AEIC CS9-06 SPECIFICATION FOR EXTRUDED INSULATION POWER CABLES AND THEIR ACCESSORIES RATED ABOVE 46 kV THROUGH 345 kVac (1 Edition) Association of Edison liluminating Companies: 600 N. 18th St., P.O. Box 2641 Birmingham, Alabama 35291-0992 December 2008 Page ihittovwww.aeic.org Copyright © 2006 by the Association of Edison Muminating Companies No pat ofthis specication may be reproduced in any frm without the brior writen permission ofthe ‘Assoriation of Edison lluminating Companies. All ights reserved. Page cs9-06Table of Contents Paragraph Title FORWARD. DISCLAIMER PREFACE BACKGROUND, 1.0 GENERAL... 1.1 Scope. 41.2 General Information 1.3 Information to be Provided by Purchaser 1.3.1 Purchaser's Specification, 1.3.2 Purchaser's Technical Information File. 4.3.3 Warranty, 1.3.4 Operating Voltage. 1.3.5 Fault Duty 1.4 Information to be Provided by Manufacturer with Proposal 1.4.1 Manufacturer's Technical Declaration File... 1.4.2 Alternative Proposals, 1.5 Definitions and Symbols 1.5.1 General 1.8.2 Definition of Tests 1.6 References 1.7 Dry Insulation. 1.8 Design Life and Reliability 1.9 Maximum Operating Temperatures and Durations 1.10 Current Rating and Cable Temperature Calculations 2.0 CABLES. 2.1 Conductors 2.1.4 General 2.1.2 Sealant for Stranded Conductors. 2.4.3 Preferred Conductor Sizes. 2.1.4 Conductor Characteristics 2.2 Conductor Shield 2.2.1 General 2.2.2 Material 2.2.3 Extruded Shield Thickness : 2.2.4 Voids, Protrusion and Irregularity Limits. 2.25 Physical Requirements 2.26 Electrical Requirements 2.3 Insulation 2.3.1 Material 2.3.2 Insulation Thickness 2.3.3 Insulation Requirements 2.3.4 Calculation of Insulation Electric Stress. 2.4. Extruded Insulation Shield. 2.4.1 General 2.4.2 Material 2.4.3 Thickness Requirements 2.4.4 Voids, Protrusions and Irregularity Limits .. 2.5 Metallic Shield/Sheath 2.5.1 General .. 2.5.2 Bedding and Longitudinal Water Blocking. 2.5.3 Shields 2.544 Sheaths 2.5.5 Radial Moisture Barrier cs9.06 Page Oh RR RALOONENNNSHAS SSSSSSSSSADASHAARRRGRSSGGSNARANSSS Page2.6 Jacket 2.6.1 General 2.6.2 Jacket Thickness “ 2.6.3 Semi-conducting Coating 2.7 Production Tests on Cable 2.7.1 General 27.2 Summary of ICEA $-108-720 Production Tests and Frequency... 2.7.3 Other Additions and Modifications to ICEA S-108-720 Production Tests. 2.7.4 Conditions Applying to Tests 2.7.5 Certified Test Reports 2.8 Qualification Tests on Cable. 2.9 Cable Identification 2.9.1 Semi-conducting Layer Marking 2.9.2 Method of Marking 2.9.3 Production Records. 2.9.4 Conductor Strand Identification 2.9.5 Production Sequence Numbers... 3.0 TERMINATIONS 3.1 General 3.2 Termination Mounting Insulation 3.3 Production Tests on Terminations. 3.4 Qualification Tests on Terminations 3.4.1 Qualification Test for Termination Mounting Insulators 4.0 JOINTS 4.4 General “ 4.2 Sheath Sectionalizing Insulators and Joint Casing Insulation... 4.3 Production Tests on Joints 4.4 Qualification Tests on Joints. - 5,0 SHEATH BONDING/GROUNDING SYSTEMS 5.1 General 5.1.1 Bonding Cables. 5.1.2 Link Boxes. 5.1.3 Sheath Voltage Limiters. 5.2 Production Tests on Sheath Bonding/Grounding Systems. 5.3 Qualification Tests on Sheath Bonding/Grounding Systems 6.0 QUALIFICATION TESTS ON COMPLETE CABLE SYSTEM 6.1 Range of Approval 7.0 PRE-QUALIFICATION TESTS ON COMPLETE CABLE SYSTEM 7.1 Range of Approval. 8.0 ELECTRICAL TESTS AFTER INSTALLATION. 9.0 QUALITY ASSURANCE 9.4 Quality System Requirements... 9.2 Manufacturing Inspection and Test Plan 9.3 Factory Inspection 9.4 Inspection and Audit by the Purchaser. 9.5 Access to Quality Assurance and Test Documents ‘9.6 Non-conformance Reports 9.7 Final Quality Assurance REPOT 10.0 SHIPPING. e 10.1 Cable Reels 10.1.1 Cable Reel Packing, Seaiing, and Shipping 10.1.2 Reel Dimensions....... 10.1.3 Marking on Reels. 10.1.4 Cable End Fittings 10.2 Containers, Boxes, and Pallets Page iv 89.06cs9.06 10.2.1 Marking of Containers, Boxes, and Pallets. 10.2.2 Packaging and Shipping 10.2.3 Packing Lists 10.2.4 Shipping Advice 11.0 APPENDICES ‘APPENDIX A ~ Basis for Void, Contaminant, and Protrusion Limits (Informative) APPENDIX B ~ Aging Factors, Design Life and Reliability Considerations for Extruded Insulation Cables and Accessories (Informative) ‘APPENDIX C — Electrical Withstand and Insulation Coordination Requirements for Specially Bonded, Insulated Metallic Shield/Sheath Systems (Informative) APPENDIX D ~ Basis for XLPE Emergency Temperature Requirements and Approximate Verification by Testing and Measurement (Informative) APPENDIX E - Generic XLPE Insulation Thickness (Informative) ‘APPENDIX F ~ Jacket Thickness Considerations (Informative)... APPENDIX G — Electrical Tests after Installation (Informative) APPENDIX H — Purchaser's Technical Information File (Informative) ‘APPENDIX I~ Manufacturer's Technical Declaration File (Informative). APPENDIX J Information to be Submitted after Award of Contract (Informative). 43 47 50 52 55 58 64 Page vFORWARD This specification was prepared by the AEIC Cable Engineering Committee Task Group 10-2: “Specification for Extruded Insulation Power Cables and their Accessories Rated above 46 KV through 345 kVac". At the time that this specification was approved, the task group had the following membership: W.A, Banker L.W. Bobb R. Ghafurian J.M. Hans. R.A Hartlein® H.R. Jones TM. Kopchick. G. A, MacPhail - Chair |. Mosier Nishioka ~ Vice Chair T. Robeson B. Shattuck R. Smith C. Spence G. Valdes M. Wedam At the time this specification was approved, the AEIC Cable Engineering Committee had the following membership. W. A. Banker LW. Bobb 4. Carter 4. Cote J.C. Erickson PL. Fontaine C.L. Fletcher M, Furtick R. Ghafurian JM. Hans R.L. Harp ~ Vice Chair/Secretary R.A Hatllein HL Hayes S.V. Heyer* H.R. Jones * Technical Advisor M. Kopchick. ‘A. MacPhail T. Metzinger - Chair |. Mosier Smith Valdes The AEIC Cable Engineering Committee thanks the Insulated Cable Engineers Association (ICEA) for the valuable contributions they fave made to this specification. Reviews were done through the Utility Power Cable Standards Technical Advisor Committee (UPCSTAC), composed of cable engineers representing cable manufacturers (ICEA) and power utiities (AEIC Cable Engineering Committee) Page vi cs9-06Specification for Extruded Insulation Power Cables asic ‘and Their Accessories Rated 46 KV through 345 kVac SPECIFICATION FOR EXTRUDED INSULATION POWER CABLES AND THEIR ACCESSORIES RATED ABOVE 46 kV THROUGH 345 kVac DISCLAIMER The Cable Engineering Committee of the Association of Edison illuminating Companies has prepared this, specification. Use of this specification is voluntary. The existence of the specification is not intended in any respect to preclude the manufacture or use of products not conforming to the specification In preparation of this specification, AEIC makes no warranty or representation in connection with its use. Persons electing to use this specification should independently evaluate their specific needs and requirements before doing so. Users are also cautioned that there may be requirements issued by governmental and other regulatory authorities that are not addressed by this specification. Because this specification is subject to review and revision, those who use it are cautioned to obtain the latest version. Alisting of the latest AEIC documents is available on the AEIC website (hipp://www.aeic.org). PREFACE The electric utility industry requires transmission power cable systems to provide safe, cost effective and reliable long-term service. Other organizations have prepared valuable standards documents. This user specification provides additional methods to help ensure that power cable systems, including cables, joints, terminations and sheath bonding systems, will meet the purchasing, quality assurance and performance needs of the electric utlty industry. BACKGROUND AEIC CS9 describes the requirements for the design and supply of single core extruded insulation power cable systems, including their accessories, for rated ac voltages above 46 KV to 345 kV. It applies to cable systems with ethylene propylene rubber (EPR) insulation above 46 kV to 138 KV, and to cable systems with cross-linked polyethylene (XLPE) insulation over the complete voltage range above 46 KV to 345 kV. ‘AEIC CS9 has evolved from AIC CS7, which was frst issued in 1982. It described power cables with only cross-linked polyethylene insulation and was written as a supplement to Insulated Cable Engineers ‘Association standard ICEA S-66-524 "Cross-Linked Thermosetting Polyethylene Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy". Since S-66-524 only applied to the 5 to 46 KV range, CS7 was developed to cover rated voltages from 69 to 138 kV, and to introduce special electric utility industry needs for the increased reliability requirements of high capacity underground transmission systems. Later revisions of CS7 were issued in 1987 and 1993, the latter providing methods for determining insulation thickness based on maximum electrical stress at the conductor shield, in addition to ‘traditional’ fixed insulation thicknesses for the various voltage classes. AEIC CS7 was re- affirmed in 1998. In 2000, ICEA withdrew ICEA S-66-524 and replaced it wih several new ‘application’ standards. This included development of a new Standard S-108-720 “Standard for Extruded Insulation Power Cables Rated above 46 KV to 345 KV", incorporating much of the content of CS7-93, and including ethylene propylene rubber insulation to 138 KV and XLPE to 345 KV. S-108-720 was first issued in July, 2004. ‘The ABIC Cable Engineering Committee considered whether a separate user specification would still be needed following ICEA’s development of a new high voltage cable standard, C8906 Page 1‘Specification for Extruded Insulation Power Cables and Their Accessories Rated 45 KV through 345 kVac AEIC This first edition of AEIC CS9 confirms AEIC's belief in the importance of purchasing complete integrated cable systems, including their accessories, for extruded insulations at transmission voltages. This is ‘especially true for the high voltage (HV) and extra high voltage (EHV) levels, where cable transmission ‘capacity can approach 1000 MVA at 345 kV, reliability is extremely important, and operating experience wih long EHV extruded insulation cable systems is relatively limited, 1.0 GENERAL 1.4 Scope This specification describes the requirements for the design and supply of single core extruded insulation Power cable systems, including their accessories, for rated ac voltages above 46 kV to 345 kV. It applies, to cable systems with ethylene propylene rubber (EPR) insulation above 46 kV to 138 kV, and to cable systems with cross-linked polyethylene (XLPE) insulation over the complete voltage range above 46 kV to 345 KV. Optional Qualification tests are described for complete cable systems (cables and accessories) rated above 46 KV to 150 kV. For cable systems above 150 kV the ests on complete cable systems are mandatory. Pre-Quallcation ‘long term aging’ tests are described for complete cable systems rated above 150 kV. The purpose is to demonstrate reliable performance of the complete cable system, throughout the design ite Accessories are limited to cable joints, terminations and link box connecting systems for bonding and grounding of metallic shield/sheath circuits. They do not include structural support systems for cables, terminations, joints, etc., nor do they include the grounding grids in manholes, joint bays, tunnels, terminal structures or power stations. For the purposes of this specification, the ‘manufacturer’ is the primary designer and supplier of the complete cable system described herein, even though some components may be subcontracted to others. In the event of conflicts between this specitication and other reference standards, this specification shall take precedence. In the event of conflicts between and among the reference standards, the most stringent requirements shall apply. Compliance with this specification in no way relieves the manufacturer of responsibility for design and manufacturing details for performance of the complete cable system. 1.2 General information Measurement units are generally expressed using the Imperial system, as is traditional for AEIC. SI unit equivalents are also provided, usually in brackets. 1.3 Information to be Provided by Purchaser 1.3.4 Purchaser's Specification ‘The scope of CS9 assumes that the purchaser will include it as part of a custom project specification (purchaser's specification’), describing particular requirements for the design and supply of cable and accessories for the intended application. It should include at least + APurchaser's Technical Information File, as described in 1.3.2 below Page 2 89-06Specitication for Extruded Insulation Power Cables aeic and Their Accessories Rated 46 kV through 345 kVae ‘+ A description of the required Manufacturer's Technical Declaration File, as described in 1.4.1 below ‘© A description of information to be Submitted After Award of Contract, similar to that described as ‘a guide in Appendix J + A description of the specific required cables and accessories, as well as their quantities ‘A description of cable system installation responsibilities, as applicable A description of civil work installation responsibilities, as applicable ‘+ Adescription of components and work to be provided by others, as applicable + Adescription of responsibilities for overall desig of the complete installed cable system + A description of special commercial requirements which could override or add to those contained within this specification, such as 1.3.3 Warranty, delivery schedules, delivery location, etc. 1.3.2 Purchaser's Technical Information File ‘When requesting proposals from cable manufacturers, the purchaser shall provide the information tabulated in ICEA S-108-720 Information to be Supplied by Purchaser. This should be supplemented .with select information taken from Appendix H Purchaser's Technical Information File, as well as any ther relevant additional information necessary to completely describe the intended apptcation 1.3.3 Warranty The manufacturer shall warrant that the supplied cable system meets or exceeds all the requirements of this specification and is free from defects in design, material, and workmanship. The manufacturer shall also warrant that the cable system has been tested in accordance with these specifications and that the results of the tests are compliant. ‘The warranty duration shalt be no less than one year from the date of cable energization, unless stated otherwise by the purchaser's specification 1.3.4 Operating Voltage ‘The cable system shall be designed for a maximum phase-to-phase operating voltage, which may exceed the rated voltage by 5 percent during continuous operation. The cable system shat! be designed for an emergency phase-to-phase operating voltage, which could exceed the rated voltage by 10 percent, for durations not more than 15 minutes for each occurrence. 4.3.5 Fault Duty Fault duties can significantly affect the design ofall fault current carrying components, such as the main ‘conductor, metallic shields, sheaths, tink boxes, bonding cables, terminations, joints, and all their respective electrical insulaions, Cable and accessory designs shall make provisions for thermal-mechanical effects due to rapid increases in temperature of the conductor and other cable and accessory components, which can lead to very high ‘axial forces. They shall also make provision for electro-dynamic effects which can apply high transverse forces as a result ofthe interaction of the current of each cable with the magnetic field produced by adjacent cables. Informative Note: Purchasers should do sufficient system studies fo determine realistic ultimate values for fault current and duration, in advance of seeking proposals from manufacturers. Investigations of fauit ‘current duration should consider the time to successful operation of secondary relays and circuit breakers, in the event that the primary protection system malfunctions. Fault duties should also consider the possibilty and effects of multiple e-closing operations by circuit breakers. ¢s9-06 Page 3‘Specification for Extruded Insulation Power Cables ‘and Their Accessories Rated 46 KV throuah 345 kVa AEIC 4.4 Information to be Provided by Manufacturer with Proposal 1.4.1 Manufacturer's Technical Declaration File ‘The manufacturer shall submit a Manufacturer's Technical Declaration File with its proposal, summarizing the information described in ICEA S-108-720 Information to be Supplied by Manufacturer, supplemented with select information taken from the Appendix | Manufactarer’s Technical Declaration File guide, as deemed necessary by the purchaser and described in the purchaser's specification, 1.4.2 Alternative Proposals Manufacturers are encouraged (0 submit alternative proposals for cable systems they consider superior to those specified herein, clearly stating the advantages in terms of cost, reliability, longevity, installation methods, etc. The alternative proposal shall meet or exceed all the technical requirements of this specification and contain the recommended changes or additions to it, together with the reasons and apnropriate supporting data. Notwithstanding the foregoing, a conforming proposal shall be submitted as a basis for comparing the alternative, before the alternative proposal will be considered by the purchaser. 1.5 Definitions and Symbols 1.5.1 General The following definitions apply to this specification, ‘Those not included shall be as described in IEEE 100 “The Authoritative Dictionary of IEEE Standards Terms” Accessory Cable joints, terminations and link box connecting systems for bonding and grounding of metallic shield/sheath circuits Active Length: Length of cable covered by insulation shield and metallic shield Agglomerate: A discernible area of compound constituents in ethylene propylene based insulation which is generally opaque and can be broken apart Amber: A localized area in cross-linked polyethylene insulation which is dissimitar in color (ranging from bright yellow to dark red) from the surrounding insulation, which passes light and is not always readily removable from the insulation matrix. This does not include clouds, swiris or flow patterns which are normally associated with the extrusion process. AWG: ‘American Wire Gauge BIL: Basic Impulse Insulation Level Bonding Cable: “The insulated conductor forming the connection between the sheath of the cable, joint or termination base, and a fink in the link box, Cable Core: The portion of a cable which includes the conductor, the conductor shield, the insulation, and the extruded insuiation shield Cable Core Extruder Run: A continuous run of cabie core with one conductor size, one conductor shield compound, one insulation compound and thickness, and one insulation shield compound, Page 4 cs9-06AEIC Cable System: Certified Test Report Contaminant: Dielectric Constant: Discharge-Free Cable Design: Discharge-Resistant Cable Design: Dissipation Factor: Dry Location: Dry Design: EPR Insulation Compound: Get Gai’ High Dielectric Constant Compound: Insulated Sheath System: Jacket Extruder Run: kemil: cs9.06 ‘Specification for Extruded Insulation Power Cables and Their Accessories Rated 45 KV through 345 kVac Cable with installed accessories. A report containing the results of production tests or qualification tests hich declares that the cable shipped to a customer meets the applicable requirements of this Standard Any solid or liquid material which is not an intended ingredient. ‘The ratio of the capacitance of a given configuration of electrodes with the 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 system at normal operating voltage. Acable design capable of withstanding electrical discharge in the insulation system at normal operating voltage. ‘The cotangent of the dielectric phase angle of a dielectric material or the tangent of the dielectric loss angle. tis often called tan 8. location not normally subject to dampness or wetness. A cable system with a circumferential metallic barrier to moisture, such as a continuous metal cable sheath, under-jacket metal laminate layer, continuous metal joint casing, impervious termination housing, etc., to prevent ingress of water during the cable system design life. ‘A mixture of ethylene propylene base resin and selected ingredients. A discemible region of compound constituents in ethylene propylene based insulation which is gelatinous, not readily removable from the insulation, and generally translucent Voltage stress at the conductor shield/insulation interface (internal stress) at nominal phase-to-ground operating voltage, V,. Voltage stress at the insulation/insulation shield interface (external stress) at nominal phase-to-ground operating voltage, V, ‘An extruded compound used for the conductor shield which has a dielectric constant typically between 8 and 200 A cable system in which the metallic shield/sheath, joint casings and termination bases are individually insulated throughout their length, except where any necessary grounding or inter-shield/sheath connections are made. A cable with a jacket, which was applied in one continuous run, having one jacket compound and one jacket thickness. Thousands of circular mils. Page 5Specification for Extruded Insulation Power Cables and Their Accessories Rated 46 KV through 345 kVac AEIC Link Box ‘Abox through which bonding and/or grounding connections are made through removable links and which may also contain sheath voltage limiters Lot (Component): ‘The quantity of components requiring one test. Lot (Material): A quantity of material used in cable or accessory construction which is produced at the same location under the same manufacturing conditions during the same time period. Master Length ‘A continuous length of cable collected on a reel at the end of an extrusion line, Maximum Conductor ‘+ Normal Operating: The highest conductor temperature permissible for Temperatures: any part of the component under normal operating load current. ‘+ Emergency Overload: The highest conductor temperature permissible for any part of the component during emergency overload of specified time, magnitude, and frequency of application ‘+ Short Circuit: The highest conductor temperature permissible for any part of the component during a circuit fault of specified time and magnitude. Nominal Value: The value by which a quantity is designated and often used in tables (taking into account specified tolerances). Partial Discharge Level: ‘The maximum continuous or repetitious apparent charge transfer, ‘measured in picocoulombs, occurring at the test voltage. pc: picocoulombs: Rated Voltage: Nominal phase-to-phase operating voltage Room Temperature (RT): 25°C #5 °C air temperature. ‘Sheath Sectionalizing Joint: A joint in which the internal shield, metallic shield/sheath and casing are electrically interrupted from each side of the joint. The interruption in the casing of the joint is done by means of a sheath sectionalizing insulator. Sheath Voltage Limiter: A device connected to a sheath or to the sheaths of specially bonded cables intended to limit sheath over-voltages during system transients, ‘Shipping Length: A.completed length of cable which has passed all test requirements. It may of may not be cut into shorter lengths before itis supplied to the end use customer. Shipping Reel: ‘A completed reel of cable shipped to the end use customer. v: Nominal phase-to-phase aperating voltage (rated voltage) Ve Nominal phase-to-ground operating voltage Ves Maximum continuous phase-to-phase operating voltage (\V+5%) Ve Phase-to-ground test voltage Page 6 cs9.06Specification for Extrude Insulation Power Cables atic and Their Accessories Ratod 46 KV through 345 kVae Vented Water Tree: ‘Awater tree which originates at the conductor shield or insulation shield Void Any cavity in a compound, either within or at the interface with another extruded layer. Wet Location: Installations underground or in concrete slabs or masonry in direct contact with the earth; in locations subject to saturation with water or other liquids and in unprotected locations exposed to weather. Wet Design: A cable system without a circumferential metallic barrier to moisture (not ‘Dry Design’ as described above). XLPE Insulation Compound: —_Cross-linked polyethylene insulation. cs9-06 Page 7‘Specification for Extruded Insulation Power Cables ‘and Their Accessories Rated 46 KY through 345 RVa¥ AEIC 1.5.2 Definition of Tests The following additional definitions clarify the various testing terms used herein and in documents referred to in this specification, Production Tests: Qualification Tests: Pre-qualification Tests: Development Tests Page 8 Tests made on each manufactured component (length of cable or accessory), or samples thereof, to confirm compliance of the finished product with this specification and other standards referenced herein. ‘They also verify that the delivered products have at least the same quality as those having passed the Qualification and Pre-quaiification Tests. Production Tests are sometimes variously referred to in other documents a8 ‘factory tests’, ‘routine tests’ and ‘acceptance tests Tests made before supplying on a general commercial basis, a type of cable, accessory or cable system (Cable and accessories) covered by this ‘specification and referenced standards, in order to demonstrate satisfactory performance characteristics for the intended application. Once successfully completed, these tests need not be repeated, unless changes are made in the cable or accessory materials, or design, or manufacturing process, or manufacturing pfant, which might change the performance characteristics. Qualification Tests are sometimes variously referred to in other documents as ‘prototype tests’, 'type tests’ and ‘design tests’ Tests made before supplying on a general commercial basis, a type of cable system covered by this specification and referenced standards, in ‘order to demonstrate satisfactory long-term performance of the complete cable system. The pre-qualification test need only be carried out once, unless there is a substantial change in the cable system with respect 10 materials, or design, or manufacturing process, or manufacturing plant, which might adversely affect the performance of the cable system Tests completed by the manufacturer during development of the cable system before pre-qualification tests. The precise nature and extent of development work and analyses shall be al the discretion of the manufacturer, but may include the following ‘+ An evaluation of the materials and processes employed, including levels of voids, contaminants, protrusions, etc. * Voltage-time endurance testing and Weibull analysis of test results, including determination of ‘n’ the long term aging exponent ‘+ Development of compatible accessories, including factory tests to assess aging effects related to electrical stress, temperature, interface pressure, environmental conditions, etc. Verification tests on full size cable systems, Correlation of development test results with service reliability requirements 89.06‘Specitication for Extruded Insulation Power Cables and Their Accessories Rated 46 KV through 345 kVac 1.6 References ‘The following standards and references form a part of this specification. The most recent editions apply. ASTM 1693 Tests for Environmental Stress Cracking of Ethylene Plastics Electra No. 128 Article: ‘Guide to the protection of specially bonded cable systems against sheath over-voltages’, January 1992 Electra No. 141 Arlicle: ‘Guidelines for Tests on High Voltage Cables with Extruded Insulation and Laminated Protective Coverings’, April 1992 Electra No. 151 ‘Atticle: ‘Earthing of GIS ~ An Application Guide’, December 1993, ICEA S-94.649 Standard for Concentric Neutral Cables Rated 5 through 46 kV ICEAS-105-692 600 Volt Single Layer Thermoset Insulated Utility Underground Distribution Cables ICEA S-108-720 ‘Standard for Extruded Insulation Power Cables Rated above 46 kV through 345 kV ICEA T-24-380 Guide for Partial Discharge Test Procedure ICEAT-27-581 Standard Test Methods for Extruded Dielectric Power, Control, Instrumentation & Portable Cables for Test ICEAT-31-610 Guide for Conducting a Longitudinal Water Penetration Resistance Test for Sealed Conductors ICEA T-32-645 Guide for Establishing Compatibility of Sealed Conductar Filler Compounds with Conductor Stress Control Materials lec 60228 Conductors of insulated cables IEC 60229 Tests on cable oversheaths which have a special protective function IEC 60287 Calcufation of the continuous current rating of cables (100% load factor) IEC 60853-2 Calculation of the cyclic and emergency current rating of cables, IEC 60529 Degrees of protection provided by enclosures (IP Code) IEC 60840 Power cables with extruded insulation and their accessories for rated voltages above 30 kV up to 150 kV ~ Test methods and requirements IEC 60859 Cable connections for gas-insulated metal-enclosed switchgear for rated voltages of 72.5 kV and above IEC 60855 Electrical test methods for power cables IEC 62067 Power cables with extruded insulation and their accessories for rated voltages above 150 kV up to 500 kV - Test methods and requirements IEEE 48 Standard Test Procedures and Requirements for Alternating Current Cable Terminations 2.5 kV through 765 kV IEEE C62.11 Standard for Metal-Oxide Surge Arresters for AC Power Circuits (> 1 kV) IEEE 100 The Authoritative Dictionary of IEEE Standards Terms IEEE 404 Standard for Extruded and Laminated Dielectric Shielded Cable Joints Rated 2,500 - 500,000 V IEEE 693 Recommended Practice for Seismic Design of Substations ISO 9001 Quality Systems - Model for quality assurance in design, development, production, installation and servicing NEMA WC26 Binational Wire and Cable Packaging NEMA 250 Enclosures for Electrical Equipment Other standards are in turn referenced from within the above documents, 1.7 Dry Insulation Cable systems having cable insulation with nominal intemal and external ac electrical stresses greater than 100 Vimil (4,0 kVimm) and 50 Vimil (2.0 kV/mm) respectively, shall be supplied with a metallic, moisture barrier to maintain a ‘dry’ insulation. Higher ac stresses may be applied to non-dry or ‘wet, desian’ cable systems, if agreed to between the purchaser and manufacturer. 659-06 Page 9Specification for Extruded Insulation Power Cables and Their Accessories Rated 46 KV through 345 kVac AEIC 1.8 Design Life and Reliability Cable systems meeting the requirements of this specification are expected to have a minimum design life of 40 years, The manufacturer shall supply test data and calculations supporting these design and reliability requirements (reference Appendix |, Item 25), if required by the purchaser's specification. The documentation shall include the electrical, thermal and mechanical performance characteristics of the cable core, laminated metallic moisture barriers (if present), solid metallic sheath, jacket and accessories. Manufacturers shall take into account the ‘Aging Factors, Design Life and Reliability Considerations for Extruded Insulation Cables and Accessories’ in Appendix B, to ensure that the cable and accessory system performs reliably for the expected design life and intended application. The design life shall also take into account the maximum operating temperature considerations described in Appendix D and 1.9 below 1.9 Maximum Operating Temperatures and Durations ‘The design and construction of the cable and accessories shall be such that they perform reliably together as a complete system, at conductor temperatures not exceeding those shown in Table 1.9-1 Table 1.9-1 Maximum Conductor Temperatures (°C) Type of Operation wre | a6 afP8 nan Rormal Operation 30 90 aera toni 105 105" ~_ Emergoney operator | 105 | _Notappicabe Short Circuit Operation 250 250 “Emergency operation at conductor temperatures up to 130 °C may be used if mutually agreed between purchaser and manufacturer and verified by qualification tests. ‘The temperatures identified for ‘Emergency Operation’ apply assuming that all of the following conditions are met: ‘+ not to exceed 216 hours duration in any single emergency operation event ‘+ not to exceed a total of 216 hours of cumulative emergency operations in any one year ‘+ not to exceed 72 hours of total emergency operation per year, on average over the 40-year design life of the cable system + not to exceed a cumulative total of 2880 hours of emergency operation over the 40-year design life of the cable system multiple emergency operations between 0 and 216 hours are permissible, provided all of the preceding conditions are met. For possible implications of exceeding these conditions, refer to Appendix B. Users are referred to Appendix D for a description of the basis of these emergency temperatureltime requirements and an explanation of verification tests. Mtemergency operation (for cables rated >150 to 345 KV) to 105 °C or higher is desired, the pre- qualification tests in IEC 62067 shall include 90 additional load cycles to the maximum emergency operation temperature, as described in Appendix D. The additional load cycles may be done during the 365-day test period or after it. In addition, the high temperature qualification tests (type tests) in IEC Page 10 cs9-06Specification for Extruded insulation Pawer Cables AEIC ‘and Their Accessories Rated 46 KV through 345 KVac 62067 and IEC 60840 shall be performed at the maximum emergency operation temperature, as described in Appendix 0. Manufacturers who have already completed qualification and pre-qualification tests for a cable system, but to temperatures lower than 105 °C, may ré-qualify their cable systems for 105 °C emergency temperature operation, by repeating the high temperature qualification (Iype) tests using the protocol described in Appendix D, or other similar protocol, a8 mutually agreed between purchaser and manufacturer. The temperaturps identified as for ‘Normal Operation’ apply to operating load cycles typical of electric ulity systems (approximately 0.80 daily load factor for transmission lines; approximately 1.0 daily load factor for generpling stations). Cable system designs shall assume that the normal maximum operation temperatures can be applied continuously throughout the cable system's design life, with corresponding daily load factors. Designs for operation at the Table 1.9-1 maximum temperatures shall take into consideration actual field- proven performance and design limits of transmission cable and accessories, as relevant to the intended application. This shall include consideration of at least the factors described in ICEA S-108-720 Appendix B, as well as the following the effects of high operating temperatures on radial expansion of XLPE insulation * possible degradation of stress relief cone interface pressure due to mechanical stress relaxation, over the cable system design life ‘+ _ the temperature gradient across the cable core and the corresponding jacket temperature limits, which could be excessive for some installation conditions. + possible loss of adhesion at the overiap of laminated moisture barriers and loss of bond adhesion to the underside of the jacket ‘+ high axial thrust forces that can be transmitted to joints and terminations, especially for large conductors. * possible permanent distortion of the insulation due to high sidewall forces at bends, resulting in a local seduction of insulation and jacket thickness + possible permanent distortion of the insulation due to radial expansion at clamps and anchors, for some sheath/shield constructions + cydlic fatigue resistance of metal moisture barriers and corresponding value of the limiting cyclic strain (see Appendix B references 18 ~ 46, and especially 18. 19, 22, 35, 38 and 40) + effective axial stiffness (longitudinal rigidity) of the cabie (see Appendix B references 18 - 46) and the design of ductpipe clearance, layouts in turrets, manholes and approaches to terminations * effective bending stiffness (flexural rigidity) of the cable (see Appendix B references 18 - 46) and the design of ductipipe clearance, layouts in tunnels, manholes and approaches to terminations The Table 1.9-1 maximum operating temperatures apply to the hottest portion of the cable system at any time. They may be used in current rating calculations when adequate information is known about the overall thermal characteristics of the cable system environment, to ensure that these temperatures shall not be exceeded. In the absence of this information, the maximum conductor temperatures used in current rating calculations shall be reduced by 10 °C, or in accordance with available data. 1.10 Current Rating and Cable Temperature Calculations Current ratings and cable temperatures shall be calculated in accordance with IEC 60287, or as described in "The Calculation of Temperature Rise and Load Capability of Cable Systems”, J.H. Neher, MH. McGrath, AIEE Transactions on Power Apparatus and Systems, vol. 76, October 1957. Daily load factor effects shall be calculated in accordance with the latter reference or IEC 60853-2. Emergency current ratings and cable temperatures shall be calculated in accordance with IEC 60853-2. Modifications to the above calculation requirements may be acceptable, based on mutual agreement between purchaser and manufacturer. cs9-06 Page 11Specification for Extruded Insulation Power Cables and Their Accessorles Rated 45 kV through 345 kVac. AgIC 2.0 CABLES Cables shalt comply with ICEA S-108-720 and as described herein It required by the purchaser's specification, the cable system manufacturer shall provide a copy of representative qualification test reports for the proposed cable with the proposal or include such testing with the proposal. ‘An Insulation System Quality Assurance Plan shall be submitted with the Manufacturer's Technical Declaration File (reference Appendix I, tem 24), if required by the purchaser's specification. The plan shall describe procedures to ensure that the cleanliness and smoothness requirements of extruded insulation and semi-conducting shield materials are met throughout the supply chain from compound supplier to the manufacturer's extruders. 24 Conductors 241.1 General The conductor material shall be copper or aluminum with circular cross-section. Ifthe cable construction ‘and cross-sectional area is not described by the purchaser's specification, the manufacturer shall provide a conductor with material, cross-sectional area and construction sufficient to meet the required normal current carrying capacity, emergency current carrying capacity and short circuit fault duty, without exceeding the temperature limits described in Table 1.9-1, in accordance with the installation conditions and other information in the purchaser's specification. 2.1.2 Sealant for Stranded Conductors If specified by the purchaser, a sealant designed as an impediment to longitudinal water penetration shall be used to fil all the interstices of stranded conductors. Compatibility with the conductor shield shall be determined in accordance with ICEA T-32-645. Longitudinal water penetration resistance shall be determined in accordance with ICEA T-31-610 and shall meet a minimum pressure requirement of 5 psig (35 kPa). 2.1.3 Preferred Conductor Sizes ICEA S-108-720 Tables 2-2 and 2-3 describe 31 possible conductor sizes ranging from 250 kcmil (127 mm’) to 4000 kcmil (2027 mm’), in copper and aluminum. Fewer ‘standard’ sizes for HV and EHV cable can resultin lower tooling costs for manufacturers, smaller spare cable inventories for purchasers and sreater opportunities for sharing of spare cables between users. Cables supplied under this specification shall therefore be limited to the conductor sizes shown in Table 2.1-1, unless described otherwise in the purchaser's specification, or proposed as an alternative by the manufacturer. Page 12 cS9-06‘Specification or Extruded insulation Power Cables AL and Their Accessories Rated 46 KV through 345 kVae Table 2.1-1 Standard Imperial Conductor Sizes (kcmil) and Nearest IEC 60228 SI Sizes (mm*) 69 kV 115 kV 138 kV 161 kV 230 KV 345 KV Komi_|_mm? | kemil_[mm? | kemi | mm | kemi [mm | kemil [| mm? | kemil_ [mm ‘500 | 240 750 | 400_| 750 | 400 | 750 | 400 | 750 |” 400 ‘1000 |~500 | 1000 [~s00_| 1000 | S00 _f tooo | s00 [1000 | S00 | 1000 | 500 1250 | 630 50 | 630 | 1250 { 630 | 1250 | 630 | 1250 [630 | 1250 | 630 1500 | 800 | 100 | 80a | 1500 | 800 | 1500 |~800_| 1500 |~ 800 |" 1500_|~ 800 1750 | 600 { 1750 | 800 | 1750 | 800 | 1750 | 800 | 1750 | 800 | 1750 |” 800 2009 | 1000 | 2000 | 1000 | 2000 | 1000 | 2000 |~1000 |~2000_| “1000 {2000 | “1000 2500 | 1200 | 2500 | 1200 | 2500 | 1200 | 2500 | 1200 | 2500 | 1200 | 2500 | 1200 3000 3000 | 1600 | 3000 | 1600 | 3000 | 1600 | 3000 | 1600 | 3000 | 1600 3500 '3500| 1600 | 3500 | 1600 |~3500 |~1600 | 3500 [1600 |~3500_| 1600 “4000. ‘4000_| 2000 |~4000 |~2000 [4000 | 2000 | “4000 | 2000" |~4000_|~2000. I ‘5000 [2500 | S000 | 2500 ICEA S-108-720 Tables 2.2 and 2-3 describe ‘soft’ metric sizes, which are mathematically correct Conversions from Imperial to SI (1.000 kemil = 0.507 mm). ‘The metric sizes shown in the above Table 24-1 are ‘hard’ conversions, complying with the closest standard sizes in IEC 60228 "Conductors of insulated cables’ 2.1.4 Conductor Characteristics ‘The conductor characteristics, including de resistances for the IEC 60228 SI conductor sizes, shall ‘comply with ICEA S-108-720, 2.2 Conductor Shield 2.2.4 General ‘The conductor shield shall provide a uniform, continuous, smooth, concentric, thermosetting, semi conducting, voltage stress control layer between the outer surface of the conductor and the inner surface of the insulation. It shall be in direct contact with the conductor and adhere well to the inner surface of the insulation under alt operating conditions. 2.2.2 Material The conductor shield material shall be as per ICEA $-108-720 except for XLPE insulations with ac electrical stress at the conductor shield greater than 200 Vimil (8.0 kV/mm), the conductor shield shall be formulated using acetylene black. The manufacturer shall verfy with the compound supplier that the sulfur and ash content is less than 0,005 % and 0.01 % respectively, ‘The nominal thickness of the extruded conductor shield shall be as per ICEA S-108-720, 2.2.4 Voids, Protrusion and Irregularity Limits ‘The maximum allowable void, protrusion and irregularity limits for XLPE insulation cables shall be as per ICEA S.108-720, except as modified in Table 2.2-1 for cables with nominal intemal ac stresses greater than 200 Vimil (8.0 kV/mm). Protrusion and irregularity heights from the conductor shield into the insulation and from the insulation into the conductor shield are one half the maximum allowable contaminant diameter, which is less than 59-06 Page 13‘Specification for Extruded Insulation Power Cables and Their Accessories Rated 46 kV through 345 kVac. AEIC described in ICEA S-108-720 for insulation intemal stresses greater than 250 Vimil (10.0 kV/mm). (Refer to Appendix A for a description of the basis for these values.) Table 2.2-1 Extruded Conductor Shield/Insulation interface; Void, Protrusion and Irregularity Limits vs. Nominal internal ac Stress (dimensions rounded to nearest 0.5 mil) e T Nominal Internal ae Stress | 495 | 425 | 150 | 175 | 200 | 225 | 250 | 275 | 300 | 325 | 350 atVy Vimil (kVimm) (4.0) | (6.0) | (6.0) | (7.0) | (8.0) | (9.0) | (10.0) | (11.0) | (12.0) (13.9) | (140) [Maximum Void Dimension mils (4m) 201 201 20] 20| 20] 20] 15 | 151 15] 10] 10 | (50)' (50)" | (59)" (60)' | (60)" | (50)' | (88)* | (38 | BBY | (25 (25 | Maximum Protrusion and irregularity Height mils (4m) 30,| 39 | 30 30 30/30] 30 | 30 | 25 | 20! 20 (75)' | (78)! | (75) ¢75)* |(75)" | (75)' | (75)' | (75? (63)* (50)" (SOY? * ‘reflects current practices and ICEA S-108-720 limits. * less than ICEA S-108-720 limits. For EPR-insulated cable the void, protrusion and irregularity limits shall be as per Table 2.2-1, but with nominal internal ac stress no greater than 200 Vimil (8.0 kV/mm), 2.2.5 Physical Requirements ‘The physical requirements of the conductor shield shall comply with ICEA S-108-720. 2.2.6 Electrical Requirements ‘The electrical requirements of the conductor shield shall comply with ICEA $-108-720, 2.3 Insulation The insulation shall be capable of withstanding all electrical stresses that will be distributed across it when the cable is energized and fully loaded to the maximum emergency operating temperature. It shall also withstand the mechanical and thermal forces that occur during installation and operation. 2.3.1 Material ‘The insulation compound shall be either unfilled cross-linkable polyethylene (XLPE) or ethylene propylene rubber (EPR). The insulation material shall comply with ICEA S-108-720 and as described herein, The insulating compound shall be specifically formulated for high voltage and extra high voltage cables, ‘not containing any contaminants with their greatest dimension larger than as described in Table 2.3-2. XLPE insulation shall be extruded together with the extruded conductor shield and extruded insulation shield, in one common triple head extruder. The three layers shall be cross-linked in a dry curing Process. XLPE insulation material shall be inspected for contaminants using a continuous sampling plan. The plan must sample a minimum of 2 percent of the insulation material volume. Material not inspected by the ‘compound supplier must be inspected at the 2 percent rate by the cable manufacturer. The material analysis shall be reported for engineering information and as a minimum, provide a statistical analysis of the size and number of contaminants found per weight of insulation inspected. Page 14 89.06Specification for Extruded insulation Power Cables IC and Thele Accessories Rated 46 KV through 345 kVac 2.3.2 Insulation Thickness For “wet design’ cables without a metallic moisture barrier, insulation thickness shall be based on the traditional values described in ICEA S-108-720, Appendix F. For “dry design” cables, the insulation thickness shall be designed based on electrical stress, a5 described in ICEA S-108-720 as well as the following, unless proposed otherwise by the manufacturer or purchaser and supported by tests: ‘+ ac stresses at the conductor shield (internal stress) and over the insulation (external stress), as calculated in 2.3.4, shall not exceed the limits described in Table 2.3-1 at the rated phase-to-ground operating voltage V,, + the ac and impulse stresses at the inner starting point of stress relief cones in accessories, shall not exceed the limits defined by the manufacturer, ‘+ consideration should be given to the ‘Generic’ nominal thicknesses described in Appendix E, which 2re intended to satisfy the nominal internal and external stress limit criteria over the standard Conductor size range and provide a degree of standardization. Table 2.3-1 Rated Voltage, Conductor Size Range, Insulation Eccentricity Limits, Nominal internat ac Stress Limits and Nominal External ac Stress Limits Maximum Nominal Rated | Conductor | Conductor | Insulation Internal ac | Nominal External Voltage | ~ Size Sie | Eccentricity | Stress Limit | ac Stress Limit KV. kemil mm? % Vimil (kV/mm) __Vimil (kV/mm) ‘6 wat | 500-4000_| 240-2000, 12 700 (4.0) 50 (2.0) ‘69 dry | 500-4000 | 240-2000 12 150 (6.0) 75 (3.0) 145 | 750-4000 | 400-2000 i2 200 (8.0) 100 (4.0) [138 [750-4000 | “400-2000 12 200 (8.0) 400 (4.0) 161 | 750-4000_| 400-2000 10 225 (9.0) 100 (4.0) 230 | 1000-5000 | 500-2500 10 275 (11.0), 125 (5.0) 345 | 1000-5000 | 500-2500 10 350 (14.0) 150 (6.0) ‘Notwithstanding the Table 2.3-1 values, for cables used with taped joints, the nominal internal and external ac stresses shall be limited to 150 Vimil (6.0 kVimm) and 75 Vimil (3.0 kV/mm), respectively Insulation eccentricity shall not exceed the values in Table 2.3-1, as described in ICEA S-108-720. 2.3.3 Insulation Requirements ‘The insulation requirements shall comply with ICEA $-108-720 and as described herein, The void, contaminant and amber limits for XLPE-insulated cables shall be as per Table 2.3-2 (see ‘Appendix A for derivation). The applicable limits shall be based on the actual calculated internal stress for the proposed cable system, which will vary with specific conductor size and insulation thickness for each rated voltage level 39-06 Page 15‘Specification for Extruded Insulation Power Cables and Their Table 2.3-2 Void, Contaminant and Amber Limits versus Nominal Internal ac Stress for XLPE oFles Rated 46 WV through 345 kVae AEIC Insulation Cable’ (dimensions rounded to nearest 0.5 mil) [emameTTT oo | wes | | vs | am | me | ow | ors | woo | mes | a acSrescatve | ao) 69 | 0 | 79 | Oo) | @o) Ho | (119 | (120) | 30 | 140) (Vm) Maxmm Vos 29 | 20 | 20 | 20 1 20 | 20 | 15 | 15, | 15, ] 10, | 10, its (um (60) | 60" | (Soy' | (50)' | ¢50)' | GO BB | GBF | 5’ | sy Maximum al comaminan | 50) s0| 80) 50! 50 | 50) so, | so! so, | 40] 40 | Dimension | (125)' | (125)" | (125)' | (125)' | (125)' | 125)" | 125)" | (125)' | 125)" | (100)* | (100° nls (um) az [Waxman Amber so. 1 00 | 100! 10 | w0,| wo, | 100, | 100] 00 | 80, | 80, ini tum}__| 250)" | (250)' | (250)" | 250)" | (250y" | 250)" | (250)' | (250)' | (250" | (200)? | 00) ® ess than ICEA S-108-720 limits. ® minimum point stresses could be higher. See 2.3.4. 2.3.4 Calculation of Insulation Electric Stress For cables with a semi-conducting conductor shield, the nominal ac electric stress at any point in the reflects current practices and ICEA $-108-720-2004 limits. insulation shall be calculated using the following formula: nominal ac voltage stress at radius r (kV/mm) V, = nominal phase-to-ground voltage (kV) jorninal radius over the insulation (mm) nominal radius over the conductor shield (mm) r= radius of a point of interest in the insulation (mm) ‘The nominal internal ac stress (Gm) Occurs at the interface between the conductor shield and the insulation, when r =r, The nominal external ac stress (Gy) Occurs atthe outside of the insulation, when r= r, The average stress = For EPR cables with a non-conducting conductor shield, the nominal ac electric stress at any point in the insulation shall be calculated using the following formula: Page 16 cs9.06Specification for Extruded Insulation Power Cables AEC and Their Accessories Rated 46 KV through 345 KVae 1orinal ac voltage stress at radius r (kVimm) jominial phase-to-ground voltage (KV) nominal radius over the conductor (mmm) 11 = nominal radius over the insulation (mm) 17, = nominal radius over the conductor shield (mm) r= radius of a point of interest in the insulation (mm) K,= dielectric constant of the insulation K,,= dielectric constant of the non-conducting conductor shield ‘The nominal internal ac stress (Ginx) occurs at the interface between the conductor shield and the insulation, when r = 1, ‘The nominal external ac stress (Gn) occurs at the outside of the insulation, when r The average stress = ‘Similar methods shall be used to determine the nominal impulse stresses, by substituting BIL for V,. informative Note: Users are reminded that CEA S-108-720 allows a 5% continuous and 10% fifleen-minute over-voltage above the rated phase-to-ground voltage (V,). In addition, ICEA $-108-720 allows 2 minimum point insulation thickness 10% less than nominal values. ‘Conductor radii can also vary from nominal values. These effects can lead to a lower value of r; and possibly higher actual stresses in cable and accessories compared to those calculated above. 2.4, Extruded Insulation Shield 2.4.1 General The extruded insuiation shield shall provide a uniform, continuous, smooth, concentric, thermosetting, semmi-conducting, Voltage stress control layer over the surface of the insulation. It shall be in direct contact with and adhere well tothe insulation under all operating conditions. it shall be designed to, conduct the insulation charging and leakage current to the overlying bedding layer and metallic shield or sheath. It shall exhibit long-term chemical stability and compatiblity with adjacent cable components and its allowable operating temperature shall be at least as high as the insulation, 89-06 Page 17Specificaticn for Extruded Insulation Power Cables and Their Accessories Rated 46 KV through 345 kVac AIC 2.4.2 Material ‘The extruded insulation shield material shall be as per ICEA S-108-720. 2.4.3 Thickness Requirements, The nominal thickness of the extruded insulation shield shall be as per ICEA S-108-720 2.4.4 Voids, Protrusions and trregularity Limits ‘The maximum allowable void, protrusion and irregularity limits shall be as described in ICEA $-108-720, repeated below. Maximum void diameter 2.0 mils (60 wm) Maximum protrusion height 5.0 mils (125 um) ‘Maximum irregularity height 5.0 mils (125 um) 2.5 Metallic Shield/Sheath 2.5.1 General ‘The metallic shield/sheath shall comply with ICEA S-108-720 and as described herein. It shall make continuous or frequent (for corrugations) electrical contact with the underlying semi-conducting layers to provide a concentric conducting path for insulation charging and leakage current, as well as neutral current, phase unbalance current, fault current, and surge current 2.5.2 Bedding and Longitudinal Water Blocking For XLPE insulations, a continuous semi-conducting bedding layer shall be applied under the metalic shield/sheath to protect the insulation from deformation due to thermal radial expansion of the core and lateral pressure at bends at maximum normal and emergency operating temperatures. The manufacturer shall design the cable such that the bedding layer functions to limit the maximum deformation of the insulation to 5% ofits thickness. Deviations shall be based on agreement between the purchaser and manufacturer, considering specific cable constructions. if longitudinal water penetration is not prevented by the bedding layer on a XLPE cable, then an additional layer of continuous semi-conducting water swelling tapes or powder shall also be applied The bedding and water blocking layers shall be semi-conducting and meet the requirements of ICEA S-108-720 and as described herein. ‘The semi-conducting bedding layer and semi-conducting water blocking layer, if used, shall be designed to effectively conduct the insulation charging and leakage current from the underlying semiconducting insulation shield to the overlying metallic shield/sheath 2.5.3 Shields Ia metallic shield is proposed, it shall comply with ICEA S-108-720. 2.5.44 Sheaths \fa continuous metallic sheath is proposed (as opposed to a metallic shield system), it shall comply with ICEA S-108-720. Sheaths shall provide the same electrical function as shields, except they shall also ensure a radial moisture barrier to the underlying layers. If required by the purchaser's specification, the manufacturer shall state the limiting value of sheath cyclic strain for 40-year life (%) (reference Appendix I, tem 12 f), to verify that cyclic fatigue testing has been Page 18 89.06Specification for Extruded Insulation Power Cables AgIC and Their Accessories Rated 48 KV through 345 kVac performed for the specific cable construction, and that itis adequate for the intended application. ‘Additional information is provided in Appendix B. 2.5.5 Radial Moisture Barrier XLPE-insulated cables shall incorporate @ metalic, radial moisture barrier, unless a ‘wet design’ cable is specifically requested by the purchaser, and insulation electric stress limits are reduced in compliance with 1.7 and 2.3.2. Radia moisture barriers can be a continuous metal sheath, as described above, or a longitudinally applied metal foll layer bonded to the inside ofthe jacket. Longitudinally applied metal fol moisture barriers shall meet the requirements of CEA S-108-720. When applied, they shall be in addition to an underlying shield, which is required to ensure a satisfactory concentric conducting path for insulation charging and leakage current, as well as neutral current, phase unbalance current, fault current, and surge current. 2.6 Jacket 26.1 General The jacket shall comply with ICEA S-108-720 and as described herein. ‘Supplemental anti-corrosion protection shall be provided for aluminum sheaths, which are not bonded to the inside of the jacket, by applying a continuous coating of waterproof compound over the sheath immediately prior to extruding the jacket Users shall consider polyethylene jackets for cold-weather instalation applications. Jackets for wet design’ XLPE cables shall be polyethylene. 2.6.2 Jacket Thickness ‘The jacket thickness shall comply with ICEA S-108.720, or as modified in the purchaser's specification for the intended application (reference Appendix F Jacket Thickness Considerations). 2.6.3 Semi-conducting Coating Unless specifically excluded by the purchaser, a continuous graphite coating or extruded semi-conducting layer shall be applied over the jacket to form an electrode for Production Tests, de testing during installation, and for periodic maintenance testing after commissioning. 2.7 Production Tests on Cable 2.74 General ‘The production tests shall comply with ICEA S-108-720, except as described herein 2.7.2 Summary of ICEA $-108-720 Production Tests and Frequency ICEA S.108-720 Production Tests and performance frequency are summarized in Tables 2.7-1 and 2.7-2 with specific variations from ICEA performance frequency noted cs9-06 Pago 19Specification for Extruded Insulation Power Cables 1d Their Accessories Rated 46 RV through 345 KV2c BIC Table 2.7-1 Electrical Tests on Main Insulation Gon Partial Discharge Test- Maximum Voltages V; Phase-to- Allowable | ac Test Voltage Withstand | Corresponding to V; /V, Rated | Ground BIL | intemal ac and Test Time Ratio (see 3. below) Voltage, | Voltage, (for Stress kv. kV Vv Vz | reference) | voltsimi [20V, | 25V, 1 30V, | WV, | VV, | WV, kv, kV, kVorest_| (kV/mm) | 1.0hr O5Shr. 0.25hr.| 1.015 | 20 69 40 350 | 150(60)| 80 | 100 | 120 | 40 | 60 | 80 115 70 550 | 200(80)! 135 | 160 | 200 | 65 | 100 | 195 138 80 650 | 200(8.0) 160 | 200 | 240 | 80 | 120 | 160 7 i 161 92 750 | 225(9.0)| 185 | 230 | 280 | 95 | 140 | 185 230 132 1050 | 275(11.0)) 265 | 330 | NWA | 135 | 200 | 265 345 200 1300 | 350(14.0)| 400 | NA | NA | 200 | 300 | 400 degassing. less. 1. ac and PD tests done on each shipping length and 49-61 Hz, after cable completion, including 2. Gwar during ac test shall be < 27-30 kV/mm; lower V, and increase test time to compensate, but regardless, test voltage must be >1.5 V, and duration < 10 hours. 3. There shall be no detectable discharge within the cable with a measurement sensitivity of 5 pC or 4. Assumes cables are used on an effectively grounded system, Table 2.7-2 Summary of ICEA S-108-720 and Supplementary Production Tests and Frequency ("identifies variations from ICEA S-108-720) Test Method Test Reference Test Frequency Conductor ‘dc Resistance 9.3.1 1 test per each shipping length” ICEAT-27-581 Diameter ICEA T-27-581 | 1 sample from each end of each shipping length* Temper ASTM Manufacturer cerificafion that values are met Non-Metallic Conductor Shield Elongation After Aging OA4 Each lot of material used for extrusion onto the cable Volume Resistivity oat Each lot of material used for extrusion onto the cable Note: This test is performed (in combination with insulation shield volume resistivity) on a ______| sample of cable _ “Thickness e428 T sample from each end of each shipping length™ Page 20 Voids, Protrusions & regularities | 9.4.12 ‘| sample from each end of each shipping cs9-06‘Specification for Extruded Insulation Power Cables asic and Their Accessories Rated 46 kV through 345 kVae Test Method Test Reference Test Frequency Tenge Wafer Boil 9.4.13 3 samples from each extruder run; near two ends & middle Spark Teat (non-conducting iayen) _[ICEAT-27°581_| 100% | Insulation Unaged & Aged Tensile & Elongation 19.4.8 1 test per 0,000 (15 km) or atleast 1 per | 9.49 extruder run Hot Creep 9.4.10 and ICEA '3 samples from each extruder run; near wo -28-562 lends & middle Voids & Contaminants 9.4.13 "| sample from each end of each shipping length” ‘Samples shall be prepared using a lathe, or (Owner-approved equivalent, to minimize contamination of the surface of the samples Diameter 19.6] 1 samplo fom each end of each shipping length* Shrinkback (XLPE only) 38 For rated voltages = 150 KV, 1 sample from each 50,000 ft (15 km) or at least 1 per extrusion run For rated voltages > 150 kV, 1 sample from each end of each extrusion run Thickness & Eccentricity 942 1 sample from each end of each shipping length” Metallic Insulation Shield ‘Elongation After Aging 9.4143 Each ot used for extrusion onto the cable Volume Resistivity 9.82 Each lot used for extrusion onto the cable Note: This testis performed (in combination with insulation shield volume resistivity) on a sample of cable Thickness 942 1 sample from each end of each shipping length” Voids & Protrusions 8418 ‘| sample from each end of each shipping length” Water Boil O42 '3 samples from each extrusion run; near two ends & middle Diameter 98 1 sample from éach end of each shipping length Metallic Shields Dimensional Measurements 95 +1 sample from each end of each shipping [Jength* Jackets Unaged & Aged Tensile & Elongation | 9.4.8 1 test per 50,000 ft (15 km) or at least 1 per 949 Jacket extruder run Thickness 9.42 +1 sample from each end of each shipping length* Other Tests Applicable to Jacket Heat Distortion a72 Each lot used for extrusion onto the cable (CEA 1-27-581 Heat Shock O74 Each lot used for extrusion onto the cable Cold bend ICEAT-27-581 | 0 sampies for <1,000 ft (0.3 km), 1 sample L for 1,000 ~ 25,000 ft (0.8 ~ 8.0 km) 1 89-06 Page 21‘Specication for Extruded insulation Power Cables and Their Accessories Rated 46 KV through 345 kVac ENC Test Method Test Reference Test Frequency) ‘Sample for each additional 25,000 ft (8 krn) of jacket extruder run. ‘Oil immersion for PVC jackets) | 8.493 Each lot used for extrusion onto the cable Volume Resistivity 9.8.2 test per 50,000 ft (15 km) or at least 1 per | jacket extruder run ll Electrical Tests ‘Ac Withstand an Test per shipping lengih Partial Discharge ICEA T-24-360_| 1 test per shipping length, ‘Metall Shield/Sheath Resisiance “test per shipping length or master length ‘Capacitance [11 test per shipping length or master length” | ‘Jacket Spark (no graphite coaling | ICEAT-27-581 | 1 test per master length, continuous or extruded semi-conducting layer) Jacket Withstand 742 test per shipping length” ‘Other Tests Moisture in Conductor ‘o14 ‘test par shipping rength Moisture Under Jacket [9.14 4 test per shipping length 2.7.3 Other Additions and Modifications to ICEA S-108-720 Production Tests Other additions and modifications to ICEA S-108-720 Production Tests shall be as follows: 2.7.3.4 Method for de Resistance Determination (ICEA S-108-720 clause 9.3.1, ICEA T-27-581 Clause 2.1) Clause 9.3.1 shall also include the following requirements The complete shipping length reel shall be placed in the test space, which shall be kept at a reasonably constant temperature for atleast 24 hours before the test. The temperature of the cable (measured by placing a thermocouple one layer below the outer layer) atthe time of the test shall be within 3°C of the testing space temperature. Note that itis not necessary for the testing space temperature to be at ‘Room Temperature’, as defined in section 1.3 above. ‘The manufacturer shall report the following. ‘+ length of cable on the reel at the time of conductor de resistance measurement ‘+ measured temperature of the cable and the test room, as well as the method of measurement + measured conductor de resistance, for each reel of cable * conductor de resistance corrected to 25 °C 2.7.3.2 Dimensional Stability The following test, derived mainly from AEIC CS7-93, shall be made to determine the dimensional stability of the cable core at high temperatures. ‘The maximum axial projection of the conductor from either end of the cable core shall be determined after ‘oven healing, in accordance with the following, 1. Aone-foot (0,3-m) long sample shall be prepared from cable located at least one foot (0.3 m) {rom the end of the reel. Each end of the sample shall be cut squarely with a fine tooth saw while at room temperature. 2. All outer coverings shall be removed from the sample, including the jacket, metallic sheaths and shielding, non-metallic shielding tapes and bedding tapes. Page 22 39.06