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Specification for Exruded insulation Power Cables 1c and Theis Ac Rated 46 kV through 345 kVac 3. The sample shall be immediately placed in a forced air convection oven at a temperature of 120 °C #2°C for a period of 20 hours, 4, After the 20-hour period, the sample shall be removed from the oven and allowed to cool for 2 hours at room temperature 5. Al the end of the cooling period, the axial distance shall be measured between the square cut ‘conductor end and the edge of the conductor shield interface at the point of circumference of the conductor where the axial displacement is a maximum. This maximum conductor projection shall be measured and recorded at both ends of the sample, using a micrometer or optical measuring device with a minimum resolution of 1 mil (0.025 mm). The maximum allowable conductor projection at either end shall be 175 mils (4.37 mm). Retests on samples shall be in accordance with ICEA S-108-720 clause 9.10. 2.1.3.3 Amber, Agglomerate, gel, Contaminant, Protrusion, irregularity and Void Tests (ICEA $-108-720 clauses 9.4.13 and 9.15) If either of the two samples from any shipping length fails, the shipping length shall be rejected 2.7.3.4 Longitudinal Water Penetration A longitudinal water penetration test shall be performed for sealed conductor cables, according to the procedures in ICEA T-31-610. Tests shall be done on a sample of completed cable. 2.7.4 Conditions Applying to Tests, The cable and accessories shall not be shipped (except when agreed to by the purchaser), unless all required tests have been completed and results of testing show compliance with all requirements of this specification All production tests prescribed by this specification shall be made at the expense of the manufacturer. ‘The manufacturer shall provide all samples. The purchaser may elect to witness tests and to make inspection of the cable during the process of manufacture, except for those processes of a confidential nature. Refer to procedures and requirements of 8.0 Quality Assurance and 9.2 Manufacturing inspection and Test Plan. Where tests are required for engineering information, the results of these tests shall not be cause for rejection, 2.7.5 Cettified Test Reports If required by the purchaser's specification, the manufacturer shall furnish the purchaser with certified copies of all production test reports required by this specification. ‘The manufacturer shall furnish certified copies of actual test values from those tests required for engineering information 28 Qual ication Tests on Cable Qualification tests shall be done in accordance with ICBA S-108-720 and as described herein. Qualification test reports shall clearly describe the insulation and semi-conducting shield compounds used to manufacture the cable made for the tests, including a copy of the suppliers technical data sheets for each compound. The location, type, and identification number of the extrusion line used to make the cable core shall also be clearly identified 89-06 Page 23‘Specification for Extruded Insulation Power Cables and Their Accessories Rated 46 KV through 345 kVac I required by the purchaser's specification, the manufacturer shall furnish the purchaser with certified copies of all qualification test reports required by this specification. 29 Cable Identification The cable identification shall comply with ICEA S-108-720 and as described herein ‘The outer surface of each cable shall be durably marked throughout its length with the manufacturer's name, type of insulation, insulation thickness, conductor material and size, sequential length indication, fated voltage and year of manufacture. Additional information may be required by governmental and regulatory authorities 2.9.1. Semi-conducting Layer Marking Polymeric insulation shielding and semi-conducting jackets shall be conspicuously identified as semi- ‘conducting. The preceding identification shall be repeated along the cable at regular intervals with ‘unmarked surfaces not exceeding six inches (15 cm) 2.9.2 Method of Marking Marking on the semi-conducting shielding shall be by surface printing only, Durable marking on an outer jacket may be accomplished by indenting or embossing to a depth not greater than 15 percent of its thickness, or by surface printing. 2.9.3 Production Records For all cables, the manufacturer shall maintain records to permit the identification of stock reel lengths and shipping reel lengths insulated adjacent to any particular stock or shipping reel length. The records shall be maintained for a period of not less than five years from the shipping date, unless a longer period is requested by the purchaser at the time of inquiry. 2.9.4 Conductor Strand Identification When center strand identitication is requested by a purchaser, the center strand of each conductor shall be indented with the manufacturer's name and the year of manufacture at regular intervals with un- indented surfaces not exceeding 12 inches (30 cm). Additional information, such as a specific purchasers identification, shall be provided with the mutual agreement between the purchaser and ‘manufacturer. 23.5 Production Sequence Numbers ‘The manufacturer shall establish sequential insulation extruder run numbers on a yearly basis. On each insulation extruder run, production sequence numbers shall be established which will permit identification of the insulation extrusion sequence (Le. the lower number is to be assigned to cables on the reel which left the insulation extruder first). The extruder run and production sequence number shall become part of the records to be maintained by the manufacturer for a period of not ess than five years from shipping date, unless a longer period is requested by the purchaser at the time of inquiry, 3.0 TERMINATIONS 3.1 General The cable system manufacturer shall provide terminations, in accordance with the purchaser's custom project specification, suitable for terminating the cable described herein. Page 24 89.06Specification for Extruded Inculation Power Cables AgIC and Their Accessories Rated 46 KV through 345 kVac Terminations for use in air shall comply with IEEE 48. Terminations in gas insulated switchgear (GIS) shall comply with IEC 60859, IEC 60840 and IEC 62067. Consideration shall also be given to GIS grounding designs, as described in Electra No. 151 article ‘Earthing of GIS ~ An application guide’. If required by the purchaser's specification, the cable system manufacturer shall provide a copy of representative qualification test reports for the proposed terminations with the proposal or include such testing with the proposal Each termination shall be packaged as a self-sufficient ‘kit. It shall contain packing lists, instructions and ali permanent and consumable materials, as required for installation by qualified Journeymen Cable Spicers, under the supervision of a manufacturer's representative. Aerial connector lugs shall be provided for each air termination. The connectors shall have NEMA four hole spacing and be capable of carrying the emergency operating current for 40 °C ambient air temperature, with sun and no wind 3.2 Termination Mounting Insulation ‘Termination mounting assemblies shall be provided with electrical insulating systems to allow temporary isolation of the shield/sheath circuit from ground for periodic maintenance testing of the jacket with a de test voltage. They shall also allow permanent isolation of the shield/sheath circuit from ground, to implement special bonding systems, such as single point bonding, as described in Electra No. 128 article "Guide to the protection of specially bonded cable systems to sheath over-voltages’. The termination isolation systems shall withstand the same electrical requirements as the external anti-corrosion serving for joint casings (see Table 4.2-1 ‘Each Part to Ground’, below) 3.3 Production Tests on Terminations Production tests shall be done in accordance with the requirements of IEEE 48 or IEC 60859 for installation in GIS, as applicable. In addition, the folowing tests shall be done on each of the termination pre-molded or prefabricated stress relief cones and the housing: 1, Parlial Discharge Measurements ~The test shail be carried out in accordance with ICEA T-24-380 or IEC 60885-2. The sensitivity of the partial discharge (PD) measurements shall be 5 PC or better. The stress cone shall be installed on a length of XLPE cable or a simulated accessory test mandrel. subject to agreement between purchaser and manufacturer. The test voltage shall be raised gradually to and held at 1.75 x V, for 10 seconds and then slowly reduced to 1.5.x V,, The magnitude of the PD at 1.5 x V, shall not exceed 5 pC. 2. Dimensional Checks ~ The dimensions of the stress cone shall be measured and checked against the tolerances established by the manufacturer. Checks shall commence no eariier than the start of cable production. 3. Visual Inspection ~ The bore of each stress cone shal be inspected with a fiber scope or other suitable instrument to determine that there are no irregularities on the surface of the bore. Each termination housing shall be visually inspected for the presence of any defects prior to shipping, 3.4 Qualification Tests on Terminations Qualification tests shall be done in accordance with IEEE 48 and IEC 60859 for installation in GIS, as applicable, and as described herein. Informative Note: Users are reminded that the IEEE 48 heating cycle voltage tests are more severe than those for IEC 60840 and 62067 Terminations shall meet the qualification test requirements of IEEE 693 ‘Recommended Practice for ‘Seismic Design of Substations’, for Moderate Site’, unless specifically excluded or more onerous requirements are identified by the purchaser. IEEE 693 requires qualification by time-history shaker table cs3-06 Page 25‘Specification for Extruded Insulation Power Cables and Thelr Accessories Rated 46 KV through 345 KVac. AgIC tests for voltage classifications 2 242 kV and static pull tests or time-history shaker table tests for voltage classifications < 242 kV. Static pull tests consist of pulling perpendicular to the top of the termination with a load twice the operating weight of the termination. The load shall be applied for a minimum of 2 s. There shall be no damage or cracks in any part, including the insulating housing, and no fluid leakage before and after the static pull test. ‘Shaker table tests are described in IEEE 693. If required by the purchaser's specification, the manufacturer shall furnish the purchaser with certified copies of all qualification test reports required by this specification. 3.4.1 Qualification Test for Termination Mounting Insulators. With the termination support structure connected to ground, 25 kVde half be maintained for one minute across the termination mounting insulation, using the termination base plate for the positive high voltage ‘connection, Having successfully withstood the application of de voltage, the test assembly shall be submitted for an impulse test. With the termination support structure grounded, ten positive, followed by ten negative impulses shall be applied across the termination mounting insulation, using the base plate for the high voltage connection. The magnitude ofthe impulses shall be in accordance with Table 4.2-1 ‘Each Part to Ground’ Termination mounting insulators shall meet the requirements of IEEE 693, by being incorporated into the termination assembly for the static pull tests or the time-history shaker table tests described in 3.4.1 4.0 Joints 44 General The manufacturer shall provide joints in accordance with the purchaser's custom project specification, suitable for jointing the cable supplied to the purchaser. Joints shall comply with IEEE 404 and as described herein Ifrequired by the purchaser's specification, manufacturers shall provide a copy of representative qualification test reports for the proposed joints with the proposal or include such testing with the proposal. Each joint shall be packaged as a self-sufficient ‘kt. It shall contain packing lists, instructions and all permanent and consumable materials, as required for instalation by qualified Journeymen Cable Splicers, under the supervision of a manufacturers representative, 4.2 Sheath Sectionalizing Insulators and Joint Casing Insul ion Unless specifically excluded by the purchaser, joints shall be provided with a sheath sectionalizing insulator with internal shield interrupt. The insulation of the two shall be coordinated so that sectionalizing insulator voltage withstand is less than the internal shield interrupt. Both shall withstand the ac and transient over-voltages imposed on them during all operating conditions, as described in the purchaser's specification. Joints supplied for use with ‘dry insulation’ cables with a metallic moisture barrier shall be provided with a metallic casing enclosure to facilitate a continuous hermetic seal between the two ends of the cable sheath. Page 26 c89.06‘Specification for Extruded Insulation Power Cables gic and Thele Accessories Rated 46 KV through 345 kVac Joint casings shall be provided with an external anti-corrosion serving (jacket) to isolate the metallic shield/sheath circuit from ground. It shall withstand the ac and transient over-voltages induced onto it during all normal and abnormal operating conditions. The sheath sectionalizing insulator and joint casing anti-corrosion covering designs shall ensure long term ability to meet the above requirements and impulse withstand levels for 33-foot (10-m) bonding leads, as described in Table 4.2-1 below. The table is derived from IEC 60840, IEC 62067 and the Electra No. 128 article ‘Guide to the protection of specially bonded cable systems to sheath over- voltages’. Itis also compatible with IEC 60229. Table 4.2-1: Metallic Shieid/Sheath Insulating Covering Impulse Withstand Voltage versus BIL Impulse Test Level (1.2 x 50 tsec) Between Parts Each Part to Ground Bonding ‘Bonding Bonding Bonding Cable Length | Cable Length | Cable Length | Cable Length 510 10° < 30" 510" 10° = 30° Rated BIL for Main insulation | (< 3m) | (8m = 19m) < 3m) | (8m = 10m) _ kv. kv. kv. kv kV 250 to 325, 60 60. 30 30 550 to 750 60 75 30 aromel| 1050 60 95 30 475 117510 1425 75 125 375 625 Notwithstanding the conservative assumption for testing based on 33-foot (10-m) bonding cable length, connections shail be as short as possible to minimize surge voltage drop, especially when exposed to high frequency transient over-voltages near GIS disconnects and breakers or near outdoor cable terminals exposed to lightning strikes. ‘The sheath sectionalizing insulators in joints shall withstand the Table 4.2-1 values ‘Between Parts’. All other components, except link box insulation, shall withstand half these values, The designs shall consider lifetime degradation due to repeated field voltage application, moisture degradation, thermal degradation, and a factor of safety. Informative Note: The recommended approach is to design the insulating coverings for metallic shield/sheath circuit components to withstand at least the Table 4.2-1 values throughout their design life, but to also provide additional protection against transient over-voltages by applying sheath voltage limiters (SVLs) with lower protective levels. (Reference Appendix C) 4.3 Production Tests on Joints Production tests shall be done in accordance with the requirements of IEEE 404. In addition, the following tests shall be done on each of the joint pre-molded or prefabricated stress relief cones: 1. Partial Discharge Measurements ~ The test shall be carried out in accordance with ICEA T- 24-380 or IEC 60885-2. The sensitivity of the partial discharge (PD) measurements shall be 5 pC or better. The stress cone shall be installed on a length of XLPE cable or a simulated accessory test mandrel, subject to agreement between purchaser and manufacturer. The test voltage shall be raised gradually to and held at 1.75 x Vg for 10 seconds and then slowly reduced to 1.5.x Vg. The magnitude of the PD at 1.5 x Vg shall not exceed 5 pC. c89-06 Page 27‘Specification for Extruded insulation Power Cable and Thelr Accessories Rated 46 kV through 345 KVac AEIC 2. Dimensional Checks ~ The dimensions of the stress cones shall be measured and checked against the tolerances established by the manufacturer. Checks shall commence no earlier than the start of cable production 3. Visual Inspection ~ The bore of each stress cone shall be inspected with a fiber scope or other suitable instrument to determine that there are no irregularities on the surface of the bore. 4.4 Qualification Tests on Joints Qualification tests shall be done in accordance with IEEE 404 and as described herein. Informative Note: Users are reminded that the IEEE 404 heating cycle voltage tests are more severe than those for |EC 60840 and 62067. In addition, IEC 60840 and 62067 impulse voltage tests for joints embodying sheath sectionalizing insulation and insulating coverings are more severe than IEEE 404-2000 for main insulation BIL greater than 1050 kV. For cables with main insulation BIL greater than 1050 KV, the external insulation of sheath sectionalizing joints shall meet the test requirements described in Table 4.2-1.. The joint casing insulation shall also be proven to withstand at least 25 kVdc for one minute, applied between the joint casing and the external ‘electrode of the submerged joint. if required by the purchaser's spectfcation, the manufacturer shall furnish the purchaser with certified Copies of all qualification test reports required by this specification. 5.0 Sheath Bonding/Grounding Systems 5.1 General Sheath Bonding/Grounding systems shall provide the sheath circuit interconnection and insulation protection systems described in Electra No. 128 article ‘Guide to the protection of specially bonded cable systems to sheath over-voltages’. The systems shall consist of bonding cables, link boxes, and sheath voltage surge arresters, as required for an ‘insulated sheath power cable system’, as defined in the Electra No. 128 article. Over-voltage protection shall be used for GIS terminations to limit transient over-voltages between the cable sheath and the GIS enclosure, as described in IEC 60859 and Electra No. 151 Article: ‘Earthing of GIS - An Application Guide’ If required by the purchaser's specification, the cable system manufacturer shall provide a copy of representative qualification test reports for the proposed sheath bonding/grounding systems withthe proposal or include such testing with the proposal If specified by the purchaser, the manufacturer shall provide drawings of the sheath bonding/grounding system and calculations of expected sheath voltages and currents, done in accordance with the Electra No. 128 article (reference Appendix J Information to be Submitted after Award of Contract) Ratings described below assume use on an effectively grounded system. 5.1.1 Bonding Cables Single conductor bonding cables shall meet the requirements of ICEA S-105-692, except that the ‘minimum average insulation thickness shall be 130 mils (3.3 mm), Bonding cable connections to link boxes shall be as short as possible, but no greater than 33 feet (10 m) in total length to a ground point. They shall be single conductor construction, provided the frequency of transient over-voltages is less than 25 kHz and the bonding cables from adjacent phase connections are Page 28 cs9.08Specification for Extruded Insulation Power Cables gic and Their Accessories Rated 45 kV through 345 kVac, touching each other. For transient frequencies greater than 25 kHz, the manufacturer shall provide ‘concentric bonding cables, as agreéd to with the purchaser. Concentric bonding cables shall meet the requirements of ANSUICEA §-94-649 except that: ‘* the minimum point central insulation thickness shall be 180 mils (4.6 mm) + the minimum point extemal insulation (jacket) thickness shall be 130 mils (3.3 mm) ‘* the conductor and insulation shields shall be eliminated the central concentric and conductors shall be identical in area and materia! (full neutral) All conductors shall be designed to withstand the rated fault current and duration, as well as the sheath currents corresponding to emergency loading. The insulation shait witistand the same impulses as the main cable jacket and joint casing insulation, as described in Table 4.2-1 Bonding cables used as a parallel earth continuity conductor (reference Electra No 128 article, Fig. 4) shall be identical to those described in the foregoing, except that their conductors only need to be designed to withstand the rated fault current and duration. 5.1.2 Link Boxes Link boxes shall be designed for centrat water-tight interconnectian of sheath crass-bonding, single point bonding and grounding systems. Link boxes shaif incorporate removable ‘links’, to easily isolate sections of sheath circuit for maintenance dc testing of cable jackets, joint sectionalizing insulators, termination mounting insulators, etc. The links shall also be designed to easily re-configure the bonding connection system to solidly bonded ‘At cross-bonding locations or single point Bonding open point locations, link boxes shall also incorporate sheath voltage limiters (SVLs) to protect the sheath circuits insulation from transient over-voltages. Link box conducting components shall be designed to withstand the rated fault current and duration, ‘The insulation between the links in all link boxes, including those without SVLs, shall be capable of, withstanding the following voltages, with an additional 25% margin to allow for variability in service: i) The de voltage used for qualification tests (25 KV + 25% for one minute), initial commissioning tests (24 kV maximum + 25% for one minute) and maintenance testing cf the sheath insulation circuit (5 KV de maximum for t minute} ii) The highest power frequency voltage arising between sheaths during an external system fault + 25% ii} 1.2.x 50 psec impulse voltage with a maximum value equal to the protective level as defined in the referenced Electra No. 128 article, paragraphs 5.1.4 and 5.2.3, + 25%, noting that if the SVLs are connected in star, the protective level must be doubled to allow for the fact thal hwo SVLs are connected in series between each pair of sheaths. Water-tightness of the fink box enclosures shall mest the requirements of IEC 60529, with the specific 1P Code classification a agreed to between the manufacturer and purchaser, depending on the location of the installation (in manholes periodically submerged, in dry manholes or tunnels, above ground outdoors, above ground indoors, elc.). Allernatively, they shall meet the requirements of NEMA 250, based on agreement between the purchaser and manufacturer. (Users are reminded that NEMA 250 Appendix A contains an equivalency conversion from NEMA to IEC classifications.) 5.1.3 Sheath Voltage Limiters ‘Sheath voltage limiters (SVs) shall meet the requirements of EEE C62.11 ‘Standard for Metal-Oxide Surge Arresters for AC Power Circuits (> 1 kV)’ 39-06 Page 29‘Specification for Extruded insulation Power Cables and Their Accessories Rated 46 KV through 345 kVac BIC ‘The metal oxide component of the SVLs shall be encased in a waterproof material to prevent absorption of moisture. ‘The SVLs shall be capable of withstanding continuously the sheath standing voltage applied to them during full load of emergency overioad. ‘The SVLs shall be capable of withstanding the highest power frequency voltage applied to them during system faults for the maximum fault current duration specified by the purchaser. The residual voltage protective evel of each SVL shall be less than the impulse withstand levels of the sheath insulating circuit, taking into account surge volage drop in bonding cable leads and SVL connection methods 5.2 Production Tests on Sheath Bonding/Grounding Systems Production tests on single conductor bonding cables shall meet the requirements of ICEA S-105-692 Production tests on SVLs shall meet the requirements of IEEE C6211 Production tests on link box water-tightness shall meet the requirements of IEC 60529 or NEMA 250. They shall also demonstrate the ability to withstand a dc test voltage of 25 KV + 25% for one minute, between the conducting components and ground. 5.3 Qualification Tests on Sheath Bonding/Grounding Systems Qualification tests on single conductor bonding cables shall meet the requirements of ICEA S-105-692 and as described herein. They shall also demonstrate the ability to withstand the impulse test vatages, described in Table 4.2-1 Qualification tests on SVLs shall meet the requirements of IEEE C62.11 Qualification tests on link box water-tightness shall meet the requirements of IEC 60529 or NEMA 250. In addition, link boxes shall withstand a water immersion test followed by an impulse voltage test carried out on one assembly, as described in the Electra No. 75 article: ‘Recommendations for tests on anti- corrosion coverings of self contained pressure cables and accessories and equipment for specially bonded circuits’, The test voltages shalll be in accordance with section 5.1.2 above. If required by the purchaser's specification, the manufacturer shall furnish the purchaser with certified copies of all qualification test reports required by this specification 6.0 QUALIFICATION TESTS ON COMPLETE CABLE SYSTEM For rated voltages >46 KV to 150 KY, if required by the purchaser's specification, the manufacturer shall demonstrate satisfactory performance of a complete cable system comprised of cable and at least one of ‘each type of accessory to be provided. Demonstration shall consist of meeting the requirements of IEC 60840 for ‘Electrical type tests on complete cable systems’, sections 12 to 12.3, but excluding 12.3.9 Resistivity of semi-conducting screens. High temperature tests shall be done at the proposed emergency operating temperature. For rated voltages > 150 kV to 345 KV, the manufacturer shall demonstrate satisfactory performance of a complete cable system comprised of cable and at least one of each type of accessory to be provided Demonstration shall consist of meeting the requirements of IEC 62067 for ‘Electrical tests on complete cable systems’, sections 12 to 12.4, but excluding 12.4.11 ‘Resistivity of semi-conducting screens. High temperature tests shall be done at the proposed emergency operating temperature, Page 30 cs9.06Specification for Extruded insulation Power Cables Age and Their Accessories Rated 46 kV through 345 kVac if required by the purchaser's specification, the cable system manufacturer shall provide a copy of representative qualification test reports for the proposed complete cable system, as defined in the foregoing, with the proposal, or include such testing with the proposal. Manufacturers claiming that they have already performed cable system qualification tests which demonstrate substantially equivalent qualification tests on the individual components and a complete cable system, shall explain the equivalency in detail with their proposal, including any supplementary tests required to provide complete conformance. 6.1 Range of Approval IEC 62067 Section 12.2 describes the ‘Range of type approval’ and the validity of type or qualification {ests done on other similar cables and accessories with respect to the purchaser's intended application The same provisions shall apply equally to the requirements of this specification, excep! forthe specific additions shown in square brackets and underlined below. ‘When the type tests have been successtully performed on one cable system of specific cross-section, rated voltage and construction, the type approval shall be accepted as valid for cable systems within the scope of this standard with other cross-sections, rated voltages and constructions, if the following conditions are met 4) the voltage group is not higher than that of the tested cable system; NOTE: In this context, cable systems of the same rated voltage group are those of rated voltages having a common value of Un [Vn, highest voltage for equipment, and the same test voltage values. b) the conductor cross-section is not larger than thal of the tested cable; ©) the cable and the accessories have the same or a similar construction as that of the tested cable system; NOTE: Cable and accessories of similar construction are those of the same type and manufacturing process of insulation and semi-conducting screens. Repetition of the electrical type tests is not necessary on account of the differences in the conductor type or material or of the protective layers applied over the screened cores or over the main insulation part of the accessory, unless these are likely to have a significant effect on the results of the test. In some instances, it may be appropriate to repeat one or more of the type tests (e.9. bending test, heating cycle test andor compatibility test). 4) the calculated maximum electrical stresses on the conductor and insulation screens, in the main insulation part(s) of the accessory and in boundaries [or interfaces] are equal to or lower than for the tested accessory; NOTE: Ifthe voltage group is the same, if the cable conductor cross-section is smaller and ifthe insulation thickness is not less than that of the tested cable, calculated maximum stress on the conductor may be 10% higher than that of the tested cable. €) [material compositions, manufacturing processes, manufacturing plants, and equipment used for ‘making the cable and accessories subjected to the tests, have not significantly changed] The type tests on cable components (see IEC 62067 clause 12.5) need not be carried out on samples from cables of diferent voltage ratings andlor conductor cross-sectional areas unless different materials are used to produce them. However, repetition of the aging tests on pieces of complete cable te check compatibility of materials (see IEC 62067 clause 12.5.4), may be required if the combination of materials applied over the screened core is different from that of the cable on which the type tests have been previously carried out A type test certificate signed by the representative of a competent [independent] witnessing body, or a [notarized] report by the manufacturer giving the test results and signed by the appropriate qualified [managing] officer, or a test cerifcate issued by [the management of] an independent test laboratory, shall be acceptable as evidence of type testing, cs9.06 Page 34‘Specification for Extruded Insulation Power Cables and Their Accessories Rated 46 KY through 348 kVac AEIC 7.0 PRE-QUALIFICATION TESTS ON COMPLETE CABLE SYSTEM For applications with a rated voltage greater than 150 kV, the manufacturer shall demonstrate satisfactory, long-term performance of a complete system, comprised of cable and at least one of each type of accessory to be provided. Demonstration shall consist of meeting the 365-day test requirements of IEC 62067 Section 13 ‘Pre-qualification test of the cable system’, with modifications to demonstrate performance at emergency conductor temperatures, as described in section 1.9 preceding. Altemative Jong term tests may be accepted, as agreed to between the purchaser and manufacturer, and provided they are applicable to the specific installation conditions, The above tests shall also be done for applications with a rated voltage above 46 kV to 150 kV, with stresses greater than 200 Vimil (8.0 kV/mm) at the cable conductor shield, or greater than 100 Vimil (4.0 kVimm) over the cable insulation, subject to agreement between the purchaser and the manufacturer. 7A Range of Approval IEC 62067 Section 13.1 describes the ‘Range of pre-qualification test approval’ and the validity of tests done on other similar cables and accessories, with respect to the purchaser's intended application. The same provisions shall apply equally to the requirements of this specification, except for the specific ‘additions shown in square brackets and underlined below. When a pre-quaification test has been successfully performed on a cable system, it qualifies the manufacturer as a supplier of [similarly constructed] cable systems with the same or lower voltage ratings, as long as the caiculated electrical stresses at the insulation screen are equal to or lower than for the system tested [and material compositions, manufacturing processes, manufacturing plants, and ‘equipment used for the cable system subjected to the tests, have not significantly changed} ‘A pre-qualifcation test certiicate signed by the representative of a competent [independent] witnessing body, or a [notarized] report by the manufacturer giving the test results and signed by the appropriate Qualified (managing] officer, or atest certificate issued by [the management of] an independent test laboratory shall be acceptable as evidence of pre-qualification testing 8.0 ELECTRICAL TESTS AFTER INSTALLATION Installation of cable systems is not included in this specification and, therefore, Electrical Tests After Installation do not form a direct part of it. However, testing of the completed cable system after installation shall be subject to mutual agreement between the purchaser and manufacturer prior to testing. For information purposes, general recommendations are described in Appendix G and in ICEA '$-108-720 9.0 Quality Assurance 9.4 Quality System Requirements ‘The manufacturer shall have a current quality assurance program and manual in place for each factory ‘engaged in the work. It shall conform to ISO 9001 or equivalent, as acceptable to the purchaser and registered by an accredited agency. ‘The manufacturer shall submit a copy of the quality assurance plans with the proposal, if required by the purchaser's specification (reference Appendix | Manufacturer's Technical Declaration File). 9.2 Manufacturing Inspection and Test Plan If required by the purchaser's specification, within two weeks after a contract is awarded, the manufacturer shall submit to the purchaser for acceptance, a final Inspection and Test Plan, conforming to the requirements of ISO 9001 or equivalent (reference Appendix J Information to be Submitted after Page 32 cs9.06Specification for Extruded Insulation Power Cables ase and Tro Accessories Rated 46 KV through 345 kVac Award of Contract). The Inspection and Test Plan shall be detailed and shall include at least the following categories: Material or Parameter to be controlled; Method of Inspection/Tests and Equipment Used; Frequency of the Inspection/Test; Reference Documents Governing the QA Activity; QA Record Form; agreed Review/Witness/Hold points, etc. ‘The Inspection and Test Plan shall contain details of quality assurance activities to be performed for all materials, manufacturing and handling processes. Inspection and test review/witness/hold points shall be jointly established between the manufacturer and purchaser. f sub-contractors are employed, the Inspection and Test Plan shall indicate the portion of the work that will be undertaken by them, including their inspection and testing 9.3 Factory Inspection The manufacturer shall carry out such inspections and tests, in accordance with the accepted "Inspection and Test Plan’, to verify the conformity of each part of the work in accordance with this specification. AL least 7 working days writen notice. prior fo each established witness/hold point, shall be given to the purchaser to allow for arrangements to be made for his attendance 9.4 Inspection and Audit by the Purchaser ‘Any quality assurance inspection carried out by the purchaser stall in no way relieve the manufacturer of full responsibilty for the quality, character or performance of the completed work, 9.5 Access to Quality Assurance and Test Documents When requested, the manufacturer shall provide timely access to, and copies of, the following documents: shop travelers, detailed shop inspection procedures, certifications, qualifications, inspection and test results, production records, process control charts, calibration certification records, and other quality assurance documents compiled during the work. 9.6 Non-conformance Reports ‘The manufacturer shall provide non-conformance reports (NCRS} to the purchaser for review and acceptance, in accordance with ISO 9001 paragraph 4.13, or equivalent, forall major factory non- conformances to this specication. The requirement for NCRs includes work by sub-contractors. All NCR shall include the manufacturer's proposed disposition andior corrective action. The manufacturer shall establish criteria for submission of NCRs to the purchaser, including the definition of major and minor non-conformances, with submission of the Inspection and Test Plan. Uniess otherwise agreed to between purchaser and manufacturer, NCRS shall be submitted within 24 hours of the manufacturer's discovery of the non-conformance. The above requirement is limited to only products which the manufacturer plans to supply to the purchaser. 9.7 Final Quality Assurance Report If specified by the purchaser, the manufacturer shall submit three certified copies of the final quality ‘assurance reports to the purchaser, certifying the compliance of the work to this specification, including all assembly and test data required in the Inspection and Test Plan, within one week of completion of final inspection and testing. The final quality assurance report shall be bound collection of relevant quality assurance documents as listed below, compiled during the manufacture of the work. Unless limited by the purchaser's specification, the final quality assurance report shall include at least: + Sub-contractor inspection reports + Receiving inspection reports © Mil test certificates 89.06 Page 33Specification for Extruded Insulation Power Cables and Their Accessories Rated 48 KV through 345 KVac AEIC ‘= Cable insulation quality reports * Material qualification reports ‘= Comporent dimensional inspection data reports ‘© Instrument and Gauge calibration certificates and records * Component test reports ‘+ Accepted non-conformance reports + Certified Test Reports in accordance with the specification 10.0 SHIPPING 10.1 Cable Reels 10.1.1 Cable Reet Packing, Sealing, and Shipping The cables shall be placed on reels so that they are protected from damage during shipment. Each end of the cable shall be firmly and properly seuured to the reel. Care shall be taken to ensure that the cable is tightly wrapped to prevent movement during transportation Reels shail be shipped with both flanges oriented vertically There shall be no water in the completed cable when the reel is shipped. Each length of cable listed on the purchaser's order or detail ist shall be shipped on a separate reel Unless specifically agreed to between the purchaser and manufacturer. The reels shall be lagged or covered with suitable material to provide physical protection for the cables during transit and during ordinary storage and handling operations. 10.1.2 Reel Dimensions ‘The minimum drum diameters for shipping reels shall be determined by the manufacturer. Reel onstruction and dimensions shall comply with NEMA WC 26. If the cable has a metallic sheath, the minimum drum diameter ofthe reels shall be in accordance with the following Table 10.1-1, or as otherwise agreed to between the purchaser and manufacturer. Page 34 cs9.06‘Specification for Extruded Insulation Power Cables BIC and Their Accessories Rated 46 KV through 345 Vac Table 10.1-1 Minimum Drum Diameter for Various Metallic Sheath Types Insulation Thickness Ratio of Outside Diameter of Reet ‘Sheath Type mils (mi) Drum to Cable Outside Diameter Lead <500 (12.7) 4 Lead 500 to 800 (12.7 to 20.3) 18 Lead > 800 (20.3) 2 ‘Aluminum (smooth tubular) a ‘Aluminum (smooth fe tubular, bonded to jacket) Corrugated Metallic [ | ees, 800 mils (20.3 mm) 18 Corugated Metalic > £00 mls (20.2 mm) a | copper or aluminum) ‘The inner or drum end of the cable, when allowed to project through the flange of the reel, shail be protected to avoid damage to the cable or seal. 10.1.3 Marking on Reels Each reel shall be marked with a durable label securely attached fo the outside of a flange. The label Shall plainly state all the identification information described in section 2.9, as well as the following. manufacturer's name and address purchaser's order and contract number destination shipping length of cable on reel reel identification number conductor size type of cable thickness and type of insulation voltage rating gross, tare and net weight Each reel shall be marked with an arrow on the flange indicating the direction the reel is to be fumed to unwind the cable, Each reel shall be identified with a unique reel number permanently attached to the outside of one of the reel flanges. Shipping reels shall be free of any information not pertaining to the order. 10.1.4 Cable End Fit ings Cables with a metallic moisture barrier shall have their ends hermetically sealed from moisture entry with durable and effective metallic end caps. Special consideration shall be given to effectively sealing cables with longitudinally applied metal foil moisture barriers. 89-06 Page 35,‘Specification for Extruded Insulation Power Cabh “Their Accessories Rated 46 KV through 345 kV: asic Apulling eye, approved by the purchaser, shall be attached at the outside end of each shipping length ‘The pulling eye shall be suitable for pulling the cable through wet or dry ducts or pipes, trenches, or tunnels. The tensile strength requirements shall be at least the same as the main cable conductor or as otherwise agreed to between the purchaser and manufacturer. Cable caps and pulling eyes shall be designed and applied to allow performing a de jacket integrity test without having to remove them and their hermetic seals. 10.2 Containers, Boxes, and Pallets 10.2.1 Marking of Containers, Boxes, and Pallets All containers, boxes, and pallets shall be identified with an aluminum tag securely attached. The following information shall be stamped in raised or indented letters on the tag manufacturer's name and address purchaser's order and contract number destination general contents quantity in container container identifying number 10.2.2 Packaging and Shipping (@) General All items shall be packaged and loaded for shipment in a manner to protect them from damage, moisture and corrosion in transit, handling, outdoor storage and transportation to the site. Burlap and other absorbent material shall not be used for packing of any material shipped. ‘The manufacturer shall be responsible for and correct any and all damage and shortages incurred during loading and transit to the delivery point (0) Packaging Joints and terminations shalt be shipped in wooden boxes with one complete accessory kit per box. Other materia that might otherwise be lost shall be boxed or wired in bundles (©) Shipping Material shail be shipped in a manner to facilitate off-loading, handling, and erection on site. Where required for proper handling and erection, lifting lugs and special liting devices shall be provided. In such cases, slinging diagrams shall be included with the shipping reports described herein. All parts shall be prepared for shipment so that handling slings may be attached readily while the parts are on the rail car, truck or ship. Where equipment is boxed and it is unsafe to attach slings to the box, provision shall be made to attach the slings to the equipment and the slings shall project through the box or crate so that attachment can be made readily ‘The manufacturer shall be responsible for tracing and expediting all shipments and for obtaining all required clearances. Page 36 cS9.06Specification for Extruded insulation Power Cables gic nd Thole Accessories Rated 46 KV through 345 kVae 10.2.3 Packing Lists Packing lists shall be included with each shipment and submitted with the shipping reports. Packing lists, shall show the following information: description of the contents of each box calculated net weight and actual gross weight of each package unit ‘overall dimensions of each individual package identification number of each package in the shipment 10.2.4 Shipping Advice ‘The manufacturer shall, on the date of material shipment, send the purchaser the following information by e-mail, fax or courier service: contract number and purchase order number items and quantities shipped carrier name bill of lading numbers: delivery point shipping date anticipated date of arrival at delivery point details of any special requirements regarding the methods of handling and storing the items shipped ‘The manufacturer shall give the purchaser not less than two working days notice of the actual arrival times of all shipments at the delivery point. cs9-06 Page 37‘Specification for Extruded Insulation Power Cables ‘aid Their Accessories Rated 46¥V through 345 KVac AEIC 11.0 APPENDICES Page 38 89-06‘Specification for Extruded insulation Power Cables agile ‘and Their Accessories Rated 46 KV through 345 kVac Appendix A — Basis for Void, Contaminant, and Protrusion Limits (Informative) The specification limits for permissible size of contaminants, voids and protrusions for XLPE insulation and extruded shields, are based mainly on Appendix A References 1. 2., and 3 1. Voids The maximum permissible void size is based on the condition that partial discharges would not occur under normal rated voltage and would extinguish even if they might occur under ac over-voltages. Void location is assumed to be at the extruded conductor shield surface ‘The following equation is developed in the Appendix A references: 550 Ge puiaa ene ° — 2.65 4 xin, In) Where 2a = diameter of void considered to be harmful (mm) V, = discharge inception voltage cable maximum ac voltage / V3 x 1.2 (kV) (assuming that the ratio of inception voltage to ‘extinction voltage is 1.2) = V,x 1.1% 1.2 (kV) (assuming a 10% over-voltage for 15 minutes) ‘outer radius of insulation (mm) inner radius of insulation (mm) ‘The above equation can also be expressed in terms of G,,., the nominal ac voltage stress at the conductor shield/insulation interface at nominal phase-to-ground operating voltage, V,: 350 1.23xG,,, x1.1x1.2—2.65 @) y, ny xdn(r,/4) @) ‘The maximum permissible void size can then be expressed in terms of various values of Gn |. Gmax | 100] 125 | 180] 175 | 200] 326 | 260] 275 | 300 | 325 | 360 | Viril kVimm) (4.0) (6.0) | (6.0) | (7.0) | (8.0) | (9.9) | (10.0) | (14.0) | (22.0) | (13.0) | (14.0) [Maximum 1 Void diam. | 2.0 2.0 2.0 2.0 20 1.9 17. 15 2a ©! | 4 | GA) | A)! | GA)! | sy) 3" | (38) mils Qe "reduced from calculated value to reflect current practices and ICEA $-108-720-2004 limits. ? less than ICEA $-108-720 limits, cs9.06 Page 39‘Specification for Extruded Insulation Power Cables and Thelr Accessories Rated 46 KV through 345 kVac AEIC 2. Contaminants and Protrusions Contaminants in the insulation form a focal high electric field in their vicinities, which may cause electrical treeing. The maximum permissible contaminant size is determined when local fields approach the electrical tree inception stress. Electrical tree generation fram contaminants and protrusions is generally considered to follow a voltage-time relationship and is also temperature dependent, according to the following equation (Reference 1.): G2 Gy, XLAXK, XK, XK, “ Where: G. = electrical tree inception stress for metallic contaminants (assumed 300 kVimm at 20 °C) Gna fhe nominal voltage stress at the conductor shield/insulation interface at nominal phase-to- ‘ground operating voltage K,= temperature coefficient (ratio of the electrical tree inception stress at 20 °C to that at 90 °C = 1.2) jeterioration coefficient; the life conversion coefficient based on a value of 1 obtained from voltage-time test data for mode! cables, the ratio between voltage raising steps oft. minutes in tree initiation tests and the design life , (5) 1, = 40 x 365 x 24x60 (minutes) (assuming a 40-year life) £,.= 16 (minutes) K;= electric stress concentrating coefficient at the tip of a metalic defect Af, (atl | _ Hb S)- a AJ (6) Where: af 2 7) a @) major axis of ellipsoidal contaminant (jum) fadius of point end used for tree initiation stress tests (assumed 10 um) By solving equation (4) with various values of Gin, and contaminant diameters (2a), one can determine the appropriate values to assure not exceeding the electric tree inception stress of 300 KVImM. Gmuc iS Of course dependent on the phase-to-ground voltage, conductor radius and insulation thickness, for the particular application, ‘The limit for amber size in the insulation is twice the contaminant diameter (4a). Page 40 cs9-06Specification for Extruded Insulation Power Cables AEIC nd Their Accessories Rated 45 KV through 345 kVac The limit for the height of protrusions (either into the shield oF into the insulation) is ane half the diameter of the contaminant (a). The maximum permissible contaminant, amber and protrusion sizes can then be expressed in terms of various values Of Gas: Gras | 100 | 125 | 150 | 475 | 200 | 225 | 250 | 275 | 300 350 | iit (kVimm) | (4.0) | (6.0) | (6.0) | 7.9) | (8.0) | 8.0) | (10.0) | (14.0) (42.0) (14.0) Maximum Contaminant | 50 | 50] 50 | 50 | 50 | 50 | 50 | 50 | 50 40 diam. 2a | (127)" | (427)" | (127y" | (n27y' | (127y' | 427)" | 279" | (r279" | zeit (100)? ris (1m) Maximune if Amberdiam. | 100 | 10.0 | 100 | 10.0 | 100 | 10.0 | 100 | 100} 100 | 80,| 8.0 4a (254)' | (254)' | (254)* | (254)' | (254)" | (254)" | (254)* | (254)" | (254)" | (220¥? | (200)? mils (um) Maximum Protrusion heightat | 30 | 30 | 30 | 30 | 30 |30 | 30 | 30] 25 | 20 } 20 conductor | (76) | (76)* | (76)' | «rey | (76)* | (76)° | ¢7ej" | 76)" | ay? | 5 | GOP shield a mils (4m) L * reduoed from calculated value to reflect current practices and |CEA S-108-720-2004 limits. ® ‘ess than ICEA S-108-720 limits. ® one half of the ICEA S-108-720 contaminant diameter, as per JEC-3408, if lower than ICEA limits Maximum protrusion height at the insulation shield is 0.6 times the value at the conductor shield, to reflect ICEA S-108-720 practice and in consideration of the approximate typical ratio between internal and ‘external ac stresses ICEA S-108-720 has an additional requirement that the insulation not contain more than 0.6 contaminants per cm’ between 51 and 127 um in diameter. Users are reminded that the formulas described above provide only a general idea of electric stresses, based on a number of assumptions. For example, elliptical, parabolic, or hyperbolic models could be Used to simulate protrusions with differences in results. The elliptical model selected above does not consider very sharp tips of protrusions, as they may exist in real life, and which would result in significantly higher stresses than those calculated using the formulas. The values translated to Tables 2.2-4 and 23-2 of the specification have. therefore, been rounded to the closest 0.5 mil (13 um) More recent work using finite element analysis has concluded that for maximum background fields in the range of 15 kVimm, as seen near the conductor shield of some high stress transmission class cables, a ‘worst-case conducting contaminant particle length in the range of 4.0 mils (100 jm) is likely to be required to cause failure for the worst-case local polymer morphology in the range of the maximum operating temperature’. This confirms the validity of the above approach. Appendix A References: 1. Standard of the Japanese Electrotechnical Committee, “JEC-3408 High Voltage Tests on Cross- linked Polyethylene Insulated Cables and their Accessories for Rated Voltages fromm 11 KV to 275kV", 1997. cs9.06 Page 41Specification for Extruded Insulation Power Cables and Their Accessories Rated 46 HV through 345 kVac AEIC 2. M.Fukawa, T. Kawai, Y. Okano, S. Sakuma, S. Asai, M. Kanaoka, H. Yamanouchi, “Development of 500 kV XLPE Cables and Accessories for Long Distance Underground Transmission Line — Part Il: Electrical Properties of 500 kV Cables’, IEEE Transactions on Power Delivery, Vol. 11, No. 2, April 1996. 3. K. Kaminaga, T. Harada, M. Ono, T. Kojima, Y. Sekii, M. Marumo, “Research and Development of 500 KV XLPE Cables”, Conference Record of 1986 IEEE International Symposium on Electrical Insulation, Washington, DC, June 9-14, 1986. 4, S. Boggs, Z. Zheng, “Defect Tolerance of Solid Dielectric Transmission Class Cable”, IEEE Electrical Insulation Magazine, Vol. 21, No. 1, January/February 2005. Page 42 cs9.06Specification for Extruded Insulation Power Cables, gic and Their Accessories Rated 46 KV through 345 kVae Appendix B — Aging Factors, Design Life and Reliability Considerations for Extruded Insulation Cables and Accessories (Informative) ‘The Electra No. 140 article “Consideration of Ageing Factors in Extruded Insulation Cables and Accessories” describes the main factors to be considered when designing and evaluating extruded insulation cables and accessories with respect to the ability to mneet design life (see Reference 1.). The following Table B-1 is extracted from it and provides a valuable remindes for every new application ‘Table B-1 Factors to be Considered in Aging of Extruded Insulation Cable Systems Semi Cables & | semi- | conducting | Sweting | metalic | Bonded accessory | conducting | “contact | tapes.or | wires! | metal” | Metatic | _ insulation | “ahielgs” | ‘layers | powders | tapes | tarrers_| sheaths | Jrckote PHYSICAL I [a Coysatiny anges z Z.Ghanges macular x | right aston 7 3 Mechanical bckedA 5 x 5 x 5 tres changes and | Snape - 4 Delormation uhder T temperature and enernaly x x x x x | sppied mechanical stese 5 Thermal expasion x x x = x tects rad) = 6, Thermal Expansion rn = 5 = | sitet (engitusina | {Maximum working © 7 —|—= z t veroad temperate B.Loss of adhesin z 9. Fatigue due to cyeie 5 x ~* bending TO Presence ot Rive = * z F - z components Too emo] T insart | [72.Damaged insulation and x * * x x | * | faut jot “Contamination = z 14 Moisture re-distibution T ~ (oot font external x x x x | renewahle sources) TS Water ree ctv x 7 ‘CHEMICAL 6 Oxidaon —— —¥—— 17 Compationty (asin of x x ¥ x x | components) J Coresion z z z z = 7 PHYSICO-CHEMICAL 7 18 Sem-conducting sted z = x T reoistvly changes 20Sutace testy 5 : 5 z z changes (oss of cletvical conte al | CS9-06 Page 43Specification for Extruded Insulation Power Cables and Their Accessories Rated 46 KV through 345 kVac AgIC ELECTRICAL, I Pt Low-level paral x discharge actly 22 Electical stress (ac and x x impulse) 3. Dissipation facior x = 24 Stabilty of elecincal x x x x connections. ‘25 Biological effects x x I Part 1.8 of the specification requires the manufacturer to supply data and calculations supporting a minimum 40-year cable system design lfe, if required by the purchaser's specification. References 2~ 17 provide some examples of work done by others to verity siilar requirements, mainly from an electrical performance perspective. Part 1.8 also requires the manufacturer to supply supporting data and calculations verifying the thermal mechanical performance of the cable system, if required by the purchaser's specification. References 18 = 46 provide examples of work done by others to verify similar requirements. Some of these references also overlap with the electrical performance references described in the preceding paragraph Part 2.5.4 requires the manufacturer to state the limiting value of sheath cyclic strain for 40-year life (%) (reference Appendix |, tem 12 e), to verify that cyclic fatigue testing has been performed for the specific cable construction, and that it is adequate for the intended application, if required by the purchaser's specification. (Cnecessary, tests shall be done in general accordance with methods described in References 22, 35, 38 arid 40. Appendix B References. Aging Factors: 1. CIGRE Working Group 21-09, "Consideration of Aging in Extruded Insulation Cables and Accessories", Electra No. 140, pages 57-75, February 1992. Electrical Design Life and Reliability Metra, Ochini, Portinari, “High Voltage Cables with Extruded Insulation, Statistical Controls and Reliability Evaluation’, {EEE Transactions on Power Apparatus and Systems, vol. PAS-94, no. 3, May/June 1975 3. Bossi, Farnetti, Portanar “Criteria for the Qualification of Extruded insulation Cables”, paper 21- 10, CIGRE 1976. 4, Kaminaga, Harada, Ono, Kojima, Sekil, Marumo, “Research and Development of 500 KV XLPE Cables", Conference Record of 1986 IEEE International Symposium on Electrical Insulation, Washington, DC, June 9-11, 1986. 5. Olshausen, Peschke, Schroth, ‘Development of EHV XLPE Cables: Dimensioning and Test Philosophy’, paper 21-107, CIGRE 1990. 6. Dorison, Sin, Argaut, Becker, Dejean, “High Voltage Cross-Linked Polyethylene Insulated Cables in the French National Grid ~ Experience in the Field — Potential Utilization at Higher Voltages’, paper 21-107, CIGRE 1994 7. Peschke, Schroth, Olshausen, “Extension of XLPE cables to 500 kV based on progress in technology", paper A.1.2, Jicable 1995, 8. Fukawa, Kawai, Okano, Sakuma, Asai, Kanaoka, Yamanouchi “Development of 500 kV XLPE Cables and Accessories for Long Distance Underground Transmission Line ~ Par Il: Electrical Properties of 500 kV Cables", IEEE Transactions on Power Delivery, Vol. 11, No. 2, April 1996. Page 44 cs9-06