectric Constant after 24 hours, maximum

3.5

I

EPR Class1

I

EPR Class 111

EPR Class IV I

28kV or less

Above 28kV 75

I

4.0

II

Increase in capacitance, maximum, percent

Stability Factor after 14 days, maximum’

~

_

_

_

_

~

_

_

_

_

~~

0.5

Il

This test shall be performed on a sample of the materia@) intended for extrusion in accordance with

10.5.5.1 Test Samples

shield and an outer insulation shield with any suitable metallic shield. The samples shall be approximately 30 feet (9.1 m) long.

10.5.5.2Test Procedure The test shall be performed with the sample cable in a 3 inch nominal diameter polyethylene or PVC

achieved.

76 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

DATE: 10/14/04 10.5.5.3 Electrical Measurements

measured at the three temperatures (may also be measured at weekly intervals). If dissipation factor does not increase by more than 10% at each of the three test temperatures, the test can be terminated. If after the one week intervals the dissipation factor measured and recorded at each of the temperatures. The sample time period.

Where:

DFn

=

the last dissipation factor measurement (average of the three samples).

incremental period temperature thereafter. The dissipation factor shall not exceed the maximum limit specified at room at any time during testing. The partial discharge shall be measured on the initial specimens and after the current loading test has exceeded, the test shall be terminated and the cable design rejected.

-

and conditions.

10.5.6.1 Test Specimens

prepared specimens shall be held for a minimum of 72 hours at room temperature followed by 16 hours minimum in the same environment as the electrical discharge test.

10.5.6.2Test Environment The discharge test shall be performed in an area provided with a controlled-draft flow of conditioned air to gasses.

10.5.6.3Test Electrodes

when positioned vertically atop the center of the insulation specimen. The contacting end shall be flat except

77

DATE: 10/14/04

diameter, centered under each upper electrode.

10.5.7 Dissipation Factor Characterization Test

When an insulation compound requires requalification within the context of this Standard, the Dissipation Factor Characterization Test shall also be performed.

10.5.7.1 Test Samples

-

be unjacketed with a concentric neutral.

10.5.7.2Thermal Conditioning

72 hours. The sample shall be supported in air (no conduit and not lying on the floor), with no test voltage a length of cable which is being load cycled for conductor shield/insulation qualification or insulation shield qualification.

10.5.7.3 Dissipation Factor Testing following sequence of conductor temperatures: 1.

Rated emergency temperature of the insulation.

The conductor temperature shall be achieved by inducing ac current in the conductor. The sample shall minimized. The dissipation factor measured at room temperature shall be less than or equal to the appropriate characterization of the insulation material.

78

DATE: 10/14/04

Part 11 APPENDICES APPENDIX A NEMA, ICEA, IEEE, ASTM AND ANSI STANDARDS (Normative) Al NEMA PUBLICATIONSt WC 26/EEMAC 201 (2000)

Binational Wire and Cable Packaging

WC 53/ICEA T-27-581 (2000)

Standard Test Methods for Extruded Dielectric

P-32-382-1999 P-45-482-1999

Short Circuit Performance of Metallic Shields and Sheaths on Insulated Cable

T-24-380-1994

Guide for Partial-Discharge Test Procedure

T-25-425, (02/81)

Guide for Establishing Stability of Volume Resistivity for Conducting Polymeric Components of Power Cables

T-28-562-1995

Test Method for Measurement of Hot Creep of Polymeric Insulation

T-31-610-1994

Guide for Conducting a Longitudinal Water Penetration Resistance Test for Sealed Conductor

T-32-645-1993

Guide for Establishing Compatibility of Sealed Conductor Filler Compounds with Conductor Stress Control Materials

T-34-664-1996

Guide for Conducting Longitudinal Water Penetration Resistance Tests on Longitudinal Water Blocked Cables

A3 IEEE AND ANSI STANDARDS* IEEE Std 82-1994

IEEE Standard Test Procedure for Impulse Voltage Tests on Insulated Conductors

IEEWANSI C2-2002

National Electrical Safety Code (NESC)

A4 ASTM STANDARDS* Soft or Annealed Copper Wire, Specification for Tough-Pitch Electrolytic Copper Refinery Shapes, Specification for

79 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

DATE: 10/14/04

Concentric-Lay Stranded Copper Conductors, Hard, Medium-Hard, or Soft, Specification for

Resistivity of Electrical Conductor Materials, Test Method for

B 231 -04

Compact Round Concentric-Lay Stranded Copper Conductors, Specification for B 609-99(2004) Aluminum 1350 Round Wire, Annealed and Intermediate Tempers, for Electrical Purposes, Specification for B 784-01

Specification for 19 Wire Combination Unilay-Stranded Aluminum 1350 Conductors for Subsequent Insulation, Specification for 19 Wire Combination Unilay-Stranded Copper Conductors for Subsequent Insulation, Specification for Tempers, Specification for Concentric-Lay-Stranded Conductors of 8000 Series Aluminum Alloy for Subsequent Covering or Insulation, Specification for Compact Round Stranded Copper Conductors Using Single Input Wire Construction, Specification for Compact Round Stranded Aluminum Conductors Using Single Input Wire Construction, Specification for

B 901-04

Compressed Round Stranded Aluminum Conductors Using Single Input Wire Construction, Specification for Compressed Round Stranded Copper Conductors, Hard, Medium-Hard, or Soft Using Single Input Wire Construction, Specification for Test Methods for

Brittleness Temperature of Plastics and Elastomers by Impact, Test Method for

80

ICEA S-94-649-2004

D 1693-01 Voltage Endurance of Solid Insulating Materials Subjected to Partial Discharges (Corona) on the Surface, Test Method For D 2765-01

Methods for

D 3349-99

Absorption Coefficient of Ethylene Polymer Material Pigmented with Carbon Black, Test Method for

D 4496-99

DC Resistance or Conductance of Moderately Conductive Materials, Test Method for Practice for Practice for

801 12, USA.

Copies may be obtained from the American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken, PA 19429-2959, USA.

81 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

DATE: 10/14/04

APPENDIX EMERGENCY OVERLOADS (Normative)

the cable.

conditions.

-

82

ICEA S-94-649-2004

DATE: 10/14/04

APPENDIX C1 The minimum and maximum diameter limits are calculated average values. Conformance with these Shield).

C2 Diameters shall be computed by the following method: Table C-1

Table C-1 Insulation Diameter Calculation II

li

(AWG or kcmil)

Minimum

Maximum

Where: C

cs

T

=

Applicable nominal conductor diameter from Part Minimum point extruded conductor shield thickness from Part

All dimensions are in mils

applied over the conductor, the diameter over the insulation will be supplied by the manufacturer.

To determine the maximum diameter over the insulation shield for a cable, add the appropriate valu

-

83

ICEA S-94-649-2004

DATE: 10/14/04

Table C-2 Insulation Shield Adders II

i(

I

Calculated Minimum Diameter over Minimum

Maximum

60

2001

nd ab ve

80

120

110

150

110

150

Example:

C 2xcs 2T Sub Total

= = = =

955

C

2.5

Plus Sub Total 1045

mils

956

mils (round to 955 for minimum diameter over insulation)

mils minimum diameter over insulation = = = = =

CS

512 24

512

30

441

60

mils mils per equation in Table C -1

mils maximum diameter over insulation

To calculate the diameters over the extruded insulation shield: From Above Plus

Sub Total From Above Plus Sub Total

= =

955

=

1045

=

mils.minimum diameter over insulation minimum value from Table -2 mils minimum diameter over insulation shield

mils maximum diameter over insulation maximum value from Table C-2 1 1 4 5 mils maximum diameter over insulation shield

84 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

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.. W

d

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I

I

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I

I

I

-

d

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I I

I I

I I

n

I

'

i

1

Q

2 I

8

w-

Li

L

ic i

4.

C

I

C

I

I

X

z

B 2 \

O

..

7

UI

I-

3

al

o

C

s

L

v

ic i

x

c

o

z

x. €

o

o C

C

I

5

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z

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--``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

DATE: 10/14/04

APPENDIX

and an insulation shield.

under all conditions. An insulation shield has a number of functions: b.

To obtain symmetrical radial distribution of voltage stress within the dielectric, thereby minimizing the possibility of surface discharges by precluding excessive tangential and longitudinal stresses.

d.

To limit radio interference.

grounded, the hazard of shock may be increased.

basis for the use of shielding. Where there is no metallic covering or shield over the insulation, the electric field will be partly in the insulation and partly in whatever lies between the insulation and ground. The external field, if sufficiently intense in air, will generate surface discharge and convert atmospheric oxygen into ozone, which may be discharge will occur, causing ozone formation. The ground may be either a metallic conduit, a damp nonmetallic conduit, or a metallic binding tape or rings on an aerial cable, a loose metallic sheath, etc. Likewise, damage to nonshielded cable may result

Where nonshielded cables are used in underground ducts containing several circuits that must be

handled by personnel who may not be acquainted with the hazards involved.

88 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

DATE: 10/14/04

The insulation shield must be grounded at least at one end and preferably at two or more locations. It is recommended that the shield be grounded at cable terminations and at splices and taps. Stress relief devices should be applied at all shield terminations. The shield should operate at or near ground potential at all times. Frequent grounding of shields reduces

nonshielded nonmetallic cable and hazardous to life.

D5 SHIELD MATERIALS Two distinct types of materials are employed in constructing cable shields. be conducting compound, fibrous tape faced, or filled with conducting compound or conducting fibrous tape. Metallic shields should be nonmagnetic and may consist of tape, braid, wires, or a sheath.

D6 SPLICES AND TERMINATIONS To prevent excessive leakage current and flashover, metallic and nonmetallic insulation shields, including any conducting residue on the insulation surface, must be removed completely at splices and terminations.

underlying insulation. This may be accomplished by the aid of heat (air or flame) or by the use of a suitable solvent.

-

89

ICEA S-94-649-2004

APPENDIX E E l INSTALLATION TEMPERATURES All cable manufactured to this Standard can be safely handled if not subjected to temperatures lower

contact the cable manufacturer for cable suitability or recommended practices.

E2 RECOMMENDED MINIMUM BENDING RADIUS The minimum bend radius to which insulated cables may be bent for permanent training during installation is eight times the overall diameter for single conductor cable. For multiplexed single conductor cables, the minimum bending radius is five times the calculated overall diameter. These limits may not be suitable for conduit bends, sheaves, or other curved surfaces around which the cable may be pulled under specified refers to the inner radius of the cable bend and not to the axis of the cable.

E4 MAXIMUM TENSION AND SIDEWALL BEARING PRESSURES Consult the cable manufacturer for recommended maximum pulling tensions and maximum sidewall bearing pressures.

E5 TESTS DURING AND AFTER INSTALLATION E5.1 During Installation At any time during installation, a dc proof test may be made at a voltage not exceeding the dc test

E5.2 After Installation Aíter installation and before the cable is placed in regular service, a high voltage dc test may be made at -

applied for 15 consecutive minutes.

E53 After the cable has been completely installed and placed in service, a dc proof test may be made at any time within the first five years at a voltage not exceeding the dc test voltage specified in Table E-1 under the

90

ICEA S-94-649-2004

DATE: 10/14/04

some evidence that dc testing of aged cross-linked polyethylene cables can lead to early cable failures. Cross-Linked Polyethylene Insulated Cables." The dc field test voltages listed in Table E-1 are intended for cable designed to meet this Standard. When older cables or other types/classes of cables or accessories are connected to the system, voltages lower than those shown may be necessary. Consult the manufacturers of the cables and/or accessories before applying the test voltage.

Table E-1

Conductor Size AWG or kcmil (mm2)

Rated Voltage Phase kV

~

Nominal Insulation Thickness mils (mm)

~~

4/0-2000 (107.2-1013)

~

445 (11.3)

91

Test Voltages-kV During/After Installation A

B

36 36

44 44

~~

580 (14.7)

First A

B

14

ICEA S-94-649-2004

APPENDIX r and th?

purchaser. The equipment for the dc voltage test shall consist of a battery, generator or suitable rectifying equipment

Table F-1 D C Test Voltages InsulationThickness :mm) . .

Conductor Size,

Rated Circuit Voltage, Phase-to-Phase Voltage

dc Test Voltage, kV

133 Percent Level

kcmil

l

(mm2) I

I

I

I

~

133 Percent Insulation Level -

35

45

170 (4.32)

45

55

165 (4.19)

205 (5.21)

45

55

210 (5.33)

250 (6.35)

70

80

250 (6.35)

70

80

2001-5000 ~

cent InLevel

I

145 (3.68)

110 (2.79) :

,

~

~

~ (3.43)l 135

135 (3.43)

4

170 (4.32)

5001-8000 (506.8-1520) 2-1 O00

(506.8-1520) ~~

15001-25000 25001-28000 28001-35000

1-3000

245 (6.22)

1-3000

265 (6.73)

(53.5-1520)

330 (8.38)

(42.4-1520)

(42.4-1520)

290 (7.37)

375 (9.53)

35001-46000

92

120

305 (7.75)

350 (8.89)

330 (8.38)

375 (9.53)

1 05

125

400 (10.2)

450 (11.4)

125

155

550 (14.0)

610 (15.5)

165

215

DATE: 10/14/04

APPENDIX G These are suggested reduced neutrals, consult the cable manufacturer for availability and suitability of neutrals. Table G-1 One-sixth Neutral Concentric Conductor for Copper Center Conductor

Il

II

II

2000

II

II

I

...

26

1 II

II

II

Concentric Copper Conductor Minimum Number of Wires

Insulated Copper Conductor

II

I

33

Table G-2 One-eighth Neutral Concentric Conductor for Copper Center Conductor

Il II

I

...

250

350

II

16AWG

14AWG

12AWG

10AWG

13

...

...

...

17

I

11

I

...

I

...

500

2000

-

II

29

19

12

...

32

20

13

...

...

23

15

...

...

31

20

12

...

...

24

15

...

...

29

l8

...

...

34

21

93

I

DATE: 10/14/04

94 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

DATE: 10114/04 Table G-5 ncentric Conductor for Aluminum Center Conductor Aluminum Conductor Size, AWG or kcmil

II

II

11

li

Concentric Copper Conductor 16AWG

14AWG

12AWG

10AWG

11

...

...

...

15

10

...

...

18

12

...

...

20

12

...

...

23

14

...

...

30

I

19

I

12

I ~

~~

...

...

24

15

10

...

28

18

11

1750

...

2000

...

I

33

...

I

21

24

I

13 15

Table G-6 One-twelfth Neutral Concentric Conductor for Aluminum Center Conductor

Size, AWG or kcmil

95

DATE: 10/14/04

wires

Where: CMA %IACS Neutral Wire Size NA,

=

Nominal diameter of one neutral wire in mils

Fractional wire portion was rounded as follows:

Nwires

wires

Nwires This would be rounded to 12 wires.

96 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

DATE: 10/14/04

APPENDIX

~

Approximate Weight

Conductor

Aluminum

Size,

AWG or kcmil

Copper

Feet

s/m

Feet

s/m

16

...

...

7.81

11.6

15

...

...

9.87

14.7

...

12.4

18.5

13

... ...

...

15.7

23.4

12

6.01

8.94

19.8

29.4

11

7.57

11.3

24.9

37.1

10

9.56

14.22

31.43

46.77

9

12.04

17.92

39.62

58.95

8

15.20

22.62

49.98

74.38

7

19.16

28.52

63.03

93.80

6

24.15

35.94

79.44

118.2

5

30.45

45.32

100.2

149.0

4

38.41

57.1 7

126.3

188.0

3

48.43

72.08

159.3

237.1

2

61 .O7

90.89

200.9

298.9

1

77.03

114.6

253.3

377.0

97.15

144.6

319.5

475.5

2/0

122.5

182.3

402.8

599.5

310

154.4

229.8

507.8

755.8

410

194.7

289.8

640.5

953.2

250

230.1

342.4

...

...

300

276.1

41 0.9

...

...

350

322.1

479.4

...

...

400

368.2

547.9

...

...

450

414.4

61 6.3

...

...

500

460.2

648.8

14

,

97

...

...

-

ICEA S-94-649-2004

DATE: 10/14/04 Table H-2

:-_._ i

Conductor Size, AWG or

Number of

kcmil

~

Each Strand m iis

-.

-

~

.

~

.

~

Approximate Weight ~ ~ ~

Aluminum Pounds per

mm _

.

Copper

s/m

Pounds per

cim

48.6

1.23

15.5

23.1

51 .O

54.5

1.39

19.5

29.1

64.2

61.2

1.56

24.6

36.7

80.9

121

68.8

1.75

31.1

46.2

102

152

77.2

1.96

39.2

58.3

129

86.7

2.20

49.4

73.5

162

242

97.4

2.47

62.3

92.7

205

305

19

66.4

1.69

78.6

117

259

385 485

7 7

2

95.7

19

74.5

1.89

99.1

147

326

ZO

19

83.7

2.13

125

186

41 1

611

310

19

94.0

2.39

157

234

518

771

410

19

105.5

2.68

199

296

653

972

250

37

82.2

2.09

235

349

772

1150

300

37

90.0

2.29

282

419

925

1380

350

37

97.3

2.47

329

489

1080

1610

400

37

104.0

2.64

376

559

1236

1840

450

37

110.3

2.80

422

629

1390

2070

500

37

116.2

2.95

469

699

1542

2300

95.0

2.41

517

768

1700

2530

550

61

600

61

99.2

2.52

563

838

650

61

103.2

2.62

61

908

2006

2990

700

61

107.1

2.72

657

978

21 60

3220 3450

2760

750

61

110.9

2.82

704

1050

2316

800

61

114.5

2.91

75 1

1120

2469

3680

900

61

121.5

3.09

845

1260

2780

4140

61

128.0

3.25

939

1400

3086

4590 5050

1100

91

109.9

2.79

1032

1540

3394

1200

91

114.8

2.92

1126

1680

3703

551

1250

91

117.2

2.98

1173

1750

3859

5740 5970 6430

1300

91

119.5

3.04

1220

1820

4012

1400

91

124.0

3.15

1313

1960

4320

1500

91

128.4

3.26

1408

21 O0

4632

6890

2240

4936

7350

1600

127

112.2

2.85

1501

1700

127

11 5.7

2.94

1596

2370

5249

1750

127

117.4

2.98

1643

2440

5403

8040

5562

a270

1800

127

119.1

3.02

1691

1900

127

122.3

3.11

1783

2650

5865

8730

2000

127

125.5

3.19

1877

2790

6176

91 90

98

~~

Conductor kcmil

Class

Class Number of Strands

Approximate Diameter of Each Strand mils

mm

Number of Strands

Approximate Diameter of Each Strand mils

mm

8

19

29.5

0.749

37

21.1

0.536

7

19

33.1

0.841

37

23.7

0.602

6

19

37.2

0.945

26.6

0.676 0.759

5

19

41.7

1.O6

29.9

4

19

46.9

1.19

33.6

0.853

3

19

52.6

1.34

37.7

0.958

2

19

59.1

1.50

42.4

1.O8

1

37

47.6

1.21

61

37.0

0.940

61

41.6

1.O6 1.19

37

53.4

1.36

U0

37

60.0

1.52

61

46.7

310

37

67.3

1.71

61

52.4

1.33

410

37

75.6

1.92

61

58.9

1.50

250

61

64.0

1.63

91

52.4

1.33

300

61

70.1

1.78

91

27.4

1.46

350

61

75.7

1.92

400

61

8 1 .o

2.06

91

62.0

1.57

66.3

1.68

450

61

85.9

2.18

70.3

1.79

500

61

90.5

2.30

74.1

1.88

550

91

77.7

1.97

127

65.8

1.67

600

91

81.2

2.06

127

68.7

1.74

650

91

84.5

2.15

127

71.5

1.82

700

91

87.7

2.23

127

74.2

1.88

750

91

90.8

2.31

127

76.8

1.95 2.02

800

91

93.8

2.38

127

79.4

900

91

99.4

2.53

127

84.2

2.14

1O00

91

104.8

2.66

127

88.7

2.25

1100

127

93.1

2.36

169

80.7

2.05

1200

127

97.2

2.47

169

84.3

2.14

1250

127

99.2

2.52

169

86.0

2.18

1300

127

101.2

2.57

169

87.7

2.23

1400

127

105.0

2.67

169

9 1 .o

2.31

1500

127

108.7

2.76

169

94.2

2.39

1600

16 9

97.3

2.47

217

85.9

2.18

1700

169

100.3

2.55

21 7

88.5

2.25

1750

169

101.8

2.59

21

89.8

2.28

1800

169,

103.2

2.62

21 7

91.1

2.31

1900

169

106.0

2.69

21 7

93.6

2.38

2000

169

108.8

2.76

21 7

96.0

2.44

NOTE:

99 --``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

DATE: 10/14/04

APPENDIX

thermoset material such as XLPE, TRXLPE or EPR. Ethylene alkene copolymer (EAM) is the ASTM nomenclature (E-Ethylene, A-Alkene and M-repeating CH2 unit of the saturated polymer backbone) for copolymers consisting of ethylene and an alkene Union of Pure and Applied Chemistry (IUPAC) in its publication Nomenclature of Organic Chemistry as follows: “Alkenes are hydrocarbons with a carbon-carbon double bond. Specific alkenes are named as a

are derived from Greek numbers (Penta, hexa, etc.).” Continuing technological developments in the manufacture of polymers for wire and cable applications hexene and octene rather than the conventional propylene. Polymers can be manufactured in various ways, as can any copolymer of ethylene and an alkene. These variations include the type of polymerization catalystko-catalyst, process conditions, molecular weight, ethylenekomonomer ratio, and ethylene (or comonomer) distribution. The resultant polymers may provide improvements while complying

general material classification such as EAM, rather than create a series of ethylene based polymeric

DATE: 10/14/04

APPENDIX

requirements listed below. The reason for this change is to provide more precise test parameters, which will in turn provide greater correlation of data from one laboratory to another.

additional length to accommodate the portion of the cable needed for the high voltage terminals used in HV Term. Section

Air Section

I L e n g th a s n e e d e d

(0.9m

--``,```,,`,,,```` ,`,,`,`,`,,-`-`,,`,,`,`,,`---

Water Section I

0.08m)

HV Term. Section

Air Section I

I

(0.9m

0.08m)

Length as needed

DATE: 10/14/04

APPENDIX K INSULATION COMPOUND INSPECTION (Normative) K1 SCOPE The two types of optical detection systems utilized to assess the cleanliness of unfilled crosslinked polyethylene or unfilled tree retardant crosslinked polyethylene insulation compound are tape inspection and pellet inspection. Pellet inspection typically has less accuracy than tape inspection, since a larger detection capability verification of these devices is being considered. Prior to the availability of these documents, caution should be exercised when comparing data from different sources. Tape inspection is primarily utilized to monitor systemic contamination level and has historically been the basis for compound acceptance specifications by compound suppliers to cable manufacturers. sample taken from the pellet stream is extruded, without filtering or screening, into a tape and examined with high-resolution computerized image analysis. Contrasting specks are detected in the tape and automatically sized, located and labeled for further examination. Pellet inspection is primarily utilized to monitor sporadic contamination, as indicated by contrasting requirement. Contrasting specks in the pellet stream are detected by high-resolution optics and pneumatically rejected while accepted compound passes through for packaging and shipment to the cable manufacturer. Rejected compound, containing the contrasting specks, is typically examined visually; the size, number and type can be used for diagnostic purposes.

K 2 PROCEDURE -

The compound supplier shall utilize two types of optical detection systems to assess the cleanliness of unfilled crosslinked polyethylene or unfilled tree retardant crosslinked polyethylene insulation compound, tape inspection and pellet inspection.

Unfilled crosslinked polyethylene or unfilled tree retardant crosslinked polyethylene insulation compound pellets collected according to a sampling plan shall be extruded, without filtering or screening, into a tape. The tape shall be inspected for contrasting specks utilizing an automated tape inspection system. The contrasting specks, including contaminants and ambers, shall be reported to the cable supplier on a material lot basis for engineering information only and the report shall be available to the cable purchaser upon request. The report shall list, as a minimum, the size and number of contrasting specks reported in accordance with the supplier’s compound release specification. Details of the compound supplier sampling plan, along with a description of the inspection equipment and detection capability shall be available upon request. K2.2

Compound Pellet Inspection Sampling Plan

Unfilled crosslinked polyethylene or unfilled tree retardant crosslinked polyethylene insulation compound pellets shall be inspected for contrasting specks using a continuous sampling plan. The plan

10 2

on a material lot basis for engineering information only and the report shall be available to the cable greatest dimension. Additionally, the report shall distinguish between embedded and loose contrasting request.

103

ICEA S-94-649-2004

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