CS9+Draft+G+June 2006ID615VER26

8/11/2019 CS9+Draft+G+June 2006ID615VER26

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Specification for Extruded Insulation Power CablesAEIC CS9-06 1st Edition and their Accessories Rated aboe !6 "# throu$h %!& "#ac

SPECI'ICA(I)* ')R

E+(R,E I*S,.A(I)* P)/ER CA.ES

A* (EIR ACCESS)RIES

RA(E A)#E !6 "# (R),2 %!& "#ac

First Edition

(Draft G, June 4, 2006)

RA'( 2 - C)*'IE*(IA.

Association of Edison Illuminating Comanies600 !ort" #$t" %treet, &ost 'ffice o 264#

irming"am Ala*ama +2-#.0--2

Decem*er 200

http344www5aeic5or$
http://www.aeic.org/http://www.aeic.org/


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Co/rig"t 2006 */ t"e Association of Edison Illuminating Comanies

!o art of t"is secification ma/ *e reroduced in an/ form it"out t"e rior ritten&ermission of t"e Association of Edison Illuminating Comanies1

All rig"ts resered1

&lease contact us at our e*site3

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(able of Contents

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Specification for Extruded Insulation Power CablesAEIC and their Accessories Rated !6 "# throu$h %!& "#ac

Vm: Maximum continuous phase-to-phase operating voltage (V+5%)

Vt: Phase-to-ground test voltage

Vented Water Tree: A water tree, which originates at the conductor shield or insulation

shield.

Void: Any cavity in a compound, either within or at the interface with

another extruded layer.

Wet Location: Installations underground or in concrete slabs or masonry in direct

contact with the earth; in locations subject to saturation with water

or other liquids and in unprotected locations exposed to weather.

XLPE Insulation Compound:Cross-linked polyethylene insulation.

15&58 efinition of (ests

The following additional definitions clarify the various testing terms used herein and in

documents referred to in this specification.

Production Tests: Tests made on each manufactured component (length of cable or

accessory), or samples thereof, to confirm compliance of the

finished product with this specification and other standards

referenced herein. They also verify that the delivered products

have at least the same quality as those having passed theQualification and Pre-qualification Tests. Production Tests are

sometimes variously referred to in other documents as factory

tests, routine tests and acceptance tests.

Qualification Tests: Tests made before supplying on a general commercial basis, a

type of cable, accessory or cable system (cable and accessories)

covered by this specification and referenced standards, in order to

demonstrate satisfactory performance characteristics for the

intended application. Once successfully completed, these tests

need not be repeated, unless changes are made in the cable or

accessory materials, or design, or manufacturing process, or

manufacturing plant, which might change the performance

characteristics. Qualification Tests are sometimes variously

referred to in other documents as prototype tests, type tests and

design tests.

CS9-06 Pa$e 9


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Pre-qualification Tests: Tests made before supplying on a general commercial basis, a

type of cable system covered by this specification and referenced

standards, in order to demonstrate satisfactory long-term

performance of the complete cable system. The pre-qualification

test need only be carried out once, unless there is a substantial

change in the cable system with respect to materials, or design, or

manufacturing process, or manufacturing plant, which might

adversely affect the performance of the cable system.

Deeloment ;ests3 ;ests comleted */ t"e manufacturer during deeloment of t"eca*le s/stem *efore re.ualification tests1 ;"e recise natureand etent of deeloment orB and anal/ses s"all *e at t"ediscretion of t"e manufacturer, *ut ma/ include t"e folloing3

An ealuation of t"e materials and rocesses emlo/ed,

including leels of oids, contaminants, rotrusions, etc1

oltage.time endurance testing and 5ei*ull anal/sis of test

results, including determination of n>, t"e long term agingeonent

Development of compatible accessories, including factory tests

to assess aging effects related to electrical stress,

temperature, interface pressure, environmental conditions, etc.

erification tests on full sie ca*le s/stems,

Correlation of development test results with service reliability

requirements

156 RE'ERE*CES

The following standards and references form a part of this specification. The most recent

editions apply.

ASTM 1693 Tests for Environmental Stress Cracking of Ethylene Plastics

Electra No. 128 Article: Guide to the protection of specially bonded cable systems against

sheath over-voltages, January 1992

Electra No. 141 Article: Guidelines for Tests on High Voltage Cables with Extruded

Insulation and Laminated Protective Coverings, April 1992

Electra No. 151 Article: Earthing of GIS An Application Guide, December 1993

ICEA S-94-649 Standard for Concentric Neutral Cables Rated 5 through 46 kVICEA S-105-692 600 Volt Single Layer Thermoset Insulated Utility Underground

Distribution Cables

ICEA S-108-720 Standard for Extruded Insulation Power Cables Rated above 46 kV

through 345 kV

ICEA T-24-380 Guide for Partial Discharge Test Procedure

ICEA T-27-581 Standard Test Methods for Extruded Dielectric Power, Control,

Instrumentation & Portable Cables for Test

CS9-06 Pa$e 10


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ICEA T-31-610 Guide for Conducting a Longitudinal Water Penetration Resistance Test

for Sealed Conductors

ICEA T-32-645 Guide for Establishing Compatibility of Sealed Conductor Filler

Compounds with Conductor Stress Control Materials

IEC 60228 Conductors of insulated cables

IEC 60229 Tests on cable oversheaths which have a special protective function

IEC 60287 Calculation of the continuous current rating of cables (100% load factor)

IEC 60853-2 Calculation of the cyclic and emergency current rating of cables

IEC 60529 Degrees of protection provided by enclosures (IP Code)

IEC 60840 Power cables with extruded insulation and their accessories for rated

voltages above 30 kV up to 150 kV Test methods and requirements

IEC 60859 Cable connections for gas-insulated metal-enclosed switchgear for rated

voltages of 72.5 kV and above

IEC 60855 Electrical test methods for power cables

IEC 62067 Power cables with extruded insulation and their accessories for rated

voltages above 150 kV up to 500 kV Test methods and requirementsIEEE 48 Standard Test Procedures and Requirements for Alternating Current

Cable Terminations 2.5 kV through 765 kV

IEEE C62.11 Standard for Metal-Oxide Surge Arresters for AC Power Circuits (> 1 kV)

IEEE 100 The Authoritative Dictionary of IEEE Standards Terms

IEEE 404 Standard for Extruded and Laminated Dielectric Shielded Cable Joints

Rated 2,500 500,000 V

IEEE 693 Recommended Practice for Seismic Design of Substations

ISO 9001 Quality Systems Model for quality assurance in design, development,

production, installation and servicing

NEMA WC26 Binational Wire and Cable Packaging

NEMA 250 Enclosures for Electrical Equipment

Other standards are in turn referenced from within the above documents.

15= R I*S,.A(I)*

Cable systems having cable insulation with nominal internal and external ac electrical stresses

greater than 100 V/mil (4.0 kV/mm) and 50 V/mil (2.0 kV/mm) respectively, shall be supplied with

a metallic moisture barrier to maintain dry insulation. Higher ac stresses may be applied to wet

design cable systems, if agreed to between the purchaser and manufacturer.

15> ESI2* .I'E A* RE.IAI.I(

Cable systems meeting the requirements of this specification are expected to have a minimum

design life of 40 years. The manufacturer shall supply test data and calculations supporting

these design and reliability requirements, if required by the purchasers specification (reference

CS9-06 Pa$e 11


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Appendix 8, Item 25). The documentation shall include the electrical, thermal and mechanical

performance characteristics of the cable core, laminated metallic moisture barriers (if present),

solid metallic sheath, jacket and accessories.

Manufacturers shall take into account the Aging Factors, Design Life and Reliability

Considerations for Extruded Insulation Cables and Accessories in Appendix 2, to ensure that

the cable and accessory system performs reliably for the expected design life and intended

application. The design life shall also take into account the maximum operating temperature

considerations described in Appendix 4 and 1.9 below.

159 A+I, )PERA(I*2 (EPERA(,RES A* ,RA(I)*S

The design and construction of the cable and accessories shall be such that they perform

reliably together as a complete system, at conductor temperatures not exceeding those shown in

Table1.9-1.

Table1.9-1 Maximum Conductor Temperatures (C)

Type of Operation XLPEEPR

(to 138 kV max)

Normal Operation 90 90

Emergency Operation

(46 150 kV)105 105*

Emergency Operation

(>150 345 kV)105 Not applicable

Short Circuit Operation 250 250

*Emergency operation at conductor temperatures up to 130C may be used if mutually

agreed between purchaser and manufacturer and verified by qualification and pre-

qualification tests.

The temperatures identified for Emergency Operation apply for no more than 72 hours duration

on average per year during the design life of the cable system, without exceeding 216 hours in

any 12 month period. Users are referred to Appendix 4 for a description of the basis of these

emergency temperature/time requirements and an explanation of verification tests.

If emergency operation (for cables rated >150 to 345 kV) to 105C or higher is desired, the pre-

qualification tests in IEC 62067 shall include 90 additional load cycles to the maximum

emergency operation temperature, as described in Appendix 4. In addition, the qualification

tests (type tests) in IEC 62067 and IEC 60840 shall be performed at the maximum emergency

operation temperature, as described in Appendix 4.

CS9-06 Pa$e 18


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The temperatures identified as for Normal Operation apply to operating load cycles typical of

electric utility systems (approximately 0.80 daily load factor for transmission lines; approximately

1.0 daily load factor for generating stations). Cable system designs shall assume that the

normal maximum operation temperatures can be applied continuously throughout the cable

systems design life, with corresponding load factors.

Designs for operation at the Table 1.9-1 maximum temperatures shall take into consideration

actual field-proven performance and design limits of transmission cable and accessories, as

relevant to the intended application. This shall include consideration of at least the factors

described in ICEA S-108-720 Appendix B, as well as the following:

the effects of high operating temperatures on radial expansion of XLPE insulation

possible degradation of stress relief cone interface pressure due to mechanical stress

relaxation, over the cable system design life

the temperature gradient across the cable core and the corresponding jacket temperature

limits, which could be excessive for some installation conditions

possible loss of adhesion at the overlap of laminated moisture barriers and loss of bondadhesion to the underside of the jacket

high axial thrust forces that can be transmitted to joints and terminations, especially for large

conductors

possible permanent distortion of the insulation due to high sidewall forces at bends, resulting

in a local reduction of insulation and jacket thickness

possible permanent distortion of the insulation due to radial expansion at clamps and

anchors, for some sheath/shield constructions

cyclic fatigue resistance of metal moisture barriers and corresponding value of the limiting

cyclic strain (see Appendix 2 references 17 42, and especially 20, 32, 35 and 37)

effective axial stiffness (longitudinal rigidity) of the cable (see Appendix 2 references 17

43) and the design of duct/pipe clearance, layouts in tunnels, manholes and approaching

terminations

effective bending stiffness (flexural rigidity) of the cable (see Appendix 2 references 17 - 43)

and the design of duct/pipe clearance, layouts in tunnels, manholes and approaching

terminations

The Table 1.9-1 maximum operating temperatures apply to the hottest portion of the cable

system at any time. They may be used in current rating calculations when adequate information

is known about the overall thermal characteristics of the cable system environment, to ensure

that these temperatures shall not be exceeded. In the absence of this information, the

maximum temperatures used in current rating calculations shall be reduced by 10C, or in

accordance with available data.

1510 C,RRE*( RA(I*2 A* CA.E (EPERA(,RE CA.C,.A(I)*S

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Current ratings and cable temperatures shall be calculated in accordance with IEC 60287, or as

described in The Calculation of Temperature Rise and Load Capability of Cable Systems, J.H.

Neher, M.H. McGrath, AIEE Transactions on Power Apparatus and Systems, vol. 76, October

1957. Daily load factor effects shall be calculated in accordance with the latter reference or IEC

60853-2.

For conductors with large cross-sections, values for the skin effect factor (ks) and proximity effect

factor (kp) shall be in accordance with the recommendations of CIGRE Technical Brochure 272

Large Cross-sections and Composite Screen Designs, WG B1.03, June 2005, unless

otherwise agreed to between purchaser and manufacturer and verified by measurement of ac

resistance during qualification tests.

Emergency current ratings and cable temperatures shall be calculated in accordance with IEC

60853-2.

85 CA.ES

Cables shall comply with ICEA S-108-720 and as described herein.

An Insulation System Quality Assurance Plan shall be submitted with the Manufacturers

Technical Declaration File (reference Appendix 9, Item 24), if required by the purchasers

specification. The plan shall describe procedures to ensure that the cleanliness and smoothness

requirements of extruded insulation and semi-conducting shield materials are met throughout

the supply chain from compound supplier to the manufacturers extruders.

851 C)*,C()RS

85151 2eneral

The conductor material shall be copper or aluminum with circular cross-section.. If the area and

construction is not described by the purchasers specification, the manufacturer shall provide a

conductor with material, cross-sectional area and construction sufficient to meet the required

normal current carrying capacity, emergency current carrying capacity and short circuit fault

duty, without exceeding the temperature limits described in Table 1.9-1, in accordance with the

installation conditions and other information in the purchasers specification.

85158 Sealant for Stranded Conductors

If specified by the purchaser, a sealant designed as an impediment to longitudinal water

penetration shall be used to fill all the interstices of stranded conductors. Compatibility with the

conductor shield shall be determined in accordance with ICEA T-32-645. Longitudinal water

penetration resistance shall be determined in accordance with ICEA T-31-610 and shall meet a

minimum pressure requirement of 5 psig (35 kPa).

CS9-06 Pa$e 1!


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8515% Preferred Conductor Si?es

ICEA S-108-720 Tables 2-2 and 2-3 describe 31 possible conductor sizes ranging from 250

kcmil (127 mm2) to 4000 kcmil (2027 mm2), in copper and aluminum. Fewer standard sizes for

HV and EHV cable can result in lower tooling costs for manufacturers, smaller spare cable

inventories for purchasers and greater opportunities for sharing of spare cables between users.

Cables supplied under this specification shall therefore be limited to the conductor sizes shown

in Table 2.1-1, unless described otherwise in the purchasers specification, or proposed as an

alternative by the manufacturer.

Table 2.1-1 Standard Imperial Conductor Sizes (kcmil) and Nearest IEC 60228 SI Sizes

(mm2)

69 kV 115 kV 138 kV 161 kV 230 kV 345 kV

kcmil mm2

kcmil mm2

kcmil mm2

kcmil mm2

kcmil mm2

kcmil mm2

500 240

750 400 750 400 750 400 750 400

1000 500 1000 500 1000 500 1000 500 1000 500 1000 500

1250 630 1250 630 1250 630 1250 630 1250 630 1250 630

1500 800 1500 800 1500 800 1500 800 1500 800 1500 800

1750 800 1750 800 1750 800 1750 800 1750 800 1750 800

2000 1000 2000 1000 2000 1000 2000 1000 2000 1000 2000 1000

2500 1200 2500 1200 2500 1200 2500 1200 2500 1200 2500 1200

3000 1600 3000 1600 3000 1600 3000 1600 3000 1600 3000 1600

3500 1600 3500 1600 3500 1600 3500 1600 3500 1600 3500 1600

4000 2000 4000 2000 4000 2000 4000 2000 4000 2000 4000 2000

5000 2500 5000 2500

ICEA S-108-720 Tables 2-2 and 2-3 describe soft metric sizes, which are mathematically

correct conversions from Imperial to SI (1.000 kcmil = 0.507 mm2). The metric sizes shown in

the above Table 2.1-1 are hard conversions, complying with the closest standard sizes in IEC

60228 Conductors of insulated cables.

8515! Conductor Characteristics

The conductor characteristics, including dc resistances for the IEC 60228 SI conductor sizes,

shall comply with ICEA S-108-720.

858 C)*,C()R SIE.

85851 2eneral

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The conductor shield shall provide a uniform, continuous, smooth, concentric, thermosetting,

semi-conducting, voltage stress control layer between the outer surface of the conductor and the

inner surface of the insulation. It shall be in direct contact with the conductor and adhere well to

the inner surface of the insulation under all operating conditions.

85858 aterial

The conductor shield material shall be as per ICEA S-108-720 except for XLPE insulations with

ac electrical stress at the conductor shield greater than 200 V/mil (8.0 kV/mm), the conductor

shield shall be formulated using acetylene black. The manufacturer shall verify with the

compound supplier that the sulfur and ash content is less than 0.005 % and 0.01 % respectively.

8585% Extruded Shield (hic"ness

The nominal thickness of the extruded conductor shield shall be as per ICEA S-108-720.

8585! #oids@ Protrusion and Irre$ularit< .i;its

The maximum allowable void, protrusion and irregularity limits for XLPE insulation cables shall

be as per ICEA S-108-720, except as modified in Table 2.2-1 for cables with nominal internal ac

stresses greater than 200 V/mil (8.0 kV/mm).

Voids are assumed to occur at the interface between the extruded conductor shield and the

insulation.

Protrusion and irregularity heights from the conductor shield into the insulation and from the

insulation into the conductor shield are one half the maximum allowable contaminant diameter,

which is less than described in ICEA S-108-720 for insulation internal stresses greater than 250

V/mil (10.0 kV/mm). (Refer to Appendix 1 for a description of the basis for these values.)

Table 2.2-1 Extruded Conductor Shield/Insulation Interface; Void, Protrusion and

Irregularity Limits vs Nominal Internal ac Stress (dimensions rounded to nearest 0.5 mil)

CS9-06 Pa$e 16


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Nominal Internal ac Stress

at Vg

V/mil (kV/mm)

100

(4.0)

125

(5.0)

150

(6.0)

175

(7.0)

200

(8.0)

225

(9.0)

250

(10.0)

275

(11.0)

300

(12.0)

325

(13.0)

350

(14.0)

Maximum Void

Dimension

mils (m)

2.0

(50)

1

2.0

(50)

1

2.0

(50)

1

2.0

(50)

1

2.0

(50)

1

2.0

(50)

2

1.5

(38)

2

1.5

(38)

2

1.5

(38)

2

1.0

(25)

2

1.0

(25)

2

Maximum Protrusion and

Irregularity Height

mils (m)

3.0

(75)1

3.0

(75)1

3.0

(75)1

3.0

(75)1

3.0

(75)1

3.0

(75)1

3.0

(75)1

3.0

(75)2

2.5

(63)2

2.0

(50)2

2.0

(50)2

1reflect current practices and ICEA S-108-720 limits.2less than ICEA S-108-720 limits.

For EPR-insulated cable the void, protrusion and irregularity limits shall be as per Table 2.2-1,

but with nominal internal ac stress no greater than 200 V/mil (8.0 kV/mm).

8585& Ph


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XLPE insulation shall be extruded together with the extruded conductor shield and extruded

insulation shield, in one common triple head extruder. The three layers shall be cross-linked in a

dry curing process.

XLPE insulation material shall be inspected for contaminants using a continuous sampling plan.

The plan must sample a minimum of 2 percent of the insulation material volume. Materialnot

inspected by the compound supplier must be inspected at the 2 percent rate by the cable

manufacturer. The material analysis shall be reported for engineering information and as a

minimum, provide a statistical analysis of the size and number of contaminants found per weight

of insulation inspected.

85%58 Insulation (hic"ness

For wet design cables without a metallic moisture barrier, insulation thickness shall be based

on the traditional values described in ICEA S-108-720, Appendix F.

For dry design cables, the insulation thickness shall be designed based on electrical stress, as

described in ICEA S-108-720 as well as the following, unless proposed otherwise by the

manufacturer or purchaser and supported by tests:

ac stresses at the conductor shield (internal stress) and over the insulation (external stress),

as calculated in 2.3.4, shall not exceed the limits described in Table 2.3-1 at the rated phase-

to-ground operating voltage Vg,

the ac and impulse stresses at the inner starting point of stress relief cones in accessories,

shall not exceed the limits defined by the manufacturer,

consideration of the Generic nominal thicknesses described in Appendix 5, which areintended to satisfy the nominal internal and external stress limit criteria over the standard

conductor size range and provide a degree of standardization.

Table 2.3-1 Rated Voltage, Conductor Size Range, Insulation Eccentricity Limits, Nominal

Internal ac Stress Limits and Nominal External ac Stress Limits

Rated

Voltage

kV

Conductor

Size

kcmil

Conductor

Size

mm2

Maximum

Insulation

Eccentricity

%

Nominal

Internal ac

Stress Limit

V/mil (kV/mm)

Nominal

External ac

Stress Limit

V/mil (kV/mm)69 wet 500-4000 240-2000 12 100 (4.0) 50 (2.0)

69 dry 500-4000 240-2000 12 150 (6.0) 75 (3.0)

115 750-4000 400-2000 12 200 (8.0) 100 (4.0)

138 750-4000 400-2000 12 200 (8.0) 100 (4.0)

161 750-4000 400-2000 10 225 (9.0) 100 (4.0)

230 1000-5000 500-2500 10 275 (11.0) 125 (5.0)

345 1000-5000 500-2500 10 350 (14.0) 150 (6.0)

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Notwithstanding the Table 2.3-1 values, for cables used with taped joints, the nominal internal

and external ac stresses shall be limited to 150 V/mil (6.0 kV/mm) and 75 V/mil (3.0 kV/mm)

respectively.

Insulation eccentricity shall not exceed the values in Table 2.3-1, as described in ICEA S-108-

720.

85%5% Insulation Reuire;ents

The insulation requirements shall comply with ICEA S-108-720 and as described herein.

The void, contaminant and amber limits for XLPE-insulated cables shall be as per Table 2.3-2

(see Appendix 1 for derivation). The applicable limits shall be based on the actual calculated

internal stress for the proposed cable system, which will vary with specific conductor size andinsulation thickness for each rated voltage level.

Table 2.3-2 Void, Contaminant and Amber Limits versus Nominal Internal ac Stress for

XLPE Insulation Cable3(dimensions rounded to nearest 0.5 mil)

Nominal

Internal ac

Stress at Vg

V/mil (kV/mm)

100

(4.0)

125

(5.0)

150

(6.0)

175

(7.0)

200

(8.0)

225

(9.0)

250

(10.0)

275

(11.0)

300

(12.0)

325

(13.0)

350

(14.0)

Maximum Void

Diameter

mils (m)

2.0

(50)1

2.0

(50)1

2.0

(50)1

2.0

(50)1

2.0

(50)1

2.0

(50)2

1.5

(38)2

1.5

(38)2

1.5

(38)2

1.0

(25)2

1.0

(25)2

Maximum

Contaminant

Dimension

mils (m)

5.0

(125)1

5.0

(125)1

5.0

(125)1

5.0

(125)1

5.0

(125)1

5.0

(125)1

5.0

(125)1

5.0

(125)1

5.0

(125)1

4.0

(100)2

4.0

(100)2

Maximum

Amber

Dimension

mils (m)

10.0

(250)1

10.0

(250)1

10.0

(250)1

10.0

(250)1

10.0

(250)1

10.0

(250)1

10.0

(250)1

10.0

(250)1

10.0

(250)1

8.0

(200)2

8.0

(200)2

1reflect current practices and ICEA S-108-720-2004 limits.2less than ICEA S-108-720 limits.3minimum point stresses could be higher. See 2.3.4.

85%5! Calculation of Insulation Electric Stress

CS9-06 Pa$e 19


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For cables with a semi-conducting conductor shield, the nominal ac electric stress at any point

in the insulation shall be calculated using the following formula:

rs

rir

VgGr

ln=

Where:

Gr= nominal ac voltage stress at radius r (kV/mm)

Vg= nominal phase to ground voltage (kV)

ri= nominal radius over the insulation (mm)

rs= nominal radius over the conductor shield (mm)

r= radius of a point of interest in the insulation (mm)

The nominal internal ac stress (Gmax) occurs at the interface between the conductor shield and

the insulation, whenr = r

s.

The nominal external ac stress (Gmin) occurs at the outside of the insulation, whenr = ri.

The average stress =rsri

Vg

For EPR cables with a non-conducting conductor shield, the nominal ac electric stress at any

point in the insulation shall be calculated using the following formula:

( )

+

=

Ki

rp

ri

kp

rc

rp

Kir

Vg

Grlnln

Where:

Gr= nominal ac voltage stress at radius r (kV/mm)

Vg= nominal phase to ground voltage (kV)

rc=nominal radius over the conductor (mm)

ri= nominal radius over the insulation (mm)

rp= nominal radius over the conductor shield (mm)

r= radius of a point of interest in the insulation (mm)

Ki= dielectric constant of the insulation

Kp= dielectric constant of the non-conducting insulation shield

The nominal internal ac stress (Gmax) occurs at the interface between the conductor shield and

the insulation, whenr = rs.

CS9-06 Pa$e 80


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The nominal external ac stress (Gmin) occurs at the outside of the insulation, whenr = ri.

The average stress =rsri

Vg

Similar methods shall be used to determine the nominal impulse stresses, by substituting BIL for

Vg.

Informative Note: Users are reminded that ICEA S-108-720 allows a 5% continuous and

10% fifteen-minute over-voltage above the rated phase-to-ground voltage (Vg). In

addition, ICEA S-108-720 allows a minimum point insulation thickness 10% less than

nominal values. Conductor radii can also vary from nominal values. These effects can

lead to a lower value ofriand possibly higher actual stresses in cable and accessories

compared to those calculated above.

85!5 E+(R,E I*S,.A(I)* SIE.

85!51 2eneral

The extruded insulation shield shall provide a uniform, continuous, smooth, concentric,

thermosetting, semi-conducting, voltage stress control layer over the surface of the insulation. It

shall be in direct contact with and adhere well to the insulation under all operating conditions. It

shall be designed to conduct the insulation charging and leakage current to the overlying

bedding layer and metallic shield or sheath. It shall exhibit long-term chemical stability and

compatibility with adjacent cable components and its allowable operating temperature shall be

at least as high as the insulation.

85!58 aterial

The extruded insulation shield material shall be as per ICEA S-108-720.

85!5% (hic"ness Reuire;ents

The nominal thickness of the extruded insulation shield shall be as per ICEA S-108-720.

85!5! #oids@ Protrusions and Irre$ularit< .i;its

The maximum allowable void, protrusion and irregularity limits shall be as described in ICEA S-

108-720, repeated below.

Maximum void diameter 2.0 mils (50m)

Maximum protrusion height 5.0 mils (125m )

CS9-06 Pa$e 81


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30/88


If required by the purchasers specification, the manufacturer shall state the limitingalue of

s"eat" c/clic strain for 40./ear life () (referenceAppendix 8, Item 12 e)), to verify that cyclic

fatigue testing has been performed for the specific cable construction, and that it is adequate for

the intended application. Additional information is provided in Appendix 2.

85&5& Radial oisture arrier

XLPE-insulated cables shall incorporate a metallic, radial moisture barrier, unless a wet design

cable is specifically requested by the purchaser, and insulation electric stress limits are reduced

in compliance with 1.7 and 2.3.2. Radial moisture barriers can be a continuous metal sheath, as

described above, or a longitudinally applied metal foil layer bonded to the inside of the jacket.

Longitudinally applied metal foil moisture barriers shall meet the requirements of ICEA S-108-

720. When applied, they shall be in addition to an underlying shield, which is required to ensure

a satisfactory concentric conducting path for insulation charging and leakage current, as well as

neutral current, phase unbalance current, fault current, and surge current.

856 BAC7E(

85651 2eneral

The jacket shall comply with ICEA S-108-720 and as described herein.

Supplemental anti-corrosion protection shall be provided for aluminum sheaths, which are not

bonded to the inside of the jacket, by applying a continuous coating of waterproof compound

over the sheath immediately prior to extruding the jacket.

Users shall consider polyethylene jackets for cold-weather installation applications.

Jackets for wet design XLPE cables shall be polyethylene.

85658 Bac"et (hic"ness

The jacket thickness shall comply with ICEA S-108-720, or as modified in the purchasers

specification for the intended application (reference Appendix 6 Jacket Thickness

Considerations).

8565% Se;i-conductin$ Coatin$

Unless specifically excluded by the purchaser, a continuous graphite coating or extruded semi-

conducting layer shall be applied over the jacket to form an electrode for Production Tests, dc

testing during installation, and for periodic maintenance testing after commissioning.

85= PR),C(I)* (ES(S )* CA.E

CS9-06 Pa$e 8%


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85=51 2eneral

The production tests shall comply with ICEA S-108-720, except as described herein.

85=58 Su;;ar< of ICEA S-10>-=80 Production (ests and 'reuenc1.5 Vgand duration < 10 hours.

3. There shall be no detectable discharge within the cable with a measurement sensitivity of 5 pC or

less.

4.Assumes cables are used on an effectively grounded system.

Table 2.7-2 Summary of ICEA S-108-720 and Supplementary Production Tests and

Frequency (* identifies variations from ICEA S-0108-720)

TestTest Method

ReferenceTest Frequency

Conductor

dc Resistance 9.3.1 1 test per each shipping length*

CS9-06 Pa$e 8!


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ICEA T-27-581

Diameter ICEA T-27-581 1 sample from each end of each shipping

length*

Temper ASTM Manufacturer certification that values are met

Non-Metallic Conductor Shield

Elongation After Aging 9.4.14 Each lot of material used for extrusion onto

the cable

Volume Resistivity 9.8.1 Each lot of material used for extrusion onto

the cable

Note: This test is performed (in combination

with insulation shield volume resistivity) on a

sample of cable

Thickness 9.4.2 1 sample from each end of each shipping

length*

Voids, Protrusions & Irregularities 9.4.13 1 sample from each end of each shipping

length*

Wafer Boil 9.4.13 3 samples from each extruder run; near twoends & middle

Spark Test (non-conducting layer) ICEA T-27-581 100%

Insulation

Unaged & Aged Tensile & Elongation 9.4.8

9.4.9

1 test per 50,000 ft (15 km) or at least 1 per

extruder run

Hot Creep 9.4.10 and ICEA

T-28-562

3 samples from each extruder run; near two

ends & middle

Voids & Contaminants 9.4.13 1 sample from each end of each shipping

length*

Samples shall be prepared using a lathe, or

Owner-approved equivalent, to minimize

contamination of the surface of the samples

Diameter 9.6 1 sample from each end of each shipping

length*

Shrinkback (XLPE only) 9.9 For rated voltages 150 kV, 1 sample from

each 50,000 ft (15 km) or at least 1 per

extrusion run

For rated voltages > 150 kV, 1 sample from

each end of each extrusion run

Thickness & Eccentricity 9.4.2 1 sample from each end of each shipping

length*Non-Metallic Insulation Shield

Elongation After Aging 9.4.14.3 Each lot used for extrusion onto the cable

Volume Resistivity 9.8.2 Each lot used for extrusion onto the cable

Note: This test is performed (in combination

with insulation shield volume resistivity) on a

sample of cable

CS9-06 Pa$e 8&


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length*

Voids & Protrusions 9.4.13 1 sample from each end of each shipping

length*

Wafer Boil 9.4.12 3 samples from each extrusionr run; near two

ends & middle

Diameter 9.6 1 sample from each end of each shippinglength*

Metallic Shields

Dimensional Measurements 9.5 1 sample from each end of each shipping

length*

Jackets

Unaged & Aged Tensile & Elongation 9.4.8

9.4.9

1 test per 50,000 ft (15 km) or at least 1 per

jacket extruder run


length*

Other Tests Applicable to JacketHeat Distortion 9.7.2

ICEA T-27-581

Each lot used for extrusion onto the cable

Heat Shock 9.7.1 Each lot used for extrusion onto the cable

Cold bend ICEA T-27-581 0 samples for -=80 Production (ests

Other additions and modifications to ICEA S-108-720 Production Tests shall be as follows:

2.7.3.1 Method for dc Resistance Determination (ICEA S-108-720 clause 9.3.1, ICEA T-27-581

clause 2.1)

CS9-06 Pa$e 86


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Clause 9.3.1 shall also include the following requirements:

The complete shipping length reel shall be placed in the test room, which shall be kept at a

reasonably constant temperature for at least 24 hours before the test. The temperature of the

cable (measured by placing a thermocouple one layer below the outer wrap) at the time of the

test shall be within 3 C compared with the testing room temperature.

The manufacturer shall report the following:

length of cable on the reel at the time of conductor dc resistance measurement

measured temperature of the cable and the test room, as well as the method of

measurement

measured conductor dc resistance, for each reel of cable

conductor dc resistance corrected to 25 C

2.7.3.2 Clarification and Extension of Shrinkback Test (ICEA S-108-720 clauses 9.9 and 9.15;

Table 4-8)

The clause 9.9 Shrinkback Test Procedure shall be modified to include a high temperature

heating-cooling cycle, to determine dimensional stability. The test shall be done following any of

the first three heating-cooling cycles which meets the acceptance limits of ICEA S-108-720

Table 4-8.

The additional heating-cooling cycle shall be to 105 C +/- 2 C for a period of 20 hours and then

cooled to room temperature.

The protrusion acceptance limit, at either end, shall be 175 mils (4.37 mm) for conductor shields

extruded directly over the conductor and 240 mils (6.00 mm) for conductor shields extruded over

semi-conducting tape shields.

2.7.3.3 Amber, Agglomerate, gel, Contaminant, Protrusion, Irrregularity and Void Tests (ICEA S-

108-720 clauses 9.4.13 and 9.15)

If either of the two samples from any shipping length fails, the shipping length shall be rejected.

2.7.3.4 Longitudinal Water Penetration

A longitudinal water penetration test shall be performed for sealed conductor cables, according

to the procedures in ICEA T-31-610. Tests shall be done on a sample of completed cable.

CS9-06 Pa$e 8=


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2.7.3.5 Segmented Conductor Eccentricity

The eccentricity of cabled segmental conductors shall be determined from measurement of both

maximum callipered and circumference tape diameters taken at five locations spaced

approximately 1 foot (30 cm) apart along the conductor. The average of five maximum

callipered diameters shall not exceed the average of the five circumference tape diameters by

more than two percent (2%). At any one location, the maximum callipered diameter shall not

exceed the circumference tape diameter by more than three percent (3%).

85=5! Conditions Appl ,A.I'ICA(I)* (ES(S )* CA.E

The qualification tests shall comply with ICEA S-108-720 and as otherwise described herein.

859 CA.E IE*(I'ICA(I)*

CS9-06 Pa$e 8>


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The cable identification shall comply with ICEA S-108-720 and as described herein.

The outer surface of each cable shall be durably marked throughout its length with the

manufacturers name, type of insulation, insulation thickness, conductor material and size,

sequential length indication, rated voltage and year of manufacture. Additional information may

be required by government and regulatory authorities.

85951 Se;i-conductin$ .a


37/88


manufacturer for a period of not less than five years from shipping date, unless a longer period

is requested by the purchaser at the time of inquiry.

%50 (ERI*A(I)*S

%51 2E*ERA.

The cable system manufacturer shall provide terminations in accordance with the purchasers

custom project specification, suitable for terminating the cable described herein.

Terminations for use in air shall comply with IEEE 48. Terminations in gas insulated switchgear

(GIS) shall comply with IEC 60859, IEC 60840 and IEC 62067. Consideration shall also be

given to GIS grounding designs, as described in Electra No. 151 article Earthing of GIS An

application guide.

If required by the purchasers specification, the cable system manufacturer shall provide a copy

of representative qualification test reports for the proposed terminations with the proposal, or

include such testing with the proposal.

Each termination shall be packaged as a self-sufficient kit. It shall contain packing lists,

instructions and all permanent and consumable materials, as required for installation by

qualified Journeymen Cablemen, under the Supervision of a manufacturers representative.

Aerial connector lugs shall be provided for each air termination. The connectors shall have

NEMA four hole spacing and be capable of carrying the emergency operating current for 40 C

ambient air temperature, with sun and no wind.

%58 (ERI*A(I)* ),*(I*2 I*S,.A(I)*

Termination mounting assemblies shall be provided with electrical insulating systems to allow

temporary isolation of the shield/sheath circuit from ground for periodic maintenance testing of

the jacket with a dc test voltage. They shall also allow permanent isolation of the shield/sheath

circuit from ground, to implement special bonding systems, such as single point bonding, as

described in Electra No. 128 article Guide to the protection of specially bonded cable systems

to sheath over-voltages. The termination isolation systems shall withstand the same electrical

requirements as the external anti-corrosion serving for joint casings (see Table 4.2-1 Each partto Ground, below).

%5% PR),C(I)* (ES(S )* (ERI*A(I)*S

Production tests shall be done in accordance with the requirements of IEEE 48 or IEC 60859 for

installation in GIS, as applicable. In addition, the following tests shall be done on each of the

termination pre-molded or prefabricated stress relief cones and the housing:

CS9-06 Pa$e %0


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1.Partial Discharge Measurements The test shall be carried out in accordance with

ICEA T-24-380 or IEC 60885-2. The sensitivity of the partial discharge (PD)

measurements shall be 5 pC or better. The stress cone shall be installed on a length

of XLPE cable or a simulated accessory test mandrel, subject to agreement between

purchaser and manufacturer. The test voltage shall be raised gradually to and held

at 1.75 x Vgfor 10 seconds, and then slowly reduced to 1.5 x Vg. The magnitude of

the PD at 1.5 x Vgshall not exceed 5 pC.

2.Dimensional Checks The dimensions of the stress cone shall be measured and

checked against the tolerances established by the manufacturer. Checks shall

commence no earlier than the start of cable production.

3.Visual Inspection The bore of each stress cone shall be inspected with a fiber

scope or other suitable instrument to determine that there are no irregularities on the

surface of the bore. Each termination housing shall be visually inspected for the

presence of any defects prior to shipping.

%5! ,A.I'ICA(I)* (ES(S )* (ERI*A(I)*S

Qualification tests shall be done in accordance with IEEE 48 and IEC 60859 for installation in

GIS, as applicable, and as described herein.

Informative Note: Users are reminded that the IEEE 48 heating cycle voltage tests are

more severe than for IEC 60840 and 62067.

Terminations shall meet the qualification test requirements of IEEE 693 Recommended Practice

for Seismic Design of Substations, for Moderate Site, unless specifically excluded or moreonerous requirements are identified by the purchaser. IEEE 693 requires qualification by time-

history shaker table tests for voltage classifications 242 kV and static pull tests or time-history

shaker table tests for voltage classifications < 242 kV. The tests are done prior to the IEEE 48

qualification tests.

Static pull tests consist of pulling perpendicular to the top of the termination with a load twice the

operating weight of the termination. The load shall be applied for a minimum of 2 s. There shall

be no damage or cracks in any part, including the insulating housing, and no fluid leakage

before and after the static pull test.

Shaker table tests are described in IEEE 693.

%5!51 ualification (est for (er;ination ountin$ Insulators

CS9-06 Pa$e %1


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With the termination support structure connected to ground, 25 kVdc shall be maintained for one

minute across the termination mounting insulation, using the termination base plate for the

positive high voltage connection.

Having successfully withstood the application of dc voltage, the test assembly shall be submitted

to an impulse test. With the termination support structure grounded, ten positive, followed by

ten negative impulses shall be applied across the termination mounting insulation, using the

base plate for the high voltage connection. The magnitude of the impulses shall be in

accordance with Table 4.2-1 Each part to Ground.

Termination mounting insulators shall meet the requirements of IEEE 693, by being incorporated

into the termination assembly for the static pull tests or the time-history shaker table tests

described in 3.4.1.

!50 B)I*(S

!51 2E*ERA.

The manufacturer shall provide joints in accordance with the purchasers custom project

specification, suitable for jointing the cable supplied to the purchaser.

Joints shall comply with IEEE 404 and as described herein.

If required by the purchasers specification, manufacturers shall provide a copy of representative

qualification test reports for the proposed joints, with the proposal, or include such testing with

the proposal.

Each joint shall be packaged as a self-sufficient kit. It shall contain packing lists, instructions

and all permanent and consumable materials, as required for installation by qualified

Journeymen Cablemen, under the supervision of a manufacturers representative.

!58 SEA( SEC(I)*A.IDI*2 I*S,.A()RS A* B)I*( CASI*2 I*S,.A(I)*

Unless specifically excluded by the purchaser, joints shall be provided with a sheath

sectionalizing insulator with internal shield interrupt. The insulation of the two shall be

coordinated so that sectionalizing insulator voltage withstand is less than the internal shieldinterrupt. Both shall withstand the ac and transient over-voltages imposed on them during all

operating conditions, as described in the purchasers specification.

Joints supplied for use with dry insulation cables with a metallic moisture barrier, shall be

provided with a metallic casing enclosure to facilitate a continuous hermetic seal between the

two ends of the cable sheath.

CS9-06 Pa$e %8


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Joint casings shall be provided with an external anti-corrosion serving (jacket), to isolate the

metallic shield/sheath circuit from ground. It shall withstand the ac and transient over-voltages

induced onto it during all normal and abnormal operating conditions.

The sheath sectionalizing insulator and joint casing anti-corrosion covering designs shall ensure

long term ability to meet the above requirements and impulse withstand levels for 33 feet (10 m)

bonding leads, as described in Table 4.2-1 below. The table is derived from IEC 60840, IEC

62067 and the Electra No. 128 article Guide to the protection of specially bonded cable systems

to sheath over-voltages. It is also compatible with IEC 60229.

Table 4.2-1: Metallic Shield/Sheath Insulating Covering Impulse Withstand Voltage versus

BIL

Rated BIL for Main Insulation

kV

Impulse Test Level (1.2 x 50 sec)

Between Parts Each Part to Ground

Bonding

Cable Length

10

( 3m)

kV

Bonding

Cable Length

10 30

(3m 10m)

kV

Bonding

Cable Length

10

( 3m)

kV

Bonding

Cable Length

10 30

(3m 10m)

kV

250 to 325 60 60 30 30

550 to 750 60 75 30 37.5

1050 60 95 30 47.5

1175 to 1425 75 125 37.5 62.5

Notwithstanding the conservative assumption for testing based on 33 foot (10 m) bonding cable

length, connections shall be as short as possible to minimize surge voltage drop, especially

when exposed to high frequency transient over-voltages near GIS disconnects and breakers, or

near outdoor cable terminals exposed to lightning strikes.

The sheath sectionalizing insulators in joints shall withstand the Table 4.2-1 values Between

Parts. All other components, except link box insulation, shall withstand half these values.

The designs shall consider lifetime degradation due to repeated field voltage application,

moisture degradation, thermal degradation and a factor of safety.

Informative Note: The recommended approach is to design the insulating coverings for metallic

shield/sheath circuit components to withstand at least the Table 4.2-1 values throughout their

design life, but to also provide additional protection against transient over-voltages by applying

sheath voltage limiters (SVLs) with lower protective levels. (Reference Appendix 3)

!5% PR),C(I)* (ES(S )* B)I*(S

CS9-06 Pa$e %%


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Production tests shall be done in accordance with the requirements of IEEE 404. In addition,

the following tests shall be done on each of the joint pre-molded or prefabricated stress relief

cones:

1.Partial Discharge Measurements The test shall be carried out in accordance with

ICEA T-24-380 or IEC 60885-2. The sensitivity of the partial discharge (PD)

measurements shall be 5 pC or better. The stress cone shall be installed on a length

of XLPE cable or a simulated accessory test mandrel, subject to agreement between

purchaser and manufacturer. The test voltage shall be raised gradually to and held

at 1.75 x Vgfor 10 seconds, and then slowly reduced to 1.5 x Vg. The magnitude of

the PD at 1.5 x Vgshall not exceed 5 pC.

2.Dimensional Checks The dimensions of the stress cones shall be measured and

checked against the tolerances established by the manufacturer. Checks shall

commence no earlier than the start of cable production.

3.Visual Inspection The bore of each stress cone shall be inspected with a fiber

scope or other suitable instrument to determine that there are no irregularities on thesurface of the bore.

!5! ,A.I'ICA(I)* (ES(S )* B)I*(S

Qualification tests shall meet the requirements of IEEE 404 and as described herein. Users are

reminded that the IEEE 404 heating cycle voltage tests are more severe than for IEC 60840 and

62067.

IEC 60840 and 62067 impulse voltage tests for joints embodying sheath sectionalizing

insulation and insulating coverings are more severe than IEEE 404-2000 for main insulation BILgreater than 1050 kV. Therefore, for cables with main insulation BIL greater than 1050 kV, the

external insulation of sheath sectionalizing joints shall meet the test requirements described in

Table 4.2-1. The joint casing insulation shall also be proven to withstand at least 25 kVdc for

one minute, applied between the joint casing and the external electrode of the submerged joint.

&50 SEA( )*I*242R),*I*2 SS(ES

&51 2E*ERA.

Sheath Bonding/Grounding systems shall provide the sheath circuit interconnection andinsulation protection systems described in Electra No. 128 article Guide to the protection of

specially bonded cable systems to sheath over-voltages. The systems shall consist of bonding

cables, link boxes and sheath voltage surge arresters, as required for an insulated sheath

power cable system, as defined in the Electra No. 128 article.

CS9-06 Pa$e %!


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Over-voltage protection shall be used for GIS terminations to limit transient over-voltages

between the cable sheath and the GIS enclosure, as described in IEC 60859 and Electra No.

151 Article: Earthing of GIS An Application Guide.

If specified by the purchaser, the manufacturer shall provide drawings of the sheath

bonding/grounding system and calculations of expected sheath voltages and currents, done in

accordance with the Electra No. 128 article (reference Appendix 10 Information to be Submitted

After Award of Contract).

Ratings described below assume use on an effectively grounded system.

&5151 ondin$ Cables

Single conductor bonding cables shall meet the requirements of ICEA S-105-692, except that

the minimum average insulation thickness shall be 130 mils (3.3 mm).

Bonding cable connections to link boxes shall be as short as possible, but no greater than 33

feet (10 m) in total length to a ground point. They shall be single conductor construction,

provided the frequency of transient over-voltages is less than 25 kHz and the bonding cables

from adjacent phase connections are touching each other. For transient frequencies greater

than 25 kHz, the manufacturer shall provide concentric bonding cables, as agreed to with the

purchaser. Concentric bonding cables shall meet the requirements of ICEA S-94-649 except

that:

the minimum average central insulation thickness shall be 180 mils (4.6 mm)

the minimum average external insulation (jacket) thickness shall be 130 mils (3.3 mm) conductor and insulation shields shall be eliminated

the central concentric and conductors shall be identical in area and material (full neutral)

All conductors shall be designed to withstand the rated fault current and duration, as well as the

sheath currents corresponding to emergency loading. The insulation shall withstand the same

impulses as the main cable jacket and joint casing insulation, as described in Table 4.2-1.

Bonding cables used as a parallel earth continuity conductor (reference Electra No 128 article,

Fig. 4) shall be identical to those described in the foregoing, except that their conductors only

need to be designed to withstand the rated fault current and duration.

&5158 .in" oxes

Link boxes shall be designed for central water-tight interconnection of sheath cross-bonding,

single point bonding and grounding systems.

CS9-06 Pa$e %&


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Link boxes shall incorporate removable links, to easily isolate sections of sheath circuit for

maintenance dc testing of cable jackets, joint sectionalizing insulators, termination mounting

insulators, etc. The links shall also be designed to easily re-configure the bonding connection

system to solidly bonded.

At cross-bonding locations, or single point bonding open point locations, link boxes shall also

incorporate sheath voltage limiters (SVLs) to protect the sheath circuits insulation from transient

over-voltages.

Link box conducting components shall be designed to withstand the rated fault current and

duration.

The insulation between the links in all link boxes, including those without SVLs, shall be capable

of withstanding the following voltages, with an additional 25% margin to allow for variability in

service:

i) The dc voltage used for qualification tests (25 kV + 25% for one minute), initial

commissioning tests (24 kV maximum +25% for one minute) and maintenance testing of

the sheath insulation circuit (5 kV dc maximum for 1 minute)

ii) The highest power frequency voltage arising between sheaths during an external system

fault + 25%

iii) A 1.2/50 microsecond impulse voltage with a maximum value equal to the protective

level as defined in the referenced Electra No. 128 article, paragraphs 5.1.4 and 5.2.3, +

25%, noting that if the SVLs are connected in star, the protective level must be doubled

to allow for the fact that two SVLs are connected in series between each pair of sheaths.

Water-tightness of the link box enclosures shall meet the requirements of IEC 60529, with the

specific IP Code classification as agreed to between the manufacturer and purchaser,

depending on location of the installation (in manholes periodically submerged, in dry manholes

or tunnels, above ground outdoors, above ground indoors, etc.). Alternatively, they shall meet

the requirements of NEMA 250, based on agreement between the purchaser and manufacturer.

(Users are reminded that NEMA 250 Appendix A contains an equivalency conversion from

NEMA to IEC classifications.)

&515% Sheath #olta$e .i;iters

Sheath voltage limiters (SVLs) shall meet the requirements of IEEE C62.11 Standard for Metal-

Oxide Surge Arresters for AC Power Circuits (> 1 kV).

The metal oxide component of the SVLs shall be encased in a waterproof material to prevent

absorption of moisture.

CS9-06 Pa$e %6


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The SVLs shall be capable of withstanding continuously the sheath standing voltage applied to

them during full load or emergency overload.

The SVLs shall be capable of withstanding the highest power frequency voltage applied to them

during system faults, for the maximum fault current duration specified by the purchaser.

The residual voltage protective level of each SVL shall be less than the impulse withstand levels

of the sheath insulating circuit, taking into account surge voltage drop in bonding cable leads

and SVL connection methods.

&58 PR),C(I)* (ES(S )* SEA( )*I*242R),*I*2 SS(ES

Production tests on single conductor bonding cables shall meet the requirements of ICEA S-

105-692.

Production tests on SVLs shall meet the requirements of IEEE C62.11.

Production tests on link box water-tightness shall meet the requirements of IEC 60529 or NEMA

250. They shall also demonstrate the ability to withstand a dc test voltage of 25 kV +25% for

one minute, between the conducting components and ground.

&5% ,A.I'ICA(I)* (ES(S )* SEA( )*I*242R),*I*2 SS(ES

Qualification tests on single conductor bonding cables shall meet the requirements of ICEA S-

105-692 and as described herein. They shall also demonstrate the ability to withstand the

impulse test voltages described in Table 4.2-1.

Qualification tests on SVLs shall meet the requirements of IEEE C62.11.

Qualification tests on link box water-tightness shall meet the requirements of IEC 60529 or

NEMA 250.

In addition, link boxes shall withstand a water immersion test followed by an impulse voltage test

carried out on one assembly, as described in the Electra No. 75 article: Recommendations for

tests on anti-corrosion coverings of self contained pressure cables and accessories and

equipment for specially bonded circuits. The test voltages shall be in accordance with section5.1.2 above.

650 ,A.I'ICA(I)* (ES(S )* C)P.E(E CA.E SS(E

For rated voltages >46 kV to 150 kV, if required by the purchasers specification, the

manufacturer shall demonstrate satisfactory performance of a complete system comprised of

cable and at least one of each type of accessory to be provided. Demonstration shall consist of

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meeting the requirements of IEC 62067 Section 12. Type tests on cable systems, with the

Voltage Test done at 2.5 x Uo (Vg) for 30 minutes (as described in IEC 60840).

For rated voltages > 150 kV to 345 kV, the manufacturer shall demonstrate satisfactory

performance of a complete system comprised of cable and at least one of each type of

accessory to be provided. Demonstration shall consist of meeting the requirements of IEC

62067 Section 12. Type tests on cable systems.

651 RA*2E )' APPR)#A.

IEC 62067 Section 12.2 describes the Range of type approval and the validity of type, or

qualification, tests done on other similar cables and accessories, with respect to the purchasers

intended application. The same provisions shall apply equally to this specification,except for the

specific additions shown in brackets and underlined below.

When the type tests have been successfully performed on one cable system of specific cross-section, rated voltage and construction, the type approval shall be accepted as valid for cable

systems within the scope of this standard with other cross-sections, rated voltages and

constructions if the following conditions are met:

a)the voltage group is not higher than that of the tested cable system;

NOTE In this context, cable systems of the same rated voltage group are those of rated voltages

having a common value of Um[Vm], highest voltage for equipment, and the same test voltage values.

b)the conductor cross-section is not larger than that of the tested cable;

c)the cable and the accessories have the same or a similar construction as that of the tested

cable system;NOTE Cable and accessories of similar construction are those of the same type and manufacturing

process of insulation and semi-conducting screens. Repetition of the electrical type tests is not

necessary on account of the differences in the conductor type or material or of the protective layers

applied over the screened cores or over the main insulation part of the accessory, unless these are

likely to have a significant effect on the results of the test. In some instances, it may be appropriate to

repeat one or more of the type tests (e.g. bending test, heating cycle test and/or compatibility test).

d)calculated maximum electrical stresses on the conductor and insulation screens, in the main

insulation part(s) of the accessory and in boundaries [or interfaces] are equal to or lower

than for the tested accessory.

NOTE If the voltage group is the same, if the cable conductor cross-section is smaller and if the

insulation thickness is not less than that of the tested cable, calculated maximum stress on the

conductor may be 10% higher than that of the tested cable.

e) [material compositions, manufacturing processes, manufacturing plants, and equipment

used for making the cable and accessories subjected to the tests, have not significantly

changed].

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The type tests on cable components (see IEC 62067 clause 12.5) need not be carried out on

samples from cables of different voltage ratings and/or conductor cross-sectional areas unless

different materials are used to produce them. However, repetition of the aging tests on pieces of

complete cable to check compatibility of materials (see IEC 62067 clause 12.5.4), may be

required if the combination of materials applied over the screened core is different from that of

the cable on which the type tests have been previously carried out.

A type test certificate signed by the representative of a competent witnessing body, or a

[notarized] report by the manufacturer giving the test results and signed by the appropriate

qualified officer, or a test certificate issued by an independent test laboratory, shall be

acceptable as evidence of type testing.

=50 PRE-,A.I'ICA(I)* (ES(S )* C)P.E(E CA.E SS(E

For applications with a rated voltage greater than 150 kV, the manufacturer shall demonstrate

satisfactory, long-term performance of a complete system, comprised of cable and at least oneof each type of accessory to be provided. Demonstration shall consist of meeting the 365 day

test requirements of IEC 62067 Section 13. Pre-qualification test of the cable system, with

modifications to demonstrate performance at emergency conductor temperatures, as described

in section 1.9 preceding. Alternative long term tests may be accepted, as agreed to between the

purchaser and manufacturer, and provided they are applicable to the specific installation

conditions.

The above tests shall also be done for applications with a rated voltage above 46 kV to 150 kV,

with stresses greater than 200 V/mil (8.0 kV/mm) at the cable conductor shield, or greater than

100 V/mil (4.0 kV/mm) over the cable insulation, subject to agreement between the purchaserand the manufacturer.

=51 RA*2E )' APPR)#A.

IEC 62067 Section 13.1 describes the Range of pre-qualification test approval and the validity

of tests done on other similar cables and accessories, with respect to the purchasers intended

application. The same provisions shall apply equally to this specification,except for the specific

additions shown in brackets and underlined below.

When a pre-qualification test has been successfully performed on a cable system, it qualifies themanufacturer as a supplier of [similarly constructed] cable systems with the same or lower

voltage ratings, as long as the calculated electrical stresses at the insulation screen are equal to

or lower than for the system tested [and material compositions, manufacturing processes,

manufacturing plants, and equipment used for the cable system subjected to the tests, have not

significantly changed].

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A pre-qualification test certificate signed by the representative of a competent [independent]

witnessing body, or a [notarized] report by the manufacturer giving the test results and signed by

the appropriate qualified officer, or a test certificate issued by an independent test laboratory

shall be acceptable as evidence of pre-qualification testing.

>50 E.EC(RICA. (ES(S A'(ER I*S(A..A(I)*

Installation of cable systems is not included in this specification and therefore Electrical Tests

After Installation do not form a direct part of it. However, testing of the completed cable system

after installation shall be subject to mutual agreement between the purchaser and manufacturer

prior to testing. For information purposes, general recommendations are described in Appendix

7 and in ICEA S-108-720.

950 ,A.I( ASS,RA*CE

951 ,A.I( SS(E RE,IREE*(S

The manufacturer shall have a current quality assurance program and manual in place, for each

factory engaged in the work. It shall conform to ISO 9001 or equivalent, as acceptable to the

purchaser and registered by an accredited agency.

If required by the purchasers specification, the manufacturer shall submit a copy of their quality

assurance plans with their proposal (reference Appendix 9 Manufacturers Technical Declaration

File).

958 A*,'AC(,RI*2 I*SPEC(I)* A* (ES( P.A*

If required by the purchasers specification, within two weeks after a contract is awarded, the

manufacturer shall submit to the purchaser for acceptance, a final Inspection and Test Plan,

conforming to the requirements of ISO 9001 or equivalent (reference Appendix 10 Information to

be Submitted after Award of Contract). The Inspection and Test Plan shall be detailed and shall

include at least the following categories: Material or Parameter to be controlled; Method of

Inspection/Tests and Equipment Used; Frequency of the Inspection/Test; Reference Documents

Governing the QA Activity; QA Record Form; agreed Review/Witness/Hold points, etc.

The Inspection and Test Plan shall contain details of quality assurance activities to be performedfor all materials, manufacturing and handling processes. Inspection and test review/witness/hold

points shall be jointly established between the manufacturer and purchaser. If sub-contractors

are employed, the Inspection and Test Plan shall indicate the portion of the work that will be

undertaken by them, including their inspection and testing.

95% 'AC()R I*SPEC(I)*

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The manufacturer shall carry out such inspections and tests, in accordance with the accepted

Inspection and Test Plan to verify the conformity of each part of the work in accordance with

this specification. At least 7 working days written notice, prior to each established witness/hold

point, shall be given to the purchaser to allow for arrangements to be made for his attendance.

95! I*SPEC(I)* A* A,I( (E P,RCASER

Any quality assurance inspection carried out by the purchaser shall in no way relieve the

manufacturer of full responsibility for the quality, character or performance of the completed

work.

95& ACCESS () ,A.I( ASS,RA*CE A* (ES( )C,E*(S

When requested, the manufacturer shall provide timely access to, and copies of, the following

documents: shop travelers, detailed shop inspection procedures, certifications, qualifications,

inspection and test results, production records, process control charts, calibration certification

records and other quality assurance documents, compiled during the work.

956 *)*-C)*')RA*CE REP)R(S

The manufacturer shall provide non-conformance reports (NCRs) to the purchaser, for review

and acceptance, in accordance with ISO 9001 paragraph 4.13, or equivalent, for all major

factory non-conformances to this specification. The requirement for NCRs includes work by

sub-contractors. All NCRs shall include the manufacturers proposed disposition and/or

corrective action. The manufacturer shall establish criteria for submission of NCRs to the

purchaser, including the definition of major and minor non-conformances, with submission of the

Inspection and Test Plan. Unless otherwise agreed to between purchaser and manufacturer,

NCRs shall be submitted within 24 hours of the manufacturers discovery of the non-

conformance.

The above requirement is limited to only products which the manufacturer plans to supply to the

purchaser.

95= 'I*A. ,A.I( ASS,RA*CE REP)R(

If specified by the purchaser, the manufacturer shall submit three certified copies of the finalquality assurance reports, to the purchaser, certifying the compliance of the work to this

specification, including all assembly and test data required in the Inspection and Test Plan,

within one week of completion of final inspection and testing. The final quality assurance report

shall be a bound collection of relevant quality assurance documents as listed below, compiled

during the manufacture of the work.

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Unless limited by the purchasers specification, the final quality assurance report shall include at

least:

Sub-contractor inspection reports

Receiving inspection reports

Mill test certificates

Cable insulation quality reports

Material qualification reports

Component dimensional inspection data reports

Instrument and Gauge calibration certificates and records

Component test reports

Accepted non-conformance reports

Certified Test Reports in accordance with the specification

1050 SIPPI*2

1051 CA.E REE.S

105151 Cable Reel Pac"in$@ Sealin$@ and Shippin$

The cables shall be placed on reels so that they are protected from damage during shipment.

Each end of the cable shall be firmly and properly secured to the reel. Care shall be taken to

ensure that the cable is tightly wrapped to prevent movement during transportation.

There shall be no water in the completed cable when the reel is shipped.

Each length of cable listed on the purchaser's order or detail list shall be shipped on a separate

reel unless specifically agreed to between the purchaser and manufacturer.

The reels shall be lagged or covered with suitable material to provide physical protection for the

cables during transit and during ordinary storage and handling operations.

105158 Reel i;ensions

The minimum drum diameters for shipping reels shall be determined by the manufacturer. Reel

construction and dimensions shall comply with NEMA WC 26.

If the cable has a metallic sheath, the minimum drum diameter of the reels shall be in

accordance with the following Table 10.1-1, or as otherwise agreed to between the purchaser

and manufacturer.

Table 10.1-1 Minimum Drum Diameter for Various Metallic Sheath Types

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Sheath TypeInsulation Thickness

mils (mm)

Ratio of Outside Diameter of Reel

Drum to Cable Outside Diameter

Lead < 500 (12.7) 14

Lead 500 to 800 (12.7 to 20.3) 18

Lead > 800 (20.3) 22

Aluminum (smooth

tubular)30

Aluminum (smooth

tubular, bonded to

jacket)

18

Corrugated Metallic

(copper or aluminum)< 800 mils (20.3 mm) 18

Corrugated Metallic

(copper or aluminum)

> 800 mils (20.3 mm) 22

The inner or drum end of the cable, when allowed to project through the flange of the reel, shall

be protected to avoid damage to the cable or seal.

10515% ar"in$ on Reels

Each reel shall be marked with a durable label securely attached to the outside of a flange. The

label shall plainly state all the identification information described in section 2.9, as well as the

following:

manufacturers name and address

purchaser's order and contract number

destination

shipping length of cable on reel

reel identification number

conductor size

type of cable

thickness and type of insulation

voltage rating

gross, tare and net weight

Each reel shall be marked with an arrow on the flange indicating the direction the reel is to be

turned to unwind the cable.

Each reel shall be identified with a number permanently attached to the outside of a reel flange.

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Shipping reels shall be free of any information not pertaining to the order.

10515! Cable End 'ittin$s

Cables with a metallic moisture barrier shall have their ends hermetically sealed from moisture

entry with durable and effective metallic end caps. Special consideration shall be given to

effectively sealing cables with longitudinally applied metal foil moisture barriers.

A pulling eye, approved by the purchaser, shall be attached at the outside end of each shipping

length. The pulling eye shall be suitable for pulling the cable through wet or dry ducts or pipes,

tr