ICEA S-94-649-2000

ICEA S-94-649-2000

STANDARD FOR

CONCENTRIC NEUTRAL CABLES RATED 5,000 - 46,000 VOLTS

Publication # ICEA S-94-649-2000

@ 2001 by INSULATED CABLE ENGINEERS ASSOCIATION, INC.

COPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling ServicesCOPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling Services

ICEA S-94-649-2000

STANDARD FOR

CONCENTRIC NEUTRAL CABLES RATED 5,000 - 46,000VOLTS

Standard # ICEA S-94-649-2OOO

Published 8y INSULATED CABLE ENGINEERS ASSOCIATION, Inc.

Post Office Box 440 South Yarmouth, Massachusetts 02664, U.S.A.

@ January 2001

Approved September 6, 2000 by INSULATED CABLE ENGINEERS ASSOCIATION, Inc. Approved July 3, 2000 by AEIC Approved


0 2001 by

INSULATED CABLE ENGINEERS ASSOCIATION, INC.

Contents may not be reproduced in any form without permission of the Insulated Cable Engineers Association, Inc.

All rights including translation into other languages, reserved under the Universal Copyright Convention,

the Berne Convention for the Protection of Literary and Artistic Works, and the International and Pan American Copyright Conventions.

INSULATED CABLE ENGiNEERS ASSOCIATION, Inc. P.O. Box 440

South Yarmouth. Massachusetts 02664 USA


ICEA S-94-649-2000 DATE: O7124100

FOREWORD

This Standards Publication for Concentric Neutral Cables Rated 5 to 46 kV (ICEA S-94-649) was developed by the Insulated Cable Engineers Association Inc. (ICEA).

ICEA standards are adopted in the public interest and are designed to eliminate misunderstandings between the manufacturer and the user and to assist the user in selecting and obtaining the proper product for his particular need. Existence of an ICEA standard does not in any respect preclude the manufacture or use of products not conforming to the standard. The user of this Standards Publication is cautioned to observe any health or safety regulations and rules relative to the manufacture and use of cable made in conformity with this Standard.

Requests for interpretation of this Standard must be submitted in writing to the Insulated Cable Engineering Association, Inc., P. O. Box 440, South Yarmouth, Massachusetts 02664. An official written

.interpretation will be provided. Suggestions for improvements gained in the use of this Standard will be welcomed by the Association.

The ICEA expresses thanks to the Association of Edison Illuminating Companies for providing the basis for some of the material included herein through their participation in the Utility Power Cable Standards Technical Advisory Committee (UPCSTAC), and to the Institute of Electrical and Eiectronics Engineers, Insulated Conductors Committee, Discussion Group A-14 for providing user input to this Standard.

The members of the ICEA working group contributing to the writing of this Standard consisted of the following:

F. Kuchta, Chairman

E. Bartolucci P. Cinquemani L. Hiivala R. Smith N. Ware

R. Bristol D. Fox F. LaGase B. Vaughn B. Yu

J. Cancelosi P. Hall A. Pack E. Walcott

i


ICEA S-94-649-2000 DATE: 07/24/00

TABLE OF CONTENTS

Part 1 GENERAL .............................................................................................................................................. 1 1.1 SCOPE ................................................................................................................................................... 1 1.2 GENERAL INFORMATION ................................................................................................................... 1 1.3 INFORMATION TO BE SUPPLIED BY PURCHASER ....................................................................... 1

Characteristics of Systems on which Cable is to be Used ...................................................... 1 Quantities and Description of Cable ......................................................................................... 2

1.4 DEFINITIONS AND SYMBOLS ............................................................................................................ 2

1.3.1 1.3.2

Part 2 CONDUCTOR ........................................................................................................................................ 5 2.0 GENERAL .............................................................................................................................................. 5 2 1 PHYSICAL AND ELECTRICAL PROPERTIES ................................................................................... 5

2.1.1 Copper Conductors ................................................................................................................... 5 2.1.2 Aluminum Conductors .............................................................................................................. 5

2.2 OPTIONAL SEALANT FOR STRANDED CONDUCTORS ................................................................ 6 2.3 CONDUCTOR SIZE UNITS ................................................................................................................... 6 2.4 CONDUCTOR DC RESISTANCE PER UNIT LENGTH ...................................................................... 6

Direct Measurement of dc Resistance Per Unit Length ........................................................... 6 Calculation of dc Resistance Per Unit Length .......................................................................... 6

2.5 'CONDUCTOR DIAMETER .................................................................................................................... 7

2.4.1 2.4.2

Part 3 CONDUCTOR SHIELD (STRESS CONTROL LAYER) .................................................................... 13 3.1 MATERIAL ........................................................................................................................................... 1 3 3.2 EXTRUDED SHIELD THICKNESS ..................................................................................................... 13

Reduced Extruded Shield Thickness ..................................................................................... 13 3.3 PROTRUSIONS AND IRREGULARITIES ......................................................................................... 13 3.4 VOIDS ................................................................................................................................................... 14 3.5 PHYSICAL REQUIREMENTS ............................................................................................................ 14 3.6 ELECTRICAL REQUIREMENTS ........................................................................................................ 14

3.2.1

3.6.1 3.6.2

Extruded Semiconducting Material ........................................................................................ 14 Extruded Nonconducting Material (For EPR Insulation Only) ............................................... 14

3.6.3 Semiconducting Tape ............................................................................................................. 14 3.7 WAFER BOIL TEST ............................................................................................................................ 14

Part 4 INSULATION ....................................................................................................................................... 15 4.1 MATERIAL ........................................................................................................................................... 15 4.2 INSULATION THICKNESS ................................................................................................................. 15

Selection of Proper Thickness ................................................................................................ 16 For Three-phase Systems with 1 O0 or 133 Percent Insulation Levei ..................... 16

4.2.1 4.2.1.1 4.2.1.2

4.2.1.3 4.2.1.4

For Deita Systems Where One Phase May Be Grounded For Periods Over One Hour .......................................................................................................... 16 For Single- and Two-Phase Systems with 100 Percent Insulation Level ........... For Single- and Two-Phase Systems with 133 Percent Insulation Level ................ 16

Insulation for DISCHARGE-FREE Cable Designs Only ........................................................ 16

Partial-Discharge Extinction Levei ................................... .................................. 1 7

4.3 INSULATION REQUIREMENTS ........................................................................................................ 16

4.3.1.1 Physical and Aging Requirements ............................................................................ 16 4.3.1.2 Electrical Requirements ............................................................................................ 17

4.3.1.2.1 4.3.1.2.2 Voltage Tests ...................................................................................................... 17 4.3.1 . 2.3 Insulation Resistance Test ................................................................................. 18 4.3.1.2.4 Accelerated Water Absorption ......................................................... ................. 18 4.3.1.2.5 Capacity and Dissipation Factor ........................................................................ 18

4.3.1

II


ICEA S-94-û49-2000 DATE: 07/24/00

4.3.1.3 Voids. Ambers. Gels. Agglomerates and Contaminants as Applicable ................... 19 Crosslinked Polyethylene Insulation (XLPE or TRXLPE) ................................. 19

Shrinkback - Crosslinked Polyethylene Insulation (XLPE or TRXLPE) Only .......... 19

4.3.2.2 Electrical Requirements ............................................................................................ 21 Discharge (Corona) Resistan ce ......................................................................... 21

4.3.2.2.2 Voltage Tests ...................................................................................................... 21 Insulation Resistance Test ................................................................................. 21 Accelerated Water Absorption ............................................................................ 21 Capacity and Dissipation Factor ........................................................................ 22

4.3.1.3.1 4.3.1 3.2 Ethylene Propylene Rubber (EPR) .................................................................... 19

Insulation For DISCHARGE-RESISTANT Cable Designs Only ........................................... 20 Physical and Aging Requirements ............................................................................ 20

4.3.1.4

4.3.2.1 4.3.2

4.3.2.2.1

4.3.2.2.3 4.3.2.2.4 4.3.2.2.5

4.3.2.3 Voids and Contaminants ........................................................................................... 22

Part 5 EXTRUDED INSULATION SHIELD ................................................................................................... 25

5.2 THICKNESS AND INDENT REQUIREMENTS .................................................................................. 25 5.1 MATERIAL ........................................................................................................................................... 25

5.4 INSULATION SHIELD REQUIREMENTS .......................................................................................... 25

5.4.1.1 Removability .............................................................................................................. 26 5.4.1.2 Voids .......................................................................................................................... 26 5.4.1.3 Physical Requirements ............................................................................................. 26 5.4.1.4 Electrical Requirements ............................................................................................ 26

Wafer Boil Test .......................................................................................................... 26 Insulation Shield for DISCHARGE-RESISTANT Cable Designs Only ................................. 26

5.4.2.1 Removability .............................................................................................................. 26 5.4.2.2 Physical Requirements ............................................................................................. 27 5.4.2.3 Electrical Requirements ............................................................................................ 27

Wafer Boil Test .......................................................................................................... 27

5.3 PROTRUSIONS ................................................................................................................................... 25

5.4.1 Insulation Shield for DISCHARGE-FREE Cable Designs Only ............................................ 25

54.1.5 5.4.2

5.4.2.4

Part 6 CONCENTRIC NEUTRAL CONDUCTOR ......................................................................................... 28 28 6.1 MATERIAL ...........................................................................................................................................

6.2 CROSS-SECTIONAL AREA ............................................................................................................... 28 6.3 LAY LENGTH ...................................................................................................................................... 28 6.4 CONCENTRIC WIRES ........................................................................................................................ 28

6.4.1 Minimum Sizes ....................................................................................................................... 28 6.4.2 Contrahelical Wire .................................................................................................................. 28

Diameter and Area .................................................................................................................. 28

6.6 OPTIONAL WATER BLOCKING COMPONENTS FOR METALLIC SHIELD ................................ 29

6.4.3 6.5 FLAT STRAPS ........................................................................ T ............................................................ 29

Part 7 JACI(ETS ............................................................................................................................................. 31

Low and Linear Low Density Polyethylene, Black (LDPWLLDPE) ....................................... 31 7.1 MATERIAL ........................................................................................................................................... 31

Medium Density Polyethylene, Black (MDPE) ....................................................................... 32 High Density Polyethylene, Black (HDPE) ............................................................................. 33 Semiconducting Jacket Type I ............................................................................................... 34 Semiconducting Jacket Type I I .............................................................................................. 35

Chlorinated Polyethylene (CPE) ............................................................................................ 37

Polypropylene, Black (PP) ...................................................................................................... 39

7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7 7.1.8 7.1.9

Polyvinyl Chloride (PVC) ............................................................................ r ........................... 36

Thermoplastic Elastomer (TPE) ............................................................................................. 38

iii


ICEA S-94-649-2000 DATE: 07124100

7.2 JACKET TYPES .................................................................................................................................. 40

7.2.2 Overlaying Jacket ................................................................................................................... 40 40 7.2.1 Extnided-To-Fill Jacket ...........................................................................................................

7.3 JACKET IRREGULARITY INSPECTION ........................................................................................... 40 7.3.1 Non Conducting Jackets ......................................................................................................... 40 7.3.2 Semiconducting Jackets ......................................................................................................... 40

Pad 8 CABLE ASSEMBLY AND IDENTIFICATION .................................................................................... 42 8.1 MULTIPLEX CABLE ASSEMBLIES .................................................................................................. 42 8.2 CABLE IDENTIFICATION ................................................................................................................... 42

8.2.1 Jacketed Cable ....................................................................................................................... 42 Optional Cable Identification ..................................................................................... 42

Optional Sequential Length Marking ...................................................................................... 43

8.2.1.1 8.2.2 Unjacketed Cable ................................................................................................................... 43 8.2.3 Optional Center Strand Identification ..................................................................................... 43 8.2.4

Part 9 TESTING AND TEST METHODS ........................................................................................................ 44 9.1 TESTING .............................................................................................................................................. 44 9.2 SAMPLING FREQUENCY .................................................................................................................. 44 9.3 CONDUCTOR TEST METHODS ........................................................................................................ 44

9.3.1 Method for DC Resistance Determination ............................................................................. 44 9.3.2 Cross-Sectional Area Determination ...................................................................................... 44 9.3.3 Diameter Determination .......................................................................................................... 44

9.4 TEST SAMPLES AND SPECIMENS FOR PHYSICAL AND AGING TESTS .................................. 44 9.4.1 General ................................................................................................................................... 44 9.4.2 Measurement of Thickness .................................................................................................... 44

9.4.2.1 Micrometer Measurements ....................................................................................... 45 9.4.2.2

Number of Test Specimens .................................................................................................... 45 Size of Specimens .................................................................................................................. 45

Optical Measuring Device Measurements ............................................................... 45

Preparation of Specimens of Insulation and Jacket ............................................................... 46 Specimen for Aging Test ........................................................................................................ 46 Calculation of Area of Test Specimens .................................................................................. 46 Unaged Test Procedures ........................................................................................................ 46

9.4.3 9.4.4 9.4.5 9.4.6 9.4.7 9.4.8

9.4.8.1 Test Temperature ...................................................................................................... 46 9.4.8.2 Type of Testing Machine ........................................................................................... 47 9.4.8.3 Tensile Strength Test ................................................................................................ 47 9.4.8.4 Elongation Test ......................................................................................................... 47

9.4.9.1 Aging Test Specimens .............................................................................................. 47 9.4.9.2 Air Oven Test ............................................................................................................ 48 9.4.9.3

Hot Creep Test ........................................................................................................................ 48

9.4.9 Aging Tests ............................................................................................................................. 47

Oil Immersion Test for Polyvinyl Chloride Jacket ..................................................... 48

Solvent Extraction ................................................................................................................... 48 Wafer Boil Test for Conductor and Insulation Shields ........................................................... 48

Insulation Shield Hot Creep Properties .................................................................... 48

9.4.13.1 Sample Preparation .................................................................................................. 49 9.4.1 3.2 Examination ................................................................................................................ 49

Protrusion, Irregularity and Void Test ....................................................................... 49 Protrusion, Indentation and Irregularity Measurement Procedure ........................... 49

9.4.1 O 9.4.1 1 9.4.12

9.4.1 3 Amber, Agglomerate, Gel, Contaminant, Protrusion, Indent, Irregularity and Void Test ................................................................................................................................. 49

9.4.12.1

9.4.1 3.3

9.4.1 3.4

Resampling for Amber, Agglomerate, Gel, Contaminant,

iv COPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling ServicesCOPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling Services

ICEA 5-94-649-2000 DATE: 07/24/00

..................................... 9.4.14 Physical Tests for Semiconducting Material Intended for Extrusion 50 9.4.14.1 Test Sample 50 .............................................................................................................. 9.4.14.2 Test Specimens ........................................................................................................ 50 9.4.14.3 Elongation ................................................................................................................. 51

9.6 DIAMETER MEASUREMENT OF INSULATION AND INSULATION SHIELD ............................... 51

9.7.1 Heat Shock ............................................................................................................................. 51

9.4.1 5 Retests for Physical and Aging Properties and Thickness .................................................... 51 9.5 DIMENSIONAL MEASUREMENTS OF THE METALLIC SHIELD 51

9.7 TESTS FOR JACKETS ...................................................................................................................... 51

9.7.2 Heat Distortion ........................................................................................................................ 52 9.7.3 Cold Bend ............................................................................................................................... 52

9.8 VOLUME RESISTWTTY ...................................................................................................................... 52

Insulation Shieid .............................................................................................................. ....... 53 Semiconducting Jacket Radial Resistivity Test ..................................................................... 53

9.8.3.1 Sample Preparation .................................................................................................. 53 9.8.3.2 Test Equipment Setup .............................................................................................. 54 9.8.3.3 Calculation ................................................................................................................. 55

SHRINKBACK TEST PROCEDURE ............................................................................................. 56 9.10.1 Sample Preparation ................................................................................................................ 56

9.10.3 Pass/Fail Criteria and Procedure ........................................................................................... 56 9.1 1 9.12 VOLTAGE TESTS .......................................................................................................................... 57

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

9.8.1 9.8.2 9.8.3

Conductor Shield (Stress Control) ......................................................................................... 52

9.9 ADHESION (Insulation Shield Removability) TEST ....................................................................... 56

9.10.2 Test Procedure ....................................................................................................................... 56

RETESTS ON SAMPLES .............................................................................................................. 56

9.1 2.1 General ................................................................................................................................... 57 AC Voltage Test ...................................................................................................................... 57

PARTIAL-DISCHARGE TEST PROCEDURE .............................................................................. 57

POLYMERIC STRESS CONTROL LAYERS ............................................................................... 57

9.10

9.1 2.2 9.13 9.14 METHOD FOR DETERMINING DIELECTRIC CONSTANT AND

DIELECTRIC STRENGTH OF EXTRUDED NONCONDUCTING

9.15 MOISTURE CONTENT .................................................................................................................. 57 9.1 5.1 Moisture Under the Jacket ...................................................................................................... 57 9.1 5.2 Moisture in the Conductor ...................................................................................................... 57 9.15.3 9.1 5.4

Water Expulsion Procedure .................................................................................................... 58 Presence of Water Test .......................................................................................................... 58

9.16 PRODUCTION TEST SAMPLING PLANS ................................................................................... 59

Part 1 O 10.0 10.1

QUALIFICATION TESTS ............................................................................................................... 62

CORE MATERIAL QUALIFICATION TESTS ............................................................................... 62

Insulation Shield Qualification ................................................................................................ 63

10.1.5 Cyclic Aging ............................................................................................................................ 65 10.1.5.1 Cable Length ............................................................................................................. 66

10.1.5.3 Conduit ...................................................................................................................... 66

Accelerated Water Treeing Test ( A m ) Procedure ............................................................ 56 10.1.6.1 General ...................................................................................................................... 66 10.1.6.2 Sample Preparation .................................................................................................. 66

GENERAL .............................................................................. ? ........................................................ 62

10.1 . 1 Conductor Shield/lnsulation Qualification .............................................................................. 62 10.1.2 10.1.3 High Voltage Time Test (HVTT) Procedure ........................................................................... 65 10.1 . 4 Hot Impulse Test Procedure ................................................................................................... 65

10.1 5.2

10.1 25.4

Sample preparation .................................................................................................. 66

Load Cycle .................................................................................... : ........................... 56 10.1 . 6


ICEA S-94-649-2000 DATE: 07/24/00

10.1.6.3 Aging Time ................................................................................................................ 66 10.1.6.4 Test Procedure .......................................................................................................... 67 10.1.6.5 Water pH ................................................................................................................... 67

Qualification Test Physical Measurements ............................................................................ 68 THERMOMECHANICAL QUALIFICATION TEST - Optional ..................................................... 68

10.2.1 Scope ...................................................................................................................................... 68 10.2.2 Procedure ............................................................................................................................... 68

10.2.2.1 Fixture ........................................................................................................................ 68 10.2.2.2 Load Cycling .............................................................................................................. 68 10.2.2.3 Electrical Measurements .......................................................................................... 69 10.2.2.4

Design Test ............................................................................................................... 69 JACKET MATERIAL QUALIFICATION TESTS ........................................................................... 70

10.3.1 Polyethylene Jackets .............................................................................................................. 70 10.3.1 . 1 Environmental Stress Cracking Test ........................................................................ 70

10.3.1 . 1 . 1 Test Specimen ................................................................................................... 71 10.3.1.1.2 Test Procedure ................................................................................................... 71

10.3.1.2 Absorption Coefficient Test ....................................................................................... 71 10.3.2 Semiconducting Jackets ......................................................................................................... 71

10.3.2.1 Brittleness Test ......................................................................................................... 71 10.3.3 Polyvinyl Chloride and Chlorinated Polyethylene Jackets ..................................................... 71

10.3.3.1 Sunlight Resistance .................................................................................................. 71 10.3.3.1.1 Test Samples ..................................................................................................... 71 10.3.3.1.2 Test Procedure ................................................................................................... 71

CV EXTRUSION QUALIFICATION TEST .................................................................................... 71 10.4.1 Thermal Conditioning .............................................................................................................. 72 10.4.2 Dissipation Factor Verification ................................................................................................ 72 10.4.3 AC Withstand Verification ....................................................................................................... 72

OTHER QUALIFICATION TESTS ................................................................................................. 72 10.5.1 Insulation Resistance .............................................................................................................. 72 10.5.2 Accelerated Water Absorption Tests ..................................................................................... 73 10.5.3 Resistance Stability Test ........................................................................................................ 73 10.5.4 Brittleness Test for Semiconducting Shields ......................................................................... 73

........................................................................... 1 O . 1.7 Qualification Test Electncal Measurements 68 10.1.8

10.2

Physical Measurements Before and After the Therrnomechanical

10.3

10.4

10.5

10.5.4.1 Test Samples ............................................................................................................ 73 10.5.4.2 Test Procedure .......................................................................................................... 73

10.5.5 Dry Electrical Test for EPR Class 111 Insulation Only ............................................................. 73 10.5.5.1 Test Samples ............................................................................................................ 73 10.5.5.2 Test Procedure .......................................................................................................... 73 10.5.5.3 Electrical Measurements .......................................................................................... 73

10.5.6 Discharge Resistance Test for EPR Class IV Insulation Only .............................................. 73 10.5.6.1 Test Specimens ........................................................................................................ 74 10.5.6.2 Test Environment ...................................................................................................... 74 10.5.6.3 Test Electrodes ......................................................................................................... 74

Dissipation Factor Characterization Test ............................................................................... 74 10.5.7.1 Test Samples ............................................................................................................ 74 10.5.7.2 Thermal Conditioning ................................................................................................ 74 10.5.7.3 Dissipation Factor Testing ........................................................................................ 75

b .

10.5.7

Part 11 APPENDICES .............................................................................................. 7 .................................. 76

A l NEMA PUBLICATIONS ......................................................................................................... 76 A2 ICEA PUBLICATIONS ......... .. .................................................................................................. 76

APPENDIX A . NEMA, ICEA, IEEE, ASTM AND ANSI STANDARDS ........................................... 76

vi COPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling ServicesCOPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling Services

ICEA 5-94-649-2000 DATE: 07/24/00

A3 IEEE STANDARDS ................................................................................................................ 76

A5 ANSI STANDARDS ................................................................................................................ 78

PROCEDURE FOR DETERMINING DIAMETERS OF CABLE ............................ 80 APPENDIX D SHIELDING ............................................................................................................... 85

DEFINITION OF SHIELDING ................................................................................................ 85 FUNCTIONS OF SHIELDING ................................................................................................ 85 USE OF INSULATION SHIELDING ...................................................................................... 85 GROUNDING OF THE INSULATION SHIELD ..................................................................... 86

D5 SHIELD MATERIALS ............................................................................................................. 86 SPLICES AND TERMINATIONS ........................................................................................... 86

HANDLING AND INSTALLATION PARAMETERS ............................................... 87 E l INSTALLATION TEMPERATURES ...................................................................................... 87 E2 E3 DRUM DIAMEÏERS OF REELS ........................................................................................... 87 E4 . MAXIMUM TENSION AND SIDEWALL BEARING PRESSURES ....................................... 87 E5 TESTS DURING AND AFTER INSTALLATION ................................................................... 87

E5 1 During Installation ..................................................................................................... 87 E5.2 After Installation ......................................................................................................... 87 €3.3 In Service .................................................................................................................. 87

OPTIONAL FACTORY DC TEST ....................................................... ; .................... 89 REDUCED NEUTRAL DESIGNS ............................................................................ 90 ADDiTIONAL CONDUCTOR INFORMATION ........................................................ 94

A4 ASTM STANDARDS .............................................................................................................. 76

EMERGENCY OVERLOADS .................................................................................. 79 APPENDIX B APPENDIX C

D1 D2 D3 D4

D6 APPENDIX E

RECOMMENDED MINIMUM BENDING RADIUS ................................................................ 87

APPENDIX F APPENDIX G APPENDIX H APPENDIX I ETHYLENE ALKENE COPOLYMER (EAM) .......................................................... 97

LIST OF TABLES

Table 2-1 Table 2-2

Table 2-3

Table 2-3 (Metric)

Table 2 4 Table 2-4 (Metric) Table 2-5

Table 3-1 Table 3-2 Table 4-1 Table 4-2 Table 4-3 Table 4-4 Table 4-5

Table 4-6 Table 4-7 Table 4-8 Table 4-9 Table 4-10 Table 4-1 1

Weight Increment Factors ........................................................................................... 7 Schedule for Establishing Maximum Direct Current Resistance Per Unit Length of Completed Cable Conductors listed in Table 24 .................... 7 Nominal Direct Current Resistance in Ohms Per 1000 Feet at 25 OC of Solid and Concentric Lay Stranded Conductor ................................................... 8 Nominal Direct Current Resistance in Milliohms Per Meter at 25 OC of Solid and Concentric Lay Stranded Conductor ................................................... 9 Nominal Diameters for Copper and Aluminum Conductors ................................. 10 Nominal Diameters for Copper and Aluminum Conductors ................................. 11 Factors for Determining Nominal Resistance of Stranded Conductors Per 1000 Feet at 25 OC ............................................................................................... 12 Extruded Conductor Shield Thickness ................................................................... 13 Extruded Conductor Shield Requirements ............................................................. 14 Conductor Maximum Temperatures ........................................................................ 15 Insulation Physical Requirements Discharge-Free Designs ................................ 17 Accelerated Water Absorption Properties Discharge-Free Designs ................... 18 Dielectric Constant and Dissipation Factor Discharge-Free Designs ................. 18 Shrinkback Test Requirements Cables Having Sealed Strand Conductors andlor a Tape 0ver.the Conductor ..................................................... 19 Shrinkback Test Requirements All Cables Not Covered by Table 4-5 ................ 20 Insulation Physical Requirements Discharge-Resistant Designs ....................... 20 Accelerated Water Absorption Properties Discharge-Resistant Designs .......... 21 Dielectric Constant and Dissipation Factor Discharge-Resistant Designs ........ 22 BIL Values ...................................................................................................... : ............ 22 Conductor Sites, Insulation Thicknesses and Test Voltages .............................. 23

vii


ICEA S-94-649-2000 DATE: 07/24/00

Table 4-1 1 (Metric) Table 5-1 Table 5-2 Table 5-3 Table 6-1 Table 6-2 Table 6-3 Table 7-1 Table 7-2 Table 7-3 Table 7 4 Table 7-5 Table 7-6 Table 7-7 Table 7-8 Table 7-9 Table 7-1 O Table 7-1 1 Table 8-1 Table 9-1 Table 9-2 Table 9-3 Table 9 4 Table 9-5 Table 9-6 Table 9-7 Table 10-1 Table 10-2 Table 10-3 Table C-1 Table C-2 Table C-3 Table C 4 Table C-5 Table €-i Table F-1 Table G-1 Table G-2 Table G-3 Table G-4 Table G-5 Table G-6 Table H-1 Table H-2 Table H-3

Conductor Sizes. Insutatm Thicknesses and Test Voltages .............................. 23 Insulation Shield Thickness Cables Without Embedded Corrugated Wires ...... 25 Extruded Insulation Shield Requirements Discharge-Free Designs ................... 26 Extruded Insulation Shield Requirements Discharge-Resistant Designs .......... 27 Concentric Neutral Wire Size .................................................................................... 29 Full Neutral Concentric Copper Conductor ............................................................ 29 One-third Neutral Concentric Copper Conductor .................................................. 30 Low Density and Linear Low Density Polyethylene. Black (LDPHLLDPE) ........ 31 Medium Density Polyethylene. Black (MDPE) ........................................................ 32 High Density Polyethylene, Black (HDPE) .............................................................. 33

Polyvinyl Chloride (PVC) ........................................................................................... 36

Polypropylene, Black (PP) ......................................................................................... 39

Semiconducting Jacket Type I ................................................................................. 34 Semiconducting Jacket Type II ................................................................................ 35

Chlorinated Polyethylene (CPE) ............................................................................... 37 Thermoplastic Elastomer (TPE) ............................................................................... 38

Extruded-To-Fill Jacket Thickness and Test Voltage ............................................ 41 Overlaying Jacket Thickness and Test Voltage ..................................................... 41 Nominal Insulation Thickness .................................................................................. 43 Test Specimens for Physical and Aging Tests ....................................................... 45 Insulation Shield Hot Creep Requirements ............................................................. 49 Bending Requirements for Heat Shock Test .......................................................... 52

Summary of Production Tests and Sampling Frequency Requirements ........... 59 Plan E ........................................................................................................................... 61 Plan F ........................................................................................................................... 61 Maximum Temperature Gradient for Thermal Aging ............................................. 69 Generic Grouping of Cable Components ................................................................ 70 AC Withstand Voltage Requirements 15-35 kV Rated Cables .............................. 72 Insulation Diameter Calculation ............................................................................... 80 Insulation Shield Adders ........................................................................................... 81 Calculated Dimensions - Concentric Stranding .................................................... 82 Calculated Dimensions - Compressed Stranding ................................................. 83 Calculated Dimensions - Compact Stranding ........................................................ 84 DC Field Test Voltages .............................................................................................. 88 DC Test Voltages ........................................................................................................ 89 One-sixth Neutral Concentric Conductor for Copper Center Conductor ........... 90 Oneeighth Neutral Concentric Conductor for Copper Center Conductor ......... 90 One-twelfth Neutral Concentric Conductor for Copper Center Conductor ........ 91 One-sixth Neutral Concentric Conductoi for Aluminum Center Conductor ...... 91 Oneeighth Neutral Concentric Conductor for Aluminum Center Conductor .... 92 One-twelfth Neutral Concentric Conductor for Aluminum Center Conductor ... 92

Concentric Stranded Class B Aluminum and Copper Conductors ..................... 95 Concentric Stranded Class C and D Aluminum and Copper Conductors .......... 96

Bending Requirements for Cold Bend Test ............................................................ 52

Solid Aluminum and Copper Conductors ............................................................... 94

viii COPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling ServicesCOPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling Services

ICEA S-94-649-2000 DATE: 07/24/00

Part I GENERAL

1.1 SCOPE

This Standard applies to materials, constructions, and testing of crosslinked polyethylene and ethylene propylene rubber insulated single conductor or multiplexed concentric neutral cables rated 5 to 46 kV which are used for the transmission and distnbution of electrical energy.

1.2 GENERAL INFORMATION

This publication is so arranged to allow selection from two design concepts, one known as "DISCHARGE-FREE" and the other as "DISCHARGE-RESISTANT, as well as allowing for selection of those individual components (such as conductors, insulation type and thickness, concentric neutral sizes, optional jackets, etc.) as required for specific installation and service conditions.

Parts 2 to 7 cover the major components of cables:

Part 2 - Conáuctor Part 3 - Conductor Shield Part 4 - Insulation Part 5 - Extruded Insulation Shield Part 6 - Concentric Neutral Conductor Part 7 - Jackets

Each of these parts designates the materials, material characteristics, dimensions, and tests applicable to the particular component and, as applicable, to the design concept.

Part 8 covers the assembly and identification of cables. Part 9 covers production test procedures applicable to cable component materials and to completed

Part 1 O covers qualification test procedures. Part 1 I contains appendices of pertinent infomation.

Units' in this Standard are expressed in the English system. For information only, their approximate

cables.

metric equivalents are included.

1.3 INFORMATION 70 BE SUPPLIED BY PURCHASER

When requesting proposals from cable manufacturers, the p;ospective purchaser should describe the cable desired by reference to pertinent provisions of this Standard. To help avoid misunderstandings and possible misapplication of the cables, the purchaser should also furnish the following information:

1.3.1

a. b.

d. e. f. 9.

C.

Characteristics of Systems on which Cable is to be Used

Load current. Frequency - hertz. Normal operating voltage between phases or phase to ground on single phase circuits. Number of phases and conductors. Fault current and duration. Cable insulation level. Minimum temperature at .which cable will be installed.

1


ICEA S-94-649-2000 DATE: 07124100

h. 1. 2. 3.

1. 2.

I .

3. 4. 5. 6.

1.3.2

a. b.

C. d. e.

f. 9. h. i. j.

k.

Description of installation. In underground ducts. Direct burial in ground. Descriptions other than the foregoing. Installation conditions. Ambient temperature. Number of loaded cables in duct bank or conduit. If in conduit, give size and type of conduit (metallic or nonmetallic), number of loaded conduits, enclosed or exposed, and spacing between conduits. Load factor. Method of bonding anc grounding of metallic neutral. Wet or dry location. Thermal resistivity (rho) of soil, concrete and/or thermal backfill.

Quantities and Description of Cable

Total number of feet, including test lengths, and lengths if specific lengths are required. Type of cable. Describe as single conductor, three-conductor parallel, three-conductor triplexed, etc.. Rated circuit voltage, phase-to-phase. Type of conductor - copper or aluminum, filled or unfilled stranded, solid. Size of conductors - AWG or circular mils. If conditions require other than standard stranding, a complete description should be given. Type of insulation. Thickness of insulation in mils. Size of neutral. Type of jacket. Maximum allowable overall diameter in inches. When duct space is not limited, it is desirable not to restrict the overall diameter. Method of cable identification.

1.4DEFiNiTIONS AND SYMBOLS

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 crosslinked pplyethylene (XLPE or TRXLPE) insulation which is dissimilar in color (ranging from bright yellow to dark red) from the surrounding insulation, which passes light and is not always readily removable from the insulation matrix. This does not include clouds, swirls or flow patterns which are normally associated with the extrusion process.

AWG: American Wire Gauge

BIL: Basic Impulse Insulation Level.

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

2 COPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling ServicesCOPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling Services

ICEA S-94-649-2000

Cable Core:

Cable Core Extruder Run:

- -Certified Test Report:

Contaminant:

Dielectric Constant:

Discharge-Free Cable Design:

Discharge-Resistant Cable Design:

Dissipation Factor:

EPR Insulating Compound:

Filled Crosslinked Polyethylene Insulation:

Gel:

High Dielectric Constant Compound:

Jacket Extruder Run:

kcmil:

Lot (Cable):

Lot (Material):

Master Length:

DATE: O7124100

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

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

A report containing the results of production tests or qualification tests which 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.

Specific Inductive Capacity

A cable designed to eliminate electrical discharge in the insulation at nonal operating voltage.

A cable design capable of withstanding electrical discharge.

The cotangent of the dielectric phase angle of a dielectric material or the tangent of the dielectric loss angle. it is often called tan 6.

A mixture of ethylene propylene base resin and selected ingredients.

XLPE insulation containing 10 percent or more of mineral fillers by weight.

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

An extruded compound used for the conductor shield which has a dielectric constant typically between 8 and 200.

A cable with a jacket which was applied in one continuous run with one jacket compound and one jacket thickness.

thousands of circular mils (formerly MCM)

b

The quantity of cable requiring one test.

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

A continuous length of cable collected on a reel at the end of an extrusion line.


ICEA S-94-649-2000

Maximum Conductor Temperatures:

Normal Operating:

Emergency Overload:

Shcrt Circuit:

Partial Discharge Level :

pc:

Room Temperature (RT):

Shipping Length:

Shipping Reel:

Translucent:

Tree Retardant XLPE Insulation:

Unfilled Crosslinked Polyethylene:

V:

V,

Vented Water Tree:

Void:

Water Tree:

XLPE insulation:

DATE: 07124100

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

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

The hignest cenductor temperature permissible for any part of !he cable line during a circuit fault of specified time and magnitude.

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

picocoulombs

25 OC f 5 OC air temperature.

A completed length of cable which has passed all test requirements. It may or may not be cut into shorter lengths before it is supplied to the end use customer.

A completed reel of cable shipped to the end use customer.

A localized area in crosslinked polyethylene (XLPE or TRXLPE) insulation dissimilar to the surrounding insulation which passes light and is not readily removable from the insulation matrix. There are no requirements for translucents in this standard.

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

XLPE insulation containing less than 10 percent mineral filler by weight.

phase-to-phase voltage

phase-to-ground voltage

A water tree which originates at the conductor shield or insulation shield

Any cavity in a compound, either within or at the interface with another extruded layer.

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

A crosslinked polyethylene insulation.


ICEA S-94-649-2000 DATE: 07124100

Part 2 CONDUCTOR

2.0 GENERAL

Conductors shall meet the requirements of the appropriate ASTM standards referenced in this Standard except that resistance will determine cross-sectional area as noted in 2.4 and diameters will be in accordance with 2.5.

Requirements of a referenced ASTM standard shall be determined in accordance with the procedure or

The following technical information on typical conductors may be found in Appendix H: method designated in the referenced ASTM standard unless otherwise specified in this Standard.

a. Approximate diameters of individual wires in stranded conductors. b. Approximate conductor weights.

2.1 PHYSICAL AND,ELECTRICAL PROPERTIES

The conductors used in the cable snall be copper in accordance with 2.1.1 or aluminum in accordance with 2.1 -2, as applicable, except as noted in 2.0. Conductors shall be solid or stranded. The outer layer of a stranded copper conductor may be coated to obtain free stripping of the adjacent polymeric layer. There shall be no moisture in stranded conductors in accordance with 9.1 5.

2.1.1 Copper Conductors

1. 2. 3. 4. 5. 6. 7. 8. 9.

ASTM B 3 for soft or annealed uncoated copper. ASTM B 5 for electrical grade copper. ASTM B 8 for Class A, B, C. or D stranded copper conductors. ASTM B 33 for soft or annealed tin-coated copper wire. ASTM B 496 for compact-round stranded copper conductors. ASTM B 784 for modified concentric lay stranded copper conductor. ASTM B 785 for compact round modified concentric lay stranded copper conductor. ASTM B 787 for 19 wire combination unilay-stranded copper conductors. ASTM B 835 for compact round stranded copper conductors using single input wire constructions.

2.1.2 Aluminum Conductors

1. 2. 3. 4. 5. 6. 7. 8.

9.

ASTM B 230 for electrical grade aluminum 1350-H19. ASTM B 231 for Class A, B, C, or D stranded aluminum 1350 conductors. ASTM B 233 for electrical grade aluminum 1350 drawing stock. ASTM B 400 for compact-round stranded aluminum i 350 conductors. ASTM B 609 for electrical grade aluminum 1350 annealed and intemediate tempers. ASTM i3 786 for 19 wire combination unilay-stranded aluminurn 1350 conductors. ASTM B 800 for 8000 series aluminum alloy annealed and intermediate tempers. ASTM 6 801 for 8000 series aluminum alloy wires, cornpact- round, compressed and concentric-lay Class A, B, C and D stranded conductors. ASTM B 836 for compact round stranded aluminum conductors using single input wire constructions.

5


ICEA S-94-649-2000 DATE: 07124100

2.2 OPTIONAL SEALANT FOR STRANDED CONDUCTORS

With the approval of the purchaser, a sealant designed as an impediment to longitudinal water penetration may be incorporated in the inierstices of the stranded conductor. Compatibility with the conductor shield shall be determined in accordance with ICEA Publication T-32-645. Longitudinal water penetration resistance shall be determined in accordance with ICEA Publication T-31-610 and shall meet a minimum requirement of 5 psig.

2.3 CONDUCTOR SIZE UNITS

Conductor size shall be expressea by cross-sectional area in thousand circular mils (kcmil). The AWG equivalents for small sizes shall be found in Table 2-4. The metric equivalents for all sizes are found in Table 2 4 (Metric).

2.4CONDUCTOR DC RESISTANCE PER UNIT LENGTH

The dc resistance per unit length of each conductor in a production or shipping length of completed cable shall not exceed the value determined from the schedule of maximum dc resistances specified in Table 2-2 when using the appropriate nominal value specified in Table 2-3. The dc resistance shall be determined in accordance with 2.4.1 or 2.4.2.

Where the outer layer of a stranded copper conductor is coated, the direct current resistance of the resulting conductor shall not exceed the value specified for an uncoated conductor of the same size.

When a sample is taken from a multiple conductor cable, the resistance shall comply with the appropriate maximum resistance value specified for a single conductor cable.

2.4.1 Direct Measurement of dc Resistance Per Unit Length

The dc resistance per unit length shall be determined by dc resistance measurements made in accordance with 9.3.1 to an accuracy of 2 percent or better. If measurements are made at a temperature other than 25 OC, the measured value shall be converted to resistance at 25 OC by using either of the following:

1. The appropriate multiplying factor obtained from ICEA T-27-58UNEMA WC-53. 2. A multiplying factor calculated using the applicable formula in ICEA T-27-5811NEMA WC-53.

If verification is required for the direct-current resistance measurement made on an entire length of completed cable, a sample at least 1 foot (0.3 m) long shall be cut from that reel length, and the direct- current resistance of each conductor shall be measured using a Kelvin-type bridge or a potentiometer.

2.4.2

b

Calculation of dc Resistance Per Unit Length

The dc resistance per unit length at 25 OC shall be calculated using the following formula:

R = K p/A Where:

R = Conductor resistance in n/l O00 ft. K = Weight increment factor, as given in Table 2'1. p = Volume resistivity in a.cmil/ft., determined in accordance with ASTM B 193 using round wires A = Cross-sectional area of conductor in kcmil, determined in accordance with 9y3.2.

When the volume resistivity is expressed in nanoohm meter (nom) and area is expressed in square millimeters (mm2) the resistance is expressed in milliohm per meter (mnlm).


ICEA S-94-649-2000

Conductor TypelSize

Solid All Sizes

Concentric-lay Strand, Class A, B, C and 0

>2000 - 3000 kcmil (MO13 - 1520 mm2)

Combination Unilay Strand All Sizes

Concentric-lay Strand 8000 Series Aluminum Ail Sizes

8 AWG - 2000 kcmil (8.37 - 1013 mm')

DATE: 07/24/00

Weight Factor (K)

1

1 .o2 1 .O3

1 .o2

1 .o2

2.5 CONDUCTOR DIAMETER

Cable Type

The conductor diameter shall be measured in accordance with 9.3.3. The diameter shall not differ from the nominal values shown in Table 2-4 by more than i 2 percent.

Maximum d c Resistance

Table 2-1 Weight Increment Factors'

Single Conductor Cables and Flat Parallel Cables

Table 2-3a Value Plus 2% (R max = R x 1.02)

Table 2-2 Schedule for Establishing Maximum Direct Current Resistance

Per Unit Length of Completed Cable Conductors listed in Table 2 4

Twisted Assemblies of Single Conductor Cables

Tabie 2-3" Value Plus 2% Plus An Additional 2% - For One Layer of Conductors (R rnax = R x 1 .O2 x 1.02)

a For conductor strandings or sizes not listed in Tables 2-3, the norninql direct current resistance per unit length of a completed singie conductor cable shail be calculated from the factors given in Table 2-5 using the following formula:

I

f R = - x 10-j A

Where: R = Conductor resistance in N1 O00 ft. f = Factor from Table 2-5 A = Cross-sectional area of conductor in kcmil

See 9.3.2 for cross-sectional area determination

7


ICEA S-94-649-2000

0.508 0.403 0.319 0.253

DATE: 07/24/00

0.522 0.414 0.329 0.261

Table 2-3 Nominal Direct Current Resistance in Ohms Per 1000 Feet at 25 OC

...

...

...

...

...

of Solid and ( Solid

...

...

...

...

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

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

Conductor Sue

AWG or kanil

Concentric Lay Stranded'

Aluminurn Aluminum

Uncoated Coated Class B.C.D ~~~~

Class B 0.678 0.538 0.427 0.338 0.269

Class D Class 8,C.D

0.652 0.519 0.41 1 0.325 0.258

Class C

0.678 0.538 0.427 0.339 0.269

1 .O5 0.833 0.661 0.524 0.415

1 .O7 0.851 0.675 0.534 0.424

O. 680 0.538 0.427 0.339 0.269

3 2 1

1 IO ZO

0.329 0.261 0.207 0.164 0.130

0.201 0.159 O. 126 0.100 0.0794

0.207 0.164 0.130 0.102 0.0813

0.334 0.266 0.21 1 0.168 0.133

0.205 0.1 62 0.129 0.102 0.0810

0.21 3 0.169 0.134 0.106

0.0842

0.213 0.169 0.134 0.106 0.0842

0.213 0.169 0.134 0.106 0.0842

0.0669 0.0530 0.0448 0.0374 0.0320

310 410 250 300 350

0.103 0.0819 0.0694

0.0495 0.0578

0.0630 0.0500

...

...

...

0.0645 0.051 1

...

...

...

0.105 0.0836 0.0707 0.0590 0.0505

0.0642 0.0510 0.0431 0.0360 0.0308

0.0667 0.0524 0.0448 0.0374 0.0320

0.0669 0.0530 0.0448 0.0374 0.0320

400 450 500 550 600

0.0433 0.0385 0.0347

1..

...

0.0442 0.0393 0.0354 0.0321 0.0295

0.0269 0.0240 0.0216 0.0196 0.0180

0.0277 0.0246 0.0222 0.0204 0.0187

0.0280 0.0249 0.0224 0.0204 0.0187

0.0280 0.0249 0.0224 0.0204 0.0187

650 700 750 800 900

...

...

...

...

...

0.0272 0.0253 0.0236 0.0221 0.01 96

0.0166 0.0154 0.0144 0.01 35 0.0120

0.0171 0.0159 0.0148 0.0139 0.0123

0.0172 0.0160 0.0149 0.0140 0.0126

0.0173 0.0160 0.01 50 0.0140 0.0126

1000 '

1100 1200 1250 1300

...

...

...

...

...

0.0177 0.01 61 0.0147 0.0141 0.0136

0.01 11 0.0101 0.00925 0.00888 0.00854

0.01 11 0.0102 0.00934 0.00897 0.00861

0.0112 0.0102 0.00934 0.00897 0.00862

0.0108 0.00981 0.00899 0.00863 0.00830

a00771 0.0071 9 0.00674 0.00634 0.0061 6

...

...

...

...

...

0.01 26 0.01 18 0.01 11 0.01 04 0.0101

0.00793 0.00740 0.00694 0.00653 0.00634

0.00793 0.00740 0.00700 0.00659 0.00640

0.00801 0.00747 0.00700 0.00659 0.00640

1400 1500 1600 1700 1750

1800 1900 2000 2500 3000

...

...

...

...

...

0.00982 0.00931 0.00885 0.0071 5 0.00596

0.00599 0.00568 0.00539 0.00436 0.00363

0.00616 0.00584 0.00555 0.00448 0.00374

0.00616 0.00584 0.00555

...

...

~

0.00622 0.00589 0.00560

...

...

' Concentric lay stranaed indudes compressed and compact mnductors.

a COPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling ServicesCOPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling Services

DATE: 07/24/00 ICEA S-94-649-2000

Table 2-3 (Metric) Nominal Direct Current Resistance in Milliohms Per Meter at 25 "C

:entric Lav Stranded Conductor Concentric Lay Sbandw'

of Solid and Ca %id

Aluminum Condudor Size AJuminurn

~ Kcmil

4

110 ZO

Coated Uncoated coated

Unmated Class B,C,D -~

Class B

2.22 1.76 1.40 1.11

0.882

Class D Class B.C.0 Class C

2.22 1.76 1.40 1.11

0.882

~~

2.16 1.71 1.36 1 .O8

0.856

3.51 2.79 2.21 1.75 1.39

2.14 1.70 1.35 1 .O7

0.846

2.23 1.76 1.40 1.11

0.882

3.44 2.73 2.17 1.72 1.36

2.10 1.67 1.32 1 .O5

0.830

8.37 10.6 13.3 16.8 21.1

26.7 33.6 42.4 53.5 67.4

~~ ~

0.699 0.554 0.440 0.348 0.276

0.699 0.554 0.440 0.748 0.276

0.659 0.522 0.413 0.328 0.260

0.679 O. 538 0.426 0.335 0.267

1.10 0.872 0.692 0.551 0.436

0.672 0.531 0.423 0.335 0.266

0.699 0.554 0.440 0.348 0.276

1 .O8 0.856 0.679 0.538 0.426

~

0.344 0.274 0.232 0.194 0.166

0.21 1 0.167 0.141 0.118 0.101

0.219 0.172 0.147 O. 123 0.105

0.219 0.174 0.147 0.123 O. 105

0.219 O. 174 0.147 0.123 0.105

0.338 0.269 0.228 0.190 0.162

0.207 0.164

...

...

...

0.212 0.168

...

...

...

85.0 107 127 152 177

203 228 253 279 304

310 410 250 300 350

400 450 500 550 600

650 700 750 800 900

1 O00 1100 1200 1250 1300

1400 1500 1600 1700 1750

1800 1900 2000 2500 3000

...

...

...

...

...

0.145 0.129 0.116 0.105

0.0968

0.0882 0.0787 0.0708 0.0643 0.0590

0.0909 0.0807 0.0728 0.0669 0.061 3

0.0918 0.0817 0.0735 0.0669 0.0613

0.0918 0.0817 0.0735 0.0669 0.0613

O. 142 0.126 0.114 ... ...

...

...

...

...

... ~~

0.0564 0.0525 0.0489 0.0459 0.041 3

~~

0.0567 0.0525 0.0492 0.0459 0.041 3

...

...

...

...

...

...

...

...

...

...

0.0892 0.0830 0.0774 0.0725 O.OE43

0.0544 0.0505 0.0472 0.0443 0.0394

0.0161 0.0522 0.0485 0.0456 0.0403

329 355 380 405 456

507 557 608 633 659

709 760 81 1 861 887

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

~

0.0354 0.0322 0.0295 0.0283 0.0272

0.0364 0.0331 0.0303 0.0291 0.0280

0.0364 0.0335 0.0306 0.0294 0.0282

0.0367 0.0335 0.0306 0.0294 0.0283

...

...

...

...

...

0.0581 0.0528 0.0482 0.0462 0.0446

...

...

...

...

...

...

...

...

...

...

0.0413 0.0387 0.0364 0.0341 0.0331

0.0353 0.0236 0.0221 0.0208 0.0202

0.0260 0.0243 0.0228 0.0214 0.0208

0.0263 0.0245 0.0230 0.0216 0.0210

..<

...

...

...

...

0.0260 0.0243 0.0230 0.0216 0.0210

0.0202 0.0192 0.0182

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

0.0322 0.0305 0.0290 0.0235 0.0195

0.0196 0.0186 0.0177 0.0143 0.01 19

0.0202 0.0192 0.0182 0.0147 0.0123

0.0204 0.0193 0.0184

...

...

912 963

1013 1266 1520

. Concentric lay stranded indudes mmprecced and compact conductors

9


ICEA 5-94-649-2000 DATE: O7124100

Table 2 4 Nominai Diameters for Copper and Aluminum Conductors

I

Nominal Diameters (Inaies)

Concentric Lay Stranded Unilay

Compressed kcmil Combination

Unilay

O. 143 0.160 0.179 0.202 0.226

AWG

8 7 6 5 4

3 2 1

110 ZO

30 410

Solid

0.1285 0.1443 0.1620 0.1819 0.2043

0.2294 0.2576 0.2893 0.3249 0.3648

0.4096 0.4600 0.5000 0.5477 0.5916

Cornpact' Compressed Class B" Class C Class D

16.51 20.82 26.24 33.09 41.74

0.146 0.164 9.184 0.206 0.232

0.148 0.166 0.186 0.208 0.234

0.134

0.169

0.213

...

...

0.141 0.158 0.178 0.200 0.225

0.148 0.166 0.186 0.208 0.235

...

...

...

...

... 52.62 66.36 83.69 105.6 133.1

0.238 0.268 0.299 0.336 0.376

0.252 0.283 0.322 0.362 0.406

0.260 0.292 0.332 0.373 0.419

0.263 0.296 0.333 0.374 0.420

0.264 0.297 0.333 0.374 0.420

0.254 0.286 0.321 0.360 0.404

...

... 0.313 0.352 0.395

167.8 211.6 250 300 350

0.423 0.475 0.520 0.570 0.616

0.456 0.512 0.558 0.61 1 0.661

0.470 0.528 0.575 0.630 0.681

~~

0.471 0.529 0.576 0.631 0.681

0.472 0.530 0.576 0.631 0.682

0.454 0.510 0.554 0.607 0.656

0.443 0.498 0.542 0.594 0.641

400 450 500 550 600

0.6325 0.6708 0.7071

...

...

0.659 0.700 0.736 0.775 0.813

0.706 0.749 0.789 0.829 0.866

0.728 0.772 0.813 0.855 0.893

0.729 0.773 0.814 0.855 0.893

0.729 0.773 0.81 5 0.855 0.893

0.701 0.744 0.784

...

...

0.685 0.727 0.766 0.804 0.840

650 700 750 800 900

0.845 0.877 0.908 0.938 0.999

0.901 0.935 0.968 1 .o00 1.061

0.929 0.964 0.998 1 .O31 1 .o94

0.930 0.965 0.999 1 .O32 1 .O93

0.930 0.965 0.998 1 .O32 1 .O95

...

...

...

...

...

0.874 0.907 0.939 0.969 1 .O28

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

1 O00 1100 1200 1250 1300

1 .O60 ... ... ... ...

1.117 1.173 1.225 1.251 1.276

1.152 1.209 1.263 1.289 1.315

1.153 1.210 1.264 1.290 1.31 6

1.153 1.211 i ,264 1.290 1.316

...

...

...

...

...

1 .o84 1.137 1.187 1.21 2 1.236

1400 1500 1600 1700 1750

...

...

...

...

...

1.323 1.370 1.41 5 1.459 1.480

1.364 1.412 1.459 1.504 1.526

1.365 1.413 1.460 1.504 1.527

1.365 1.413 1.460 1 .504 1.527

...

...

... 1..

...

1.282 1.327 1.371 1.413 1.434

1800 1900 2000 2500 3000

...

...

...

...

...

1.502 1.542 1.583 1.769 1.938

1.548 1.590 1.632 1.824 1.998

1.548 1.590 1.632 1.824 1.999

1.549 1.591 1.632 1.824 1.999

...

...

...

...

...

1.454 1.494 1.533

...

...

...

...

...

...

...

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


ICEA S -94-649-2000

Concentric Lay Stranded

Compresed Class B- Class C Class D

3.71 3.76 3.76 4.01 4.17 4.22 4.22 4.52 4.67 4.72 4.72 5.08 523 5.28 5.31 5.72 . 5.89 5.94 5.97

6.40 6.60 6.68 6.71 7.19 7.42 7.52 7.54 8.18 8.43 8.46 8.46 9.19 9.47 9.50 9.50 10.3 10.6 10.7 10.7

3.58

DATE: 07/24100

Combination Unilay Uniiay Compressed

3.63 ... 4.06 ... 4.55 ... 5.1 3 ... 5.74 ...

6.45 ... 7.26 ... 8.15 7.95 9.14 8.94 10.3 10.0

Conductor

Kariil

11.6 11.9 12.0 12.0 ... 13.0 13.4 13.4 13.5 ... 14.2 14.6 14.6 14.6 ... 15.5 16.0 16.0 16.0 ... 16.8 17.3 17.3 17.3 ... 17.9 18.5 18.5 18.5 ... 19.0 19.6 19.6 19.6 ... 20.0 20.7 20.7 20.7 ... 21.1 21.7 21.7 21.7 ... 22.0 22.7 22.7 22.7 ... 22.9 23.6 23.6 23.6 ... 23.7 24.5 24.5 24.5 ... 24.6 25.3 25.4 25.3 ... 25.4 26.2 26.2 26.2 ... 26.9 27.8 27.8 27.8 ...

28.4 29.3 29.3 29.3 ... 29.8 30.7 30.7 30.8 ... 31.1 32.1 32.1 32.1 ... 31.8 32.7 32.8 32.8 ... 32.4 33.4 33.4 33.4 ...

33.6 34.6 34.7 34.7 ... . 34.8 35.9 35.9 35.9 ... 35.9 37.1 37.1 37.1 ... 37.1 38.2 38.2 38.2 ... 37.6 38.8 38.8 38.8 ...

38.2 39.3 39.3 39.3 ... 39.2 40.4 40.4 40.4 ... 40.2 41.5 41.5 41.5 ... 44.9 46.3 46.3 46.3 ... 49.2 50.7 50.8 50.8 ...

13.3 16.8 21.1

26.7 33.6

t 42.4 110 53.5 ZO 67.4

11.3 12.6 13.8 15.1 16.3

17.4 18.5 19.5 20.4 21.3

22.2 23.0 23.9 24.6 26.1

27.5 28.9 30.1 30.8 31.4

32.6 33.7 34.8 35.9 36.4

36.9 37.9 38.9 ... ...

300 350

650 700 750 800 900

329 355 380 405 456

...

...

...

...

...

...

...

...

... ,..

...

...

...

...

...

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

Nominal Diameten (mm)

I

21.5 22.3 23.1 23.8 25.4

26.9 ... ... ... ...

...

...

...

...

...

Solid Compact.

4.1 1 4.29 4.62 ... 5.19 5.41

1700 1750

5.83 6.05 6.54 6.81 7.35 7.59 8.25 8.53 9.27 9.55

10.4 10.7 11.7 12.1 -e3 13.2 13.9 14.5 15.0 15.6

16.1 16.7 17.0 17.8 18.0 18.7 ... 19.7 ... 20.7

861 887

1800 1900 2000 2500 3000

912 963 i013 1266 1520

...

...

...

...

...

...

...

...

...

... Diameters snown are for compact round, compact modified concenuic and compact single input wire.

** Diameters shown are for wncentnc round and modified concenuic.

11


ICEA S-94-649-2000 DATE: 07/24/00

conductor Size

Aluminum Uncoated copper

Table 2-5' Factorst for Determinina Nominal Resistance of Stranded Conductors Per 1000 Feet at 25 OC

Diameter of Individual Coated Copper Wires in inches for Stranded Conductors All Sizes

0.460 Under 0.290 Under 0.103 to 0.290, to 0.103, to 0.0201, inclusive Inclusive inclusive

Under 0.0201 to 0.0111, Inclusive

11456

11568

Concentric Stranded

(8.37 - 1013 mm2) 8 AWG - 2000 kcmil

Under 0.01 li to 0.0010, Inclusive

11580

11694

17692 10786

I I > 2000 - 3000 kaii i l I 17865 I 10892 I 11153 I 11211 1 11327 (MO13 - 1520 mm')

11045 11102 11217

Conductivity utilized for above fadors, Percent

' The factors given in Table 2-5 snaii be b a d on the following:

A. Resistivity 1. A volume resistivity of 10.575 n.anillft (100% conductivity) at 25 OC for uncoated (bare) copper. 2. A 25 OC volume resistivity converted from the 20 OC values specified in ASTM B 33 for tin coated copper. 3. A volume resistivity of 17.345 r;.cmil/ft (61.0% conductivity) at 25 OC for aluminum.

B. increase in Resistance Due to Stranding 1. The value of K (weight increment factor) given in Table 2-1.

94.16 I 93.15

t See Table 2-2 for Use of Factors.


DATE: 07124100 ICEA S-94-649-2000

16 0.41 212 - 550 (1 07 - 279)

i 4

Part 3 CONDUCTOR SHIELD (STRESS CONTROL LAYER)

3.1 MATERIAL

The conductor shall b e covered with an extmded thermosetting conductor shield material. The extruded material shall be either semiconducting or nonconducting for ethylene propylene rubber (EPR) type insulation and semiconducting only for crosslinked polyethylene (XLPE or TRXLPE) type insulation. The extruded shield shall be compatible with all cable component materials with which it is in contact. The allowable operating temperatures of the conductor shield shall be equal to or greater than those of the insulation. The conductor shield shall be easily removable from the conductor and the outer surface of the extruded shield shall be firmly bonded to the overlying insulation.

A semiconducting tape may be used between the conductor and the extruded shield. The tape, if utilized, shall not be considered as part of the extruded shield thickness.

3.2 EXTRUDED SHIELD THICKNESS

(See 9.4.2). The extruded conductor shield thicknesses shall be as follows:

Table 3-1 Extruded Conductor Shield Thickness

~~

Extruded Shield Thickness

mils

Conductor Size, AWG or kcmil

(mm2)

A (8.37 - 107) I l 2 I Il 8 - 410

0.61 1001 and larger (507 and larger)

3.2.1 Reduced Extruded Shield Thickness

For compact round and solid conductors which have a diameter eccentricity less than or equal to 2 mils (0.051 mm) measured before the extruded shield is applied, the extruded shieid thickness may be 50 percent of Table 3-1 values with prior agreement between the manufacturer and the purchaser. Protrusions and irregularities into the conductor shield shall not exceed 50% of the required minimum point shield thickness. All other requirements remain unchanged. Diameter eccentricity is defined as the maximum diameter minus the minimum diameter of a given cross section.

3.3 PROTRUSIONS AND IRREGULARITIES

(See 9.4.13). The contact surface between the extruded conductor shield and :he insulation shall be


ICEA S-94-649-2000 DATE: 07/24/00

cylindrical and free from protrusions and irregularities that extend more than 5 mils (0.127 mm) into the insulation and 7 mils (0.18 mm) into the extruded conductor shield.

3.4VOIDS

(See 9.4.13). The extruded conductor shield and insulation interface shall be free of any voids larger than 3 mils (0.076 mm).

3.5 PHYSICAL REQUIREMENTS

The crosslinked material intended for extrusion as a conductor shield shall meet the following requirements:

Table 3-2 Extruded Conductor Shield Requirements

Physical Requirements 1 Extruded Conductor Shield

Elongation aíter air oven test for 168 hours at 121 OC 11 OC (for insulations rated 90 OC) or at 136 OC f l OC (for insulations rated 105 OC),

minimum Dercent

1 O0

II Brittleness temperature not warmer than, OC I -2 5

3.6 ELECTRICAL REQUIREMENTS

3.6.1 Extruded Semiconducting Material

(See 9.8.1). The volume resistivity of the extruded semiconducting conductor shield shall not exceed 1 O00 ohmmeter at the maximum normal operating temperature and emergency operating temperature.

3.6.2 Extruded Nonconducting Material (For EPR Insulation Only)

The extruded nonconducting conductor shield shall withstand a 2.0 kV dc spark test, for test frequency see Table 9-5, and meet the following requirements at room temperature, at the maximum normal operating temperature, and emergency operating temperature:

4

Dielectric Constant, range 8 - 200

60 Hz ac voltage withstand stress, volts per mil, minimum-

L dielectric constant

3.6.3 Semiconducting Tape

If a semiconducting tape is used over the conductor, the maximum dc resistance of the tape at room temperature shall be 10,000 ohms per unit square when determined in accordance with ASTM D 4496.

3.7 WAFER BOIL TEST

(See 9.4.1 2). The extruded conductor shield shall be effectively crosslinked.


K E A S-94-649-2000

XLPE, TRXLPE, and EPR Classes I, I I & IV

DATE: 07/24/00

90 OC 130 OC 250 OC

Pari 4 INSULATION

EPR Class III 1 105°C" I 140 O C

4.1 MATERIAL

250 O C

The insulation shall be one of the following materials meeting the dimensional, electrical, and physical requirements specified in this section:

.Filled or unfilled crosslinked polyethylene (XLPE)

.Filled or unfilled tree retardant crosslinked polyethylene (TRXLPE) Ethylene propylene rubber (EPR)

A filled crosslinked polyethylene or filled tree retardant crosslinked poiyethylene insulation (XLPE or TRXLPE), meeting the requirements of this specification, is one that contains 10 percent or more of mineral fillers by weignt. A tree retardant crosslinked polyethylene insulation is a compound containing the following: an additive, a polymer modification, or filler that retards the development and growth of water trees in the compound. These XLPE and TRXLPE insulations are intended for use only in cables of the "DISCHARGE- FREE design concept. (See 4.3.1)

Ethylene propylene rubber insulation has four classifications: I , I I & I I I are for use only in cables of the"D1SCHARGE-FREE" design (See 4.3.1); IV is for use only in cables of the "DISCHARGE-RESISTANT' design (See 4.3.2).

All of the insulations are suitable for use on cables in wet or dry locations at voltages between 5 and 46 kV between phases at the 100 and 133 percent insulation level. The conductor temperature shall not exceed the following:

Table 4-1 Conductor Maximum Temperatures

Normal Emergency 1 Short Circuit" insulation Materialt Operation Overload* i

'See Appendix B ."Lower temperatures for normal operation may be required because of the type of material used in the cable joints. terminations and separable connectors or because of cable environment wnditions. Cable users should be aware that all of the jackets descnbed in Pari 7 are not necessarily suitable for cables having this maximum temperature rating. Consult cable manufacturer for further information. "'Condudor fault airrent shall be determined in accordance with I C s P-32-382. tother insulation materials composed of Ethylene and Alkene units, which are designated as EAM, may be available and can meet the same physical and electrical requirements as the insulation materiais descnoed in this standard. See Appendix I and/or contad the manufacturer for further information.

4.2 INSULATION THICKNESS -

The insulation thicknesses given in Table 4-1 1 are based on the rated circuit voltage, phase-to-phase, and on the cable insulation level.

15


ICEA S-94-649-2000 DATE: O7124100

The minimum thickness and maximum thickness of the insulation shall be as specified in Table 4-11

For identification, nominal thicknesses are shown in Table 8-1. (see 9.4.2 for method of measurement).

4.2.1 Selection of Proper Thickness

The thickness of insulation for various systems shall be determined as follows:

4.2.1.1 For Three-phase Systems with 100 or 133 Percent Insulation Level

Use the thickness values given in the respective columns of Table 4-1 1.

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

See 173 percent level in note c following Table 4-1 1

4.2.1.3 For Single- and Two-Phase Systems with 100 Percent Insulation Level

Multiply the voltage to ground by 1.73 and use the resulting voltage value or next higher rating to select the corresponding insulation thickness in the 1 O0 percent insuiation level column of Table 4-1 1.

4.2.1.4 For Single- and Two-Phase Systems with 133 Percent Insulation Levei

Multiply the voltage to ground by 1.73 and use the resulting voltage value or next higher rating to select the corresponding insulation thickness in the 133 percent insulation level column of Table 4-1 1.

4.3 INSULATION REQUIREMENTS

Insulations used in DISCHARGE-FREE cable designs are described in 4.3.1. Insulations used in DISCHARGE-RESISTANT cable designs are described in 4.3.2.

4.3.1 Insulation for DISCHARGE-FREE Cable Designs Only

4.3.1.1 Physical and Aging Requirements

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


ICEA S-94-649-2000

I

Physical Requirements

DATE: 07/24/00

Insulation Type

XLPE and TRXLPE EPR Class

Unfilled Filled I II 111

Tensile Strength, Minimum psi 1800 700 1200 ( M W (12.5) (4.8) (8.2)

700 (4.8)

*For XLPE and TRXLPE insulations if this value is exceeded, the Solvent Extraction Test may be performed and will serve as a referee method to determine compliance (a maximum of 30 percent weight loss after 20 hour drying time).

Elongation at Rupture, 250 Minimum Percent

4.3.1.2 Electrical Requirements

4.3.1.2.1 Partial-Discharge Extinction Level 6

250

(See 9.13). Each shipping length of completed cable shall be subjected to a partial discharge test. The partial discharge shall not exceed 5 picocoulombs at the ac test voltage given in Table 4-1 1.

Aging Temperature, OC 121 121

of Unaged Value

Percentage of Unaged Value

Tensile Strength, Minimum Percentage 75 75 80

Elongation, Minimum 75 1 75 80

4.3.1.2.2 Voltage Tests

136

75

75

(See 9.12). Each shipping length of completed cable shall withstand, without failure, the ac test voltages given in Table 4-1 1. The test voltage shall be based on the rated voltage of the cable and the size of the conductor.

Factory dc testing is not required by this specification. However, a dc test may beperformed with prior agreement between the manufacturer and the purchaser. Suggested dc test voltages are listed in Appendix F.

For purposes of this Standard, the BIL shall be in accordance with Table 4-10. The minimum impulse

‘Elongation, Maximum Percent 175

17

1 O0 50

‘Set, Maximum Percent 1 1 0 1 5 5


ICEA S-94-649-2000 DATE: 07/24/00

withstand value for all discharge-free cable designs shall be 800 Vlmil (31.5 kV/mm) except for XLPE of TRXLPE insulated cable designs rated for 15 kV where the minimum impulse withstand value shall be 1200 V/mil (47.2 kV/mm).

4.3.1.2.3 Insulation Resistance Test

(See 10.5.1). Each insulated conductor in the completed cable shall have an insulation resistance not less than that corresponding to a constant of 20,000 at 15.6 OC.

4.3.1.2.4 Accelerated Water Absorption

(See 10.5.2). The insulation shall meet the following requirements:

Accelerated Water Absorption Properties

(Electrical Method) --

Table 4-3 Accelerated Water Absorption Properties

Discharge-Free Designs

insulation Type

XLPE and EPR Class EPR TRXLPE i is II Class 111

Dielectric Constant after 24 hours, maximum

Water Immersion Temperature, OC I 75 I 75 I ' 90

3.5 I 4.0

Increase in capacitance, maximum, percent 1 to 14 days 7 to 14 days

Stability Factor after 14 days, maximum'

Alternate to Stability Factor - Stability Factor difference, 1 to 14 days, maximum'

3.0 3.5 1.5 1.5

1 .o

0.5

'Only one of these two requirements need be satisñed, not both.

Dieiectric Constant

Dissipation Factor, Percent

4.3.1.2.5 Dielectric Constant and Dissipation Factor

3.5 I 3.5 4.0

0.1 0.5 I .2 1 .-

The insulation shall meet the following maximum requirements for dielectric constant and dissipation factor at room temperature when tested in accordance with ICEA T-27-581/NEMA WC-53.

Table 4 4 Dielectric Constant and Dissipation Factor


Insulation Type II


ICEA S-94-649-2000

Oven Cycle I Total Shrinkback mils (rnm) I Action 1

1 O to 20 (0.51) Pass: Terminate Test

2 O to 40 (1.02) Pass: Terminate Test

> 20 (0.51)

> 40 (1 .O21

RFcord and Continue Cycling Test

Record and Continue Cvcfing

4.3.1.3 Voids, Ambers, Gels, Agglomerates and Contaminants as Applicable

3 I

4.3.1.3.1 Crosslinked Polyethylene insulation (XLPE or TRXLPE)

Pass: Terminate Test i Fail: Terminate Test O to 320 (8.13) > 320 (8.13)

DATE: 07/24/00

(See 9.4.13). The insulation of the completed cable shall be free from:

1) Any void larger than 3 mils (0.076 mm). The number of voids larger than 2 mils (0.051 mm) shall not exceed 30 per cubic inch (1.8 per an’) of insulation.

2) Any contaminant larger than 5 mils (0.127 mm) in its greatest dimension and no more than 15 per cubic inch (0.9 per cm’) between 2 and 5 mils (0.051 and 0.127 mm).

3) Any amber that is larger than 10 mils (0.254 mm) in its greatest dimension.

4.3.1.3.2 Ethylene Propylene Rubber (EPR)


1) Any void larger than 4 mils (0.102 mm).

2) Any contaminant, gel, or agglomerate larger than 10 mils (0.254 mm) in its greatest dimension. A distinction between contaminants, gels, and agglomerates is not required.

4.3.1.4 Shrinkback - Crosslinked Polyethylene Insulation (XLPE or TRXLPE) Only

(See 9.10). The conductor shall not protrude beyond the insulation (total of both ends) by more than the amounts shown in Table 4-5 or 4-6.

Table 4-5 Shrinkback Test Requirements

Cables Having Sealed Strand Conductors andlor a Tape Over the Conductor

19


~ ~~ ~~

KEA S-94-649-2000 DATE: 07/24/00

Tensile Strength, Minimum psi

Elongation at Rupture, Minimum Percent

Table 4-6 Shnnkback Test Requirements

All Cables Not Covered by Table 4-5

550 (3.8)

250

~

I _ _ _ _ ~

Oven Cycle ! Total Shrinkback mils (mm) Action

O to 20 (0.51) > 20 (0.51) but I 60 (1 52)

> 60 (1 52)

O to 40 (1.02)

> 100 (2.54)

> 100 (2.54)

Pass: Terminate Test Continue Cycling Fail: Terminate Test

Pass: Teminare Test

Fail: Terminate Test

1

2 > 40 (1.02) but I 100 (2.54) Continue Cycling

3 o to 100 (2.54) Pass: Terminate Test Fail: Terminate Test

Tensile Strenqth, Minimum Percentaqe of Unaged Value

4.3.2 Insulation For DISCHARGE-RESISTANT Cable Designs Only

75

4.3.2.1 Physical and Aging Requirements


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

175

Table 4-7 Insulation Physical Requirements

Dlscharge-Resistant Designs

Elongation, Maximum Percent

EPR Class IV All Voltage Ratings Physical Requirements

50 I


ICEA S-94-649-2000

Dielectric Constant after 24 hours, maximum

Increase in capacitance, maximum percent 1 to 14 days 7 to 14 days

Stabilitv Factor after 14 davs. maximum'

DATE: 07/24/00

4.0 4.0

7.0 3.5 4.0 1.5

1 .o 1 .o


4.3.2.2.1 Discharge (Corona) Resistance

(See 10.5.6) The insulation shall be verified as corona discharge resistant using a 21 kV 60 Hz voltage applied for 250 hours. No failure nor surface erosion visible with 15 times magnification shall occur. Partial discharge measurements are not required for DISCHARGE-RESISTANT cables.

4.3.2.2.2 Voltage Tests

(See 9.12). Each shipping length of completed cable shall withstand, without failure, the ac test voltages given in Table 4-1 1. The test voltage shall be based on the rated voltage of the cable and the size of the conductor.

Factory dc testing is not required by this specification. However, a dc test may be performed with prior agreement between the manufacturer and the purchaser. Suggested dc test voltages are listed in Appendix F.

For purposes of this Standard, the EIL shall be in accordance with Table 4-10. The minimum impulse withstand value for all discharge-resistant cable designs shall be 800 Vlmil (31.5 kVlrnm).

4.3.2.2.3 Insulation Resistance Test

(See 10.5.1) Each insulated conductor in the completed cable shall have an insulation resistance not less than that corresponding to a constant of 20,000 at 15.6 "C.

4.3.2.2.4 Accelerated Water Absorption

(See 10.5.2) The insulation shall meet the following requirements:

Table 4-8 Accelerated Water Absorption Properties

Discharge-Resistant Designs

For Cables For Cables

or less and 46 kV

Accelerated Water Absorption Properties (Electrical Method at 75 OC)

- ~ - ~ ~~ - 1 - 0.5 Alternate to Stability Factor - Stability Factor II difference, 1 to 14 davs, maximum'

* Only one of these two requirements need to be satisfied. not both.

21


KEA S-94-649-2000

Cables Rated 5-28 kV

Properties

DATE: 07/24/00

For Cables Rated 35 kV & 46 kV

4.3.2.2.5 Dielectric Constant and Dissipation Factor

~

Dielectric Constant 4.0

The insulation shall meet the following maximum requirements for dielecîric constant and dissipation factor at room temperature when tested in accordance with ICEA T-27-581/NEMA WC-53.

4.0

Dissioation Factor, Percent 2.0 I 1.5

4.3.2.3 Voids and Contaminants

5


60

1 ) Any void larger than 4 mils (0.1 02 mm).

15'

25

2) Any contaminant, gel, or agglomerate larger than 10 mils (0.254 mm) in its greatest dimension. A distinction between contaminants, gels, and agglomerates is not required.

110

150 *

Table 4-1 O EIL Values

¡

Cable Rating Il kV

35 200

46 250

*IL kV Il

II 28 I 150 II

'Cable used for qualification test

22


ICEA S-94-649-2000

Rated Circuit Voltage,

Phase-to-Phase Voltagea

2001-5000

5001 -8000

DATE: 07/24/00

insulation Level' (miis) ac Test Voltage, kvd 1 Conductor -

î33 Percent 100 Per- 133 Per- cent In-

Minimum Maximum Minimum Maximum sulation su'ation

sire, 1 O0 Percent ' cent In- (AWG or

kcmil)b

61000' 85 120 110 1 145 18 23

Level Level ,

1001-3000 135 I 170 135 170 28 28

5.1000 110 145 135 170 23 28 1 t I

Table 4-1 1 Conductor Sizes, Insulation Thicknesses and Test Voltages

I 1001-3000

15001-25000 I 1-3000

2-1 O00

1001-3000 awl-1 mo

165 205 I 165 205 35 1 35

245 200 I 305 350 52 6 4 ,

165 205 210 250 35 44

210 250 21 o 250 44 44

450 1 68 . I ô4

25001 -280.00 1-3000 265 310 330 375 1 56

28001 -35000 110-3000 330 375 I 400

Insulation Levei' (mm) ac Test Voltage, kvd Rated Circuit

Conductor

(mmz)b

Voltage, Cue, i O0 Percent 133 Percent ! í00Per- ' 133 Per- Phase-to-Phase cent In- cent In-

sulation Voltage' Minimum Maximum Minimum Maximum sulation Level Level

35001-46000

Table 4-1 1 (Metric) Conductor Sizes, Insulation Thicknesses and Test Voltages

2001-5000 8.37-506.7. 2.16 3.05 I 2.79 I 3.68 18 I 23

5 0 6 . a m o 3.43 4.32 3.43 4.32 I 28 28

35

5001 -8000 13.3-506.7 2.79 3.68 3.43 4.32 1 23 i 5 0 6 . a m o 4.19 I 5.21 4.19 5.21 35

6.35 1 44 44

8001 -1 5000 33.6-506.7 4.19 5.21 I 5.33 6.35

506. & 1 520 5.33 6.35 5.33

15001 -25000 42.4-1520 6.22 7.37 7.75 8.89 52

25001-28000 42.4-1520 6.73 I 7.87 8.38 9.53 I 56 I 69

116

1 28001 -35000 535-1520 8.38 I 9.53 10.2 11.4

1' 3500146000 I 107.2-1520 10.8 12.3 14.0 15.5 I 89

Notes o n Table 4-1 1 : v h e actual operating voltage shall not exceed the rated araiit voltage by more than (a ) 5 percent during mntinuous'operation or (b) 10 percent during emergenaes lasting not more than 15 minutes.

23


DATE: 07124100 ICEA S-94-649-2000

90 limit the maximum voltage stress on the insulation at the conductor to a safe value, the conductor size shall not be l e s than the minimum size shown for e a b rated arcuit voltage category. ‘Selection of the cable insuiation level to be used in a particular installation shall be made on the basis of the applicable phase-twhase voltage and the general system category as outlined below:

100 Percent Level - Cables in this category may be applied where the system is provided with relay proteCöon such that ground faults will be deared as rapidly as possible. but in any case within 1 minute. While these cables are applicable to the great majority of cable installations that: are on grounded systems. they may be used also on other systems for which the application of cable is acceptable provided the above dearing requirements are met in completely deenergking the faulting sedon.

Where additional insulation thickness is desired, it shall be the same as for the 133 percent insulation level.

I33 Percent Level -This insulation level mrfecwnds tû that formerly designated for ungrounded systsms. Cables in this category may be applied in situations where the deanng time requirements of the 100 percent level category cannot be met and yet there IS

adequate assurance that the faulted section will be de-energzed in a time not exceeding 1 hour. Also they may be used when additional insulation strength over the 100 percent level category is desirable.

173 Percent Level - Cables in this category should be applied on systems where the time required to de-energue a grounded section is indefinite. Their use is recommended also for resonant grounded system. Consult the manufacturer for insulation thid<nesses.

d~~ ac voltages are rmc values.

?here may be unusual installations andior operating conditions where mechanical considerations dictate the use of the 133% insulation thicknesses. When such conditions are antiapated, the user should consult with the cable supplier to determine the appropnate insulation thickness.

In mmmon with other electrical equipment, the use of cables is not recommended on systems where the ratio of the zero to positive phase reactana? of the system at the point of cable application lies between -1 and 4 0 since excessively high voltages may be encountered in the case of ground faults.

24


ICEA S-94-649-2000

Diameter Over the Insulation

inches (mm)

o - 1.000 (O - 25.40)

1.001 - 1.500 (25.43 - 38.10)

1.501 - 2.000

DATE: 07124100

Concentric Neutral Indent

mils mm mils mm mils mm

30 0.76 60 1.52 15 0.38

40 1 1.02 75 1.91 I 15 0.38

90 2.29 20 0.51

Minimum Maximum Point Point

1

Part 5 EXTRUDED INSULATION SHIELD

I 55 I 1.40

55 1.40 105

(38.13 - 50.80) I 2.001 and larger

(50.83 and larger) 8

5.1 MATERIAL

2.67 20 i 0.51

The insulation shield shall be an extruded semiconducting material compatible with all cable components with which it is in contact. The extruded shield shall be readily distinguishable from the insulation and plainly identified as semiconducting.

Cables of the DISCHARGE-FREE design shall use a thermosetting material. (See 5.4.1) Cables of the DISCHARGE-RESISTANT design shall use either a thermoplastic or a thermosetting

material. (See 5.4.2)

5.2 THICKNESS AND INDENT REQUIREMENTS

The thickness and concentric neutral indent requirements for the insulation shield are as indicated in the table below. The minimum point thickness does not apply to locations under the concentric neutral indent. For jacketed cable, the indent shall be measured after the application of the jacket.

Table 5-1 Insulation Shield Thickness

~~

//Calculated Minimum Insulation Shield Thickness Maximum

5.3 PROTRUSIONS

(See 9.4.13). The contact surface between the extruded insulation shield and the insulation shall be cylindrical and free from protrusions and irregularities that extend more than 5 mils (0.127 mm) into the insulation and 7 mils (0.180 mm) into the extruded insulation shield. This does not apply to concentric neutral indent.

5.4 INSULATION SHIELD REQUIREMENTS

Insulation shields used in DISCHARGE-FREE cable designs are described in 5.4.1. Insulation shields used in DISCHARGE-RESISTANT cable designs are described in 5.4.2.

25


ICEA 5-94-649-2000


DATE: 07/24/00

Thermoset Material

5.4.1 Insulation Shield for DISCHARGE-FREE Cable Designs Only

5.4.1.1 Removability

(See 9.9). The tension necessary to remove the insulation shield from the insulation at room temperature shall be not less than 3 pounds (13.4 N) and not greater than 24 pounds (107 N). The insulation shield shall be readily removable in the field at temperatures from -10 OC to 40 OC when scored to a depth of 1 mil (0.025 mm) less than the specified minimum point thickness of the insulation shield without tearing or leaving residual conductive material on the insulation surface which is not removable with light rubbing. Sanding should not be required to remove the residual material.

At the option/approval of the purchaser, an insulation shield which is bonded may be supplied. In this case, the tension necessary to remove the insulation shield at room temperature shall be not less than 24 pounds (1 07 N).

5.4.1.2 Voids

(See 9.4.1 3). The extruded insulation shield and insulation interface shall be free of any voids larger than 5 mils (0.127 mm).

5.4.1.3 ' Physical Requirements

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

Table 5-2 Extruded Insulation Shield Requirements


5.4.1.4 Electrical Requirements *

(See 9.8.2). The volume resistivity of the extruded insulation shield shall not exceed 500 ohmmeter at the maximum normal operating temperature and at a temperature of 1 1 O OC.

5.4.1.5 Wafer Boil Test

(See 9.4.1 2). The extruded thermoset insulation shield shall be effectively crosslinked.

5.4.2 Insulation Shield for DISCHARGE-RESISTANT Cable Designs Only

5.4.2.1 Removability

Elongation after air oven test for 168 hours at 121 OC Il OC (for insulations rated 90 OC)

or at 136 OC I 1 OC (for insulations rated 105 OC), minim<m percent

Brittleness temperature not warmer than, OC

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


ICEA S-94-649-2000

Elongation after air oven test at

Brittleness temperature not warmer than, OC

121 OC i 1 OC for Í68 hours, minimum percent

DATE: 07l24100

1 O0 1 O0

-25 -1 o

5.4.2.2 Physical Requirements

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

Table 5-3 Extruded Insulation Shield Requirements

Discharge-Resistant Designs

Physical Requirements Thermoplastic 1 'E:;? I Material


(See 9.8.2). The volume resistivity of the extruded insulation shield shall not exceed 500 ohm-meter at the maximum normal operating temperature and at a temperature of 1 1 O OC.

5.4.2.4 Wafer Boil Test

(See 9.4.12). A thermosetting extruded insulation shield material shall be effectively crosslinked.

27


ICEA S-94-649-2000 DATE: 07/24/00

Pari 6 CONCENTRIC NEUTRAL CONDUCTOR

6.1 MATERIAL

The concentric neutral conductor shall be composed of a serving of either round annealed copper wires or flat annealed copper straps. The wires or straps shall meet the chemical requirements of ASTM B 5 and the resistivity, tensile, and elongation requirements of ASTM B 3 for uncoated neutrals or ASTM B 33 fortin- coated neutrals. The wires or straps shall be applied helically over and in contact with the insulation shield.

6.2 CROSS-SECTIONAL AREA

The cross-sectional area of the concentric neutral conductor shall be as follows:

1) For single-phase system, at least 98 percent of the product of the appropriate number of wires given in Table 6-2 and the appropriate nominal circular mil area tabulated in Table 6-1.

2) For three-phase system, at least 98 percent of the product of the appropriate number of wires given in Table 6-3 and the appropriate nominal circular mil area tabulated in Table 6-1.

3) Other neutral cross-sectional areas based on specific fault-clearing requirements may be supplied with agreement between the manufacturer and the purchaser. ICEA Publication P-45-482 shall be utilized to determine neutral cross-sectional area for specific fault-clearing requirements. See Appendix G for typical reduced neutral constructions.

6.3 LAY LENGTH

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

6.4 CONCENTRIC WIRES

6.4.1 Minimum Sizes

The minimum size wire for an unjacketed cable shall be a No. 14 AWG. The minimum size wire for a jacketed cable shall be a No. 16 AWG.

6.4.2 Contrahelical Wire

9

For unjacketed cables, if agreed upon between the purchaser and manufacturer, one of the wires may be applied over the other neutral wires in the opposite direction, but with the same lay length as the other neutral wires.

6.4.3 Diameter and Area

The nominal diameters and nominal circular mil area of the wires shail be as specified in Table 6-1. The individual wires comprising a given concentric neutral may vary I 5 percent in diameter from the appropriate nominal value, but the total circular mil area of the specified concentric neutral shall be in accordance with 6.2.


ICEA S-94-649-2000

16 50.8

DATE: 07/24/00

1.29 2.58 I

6.5 FLAT STRAPS

14 64.1 ¡ 1.63

The minimum thickness of flat straps shall be 20 mils and the width of the strap shall not be less than three times the strap thickness. The minimum cross-sectional area for a strap shall not be less than that specified for wires in 6.4.1.

4.1 1

6.6OPTIONAL WATER BLOCKING COMPONENTS FOR METALLIC SHIELD

12

10

9

8

With the approval of the purchaser, any component(s) designed as an impediment to longitudinal water penetration may be incorporated in the interstices and/or the interfaces of the metallic shield. If the component is a tape and is applied under the metallic shield, it must be semiconducting and meet the requirements of 5.4. Longitudinal water penetration resistance shall be determined in accordance with ICEA Publication T-34-664 and shall meet a minimum requirement of 5 psig.

80.8 2.05 1 6.53 I 101.9 2.59 10.38

114.4 2.91 13.09

128.5 3.26 16.51

Insulated Conductor Size. AWG or kcmil

1 mi,s Diameter , mm I Nominal Area (kcmil) 1 1 AWG size

Concentric Conductor Minimum Number of Wires i

Copper Aluminum ~ 1 16AWG 14AWG - ... 4 1 O' 6

4 2 16' 10

3 1 20' 13

2 110 26' I 16

~~

72AWG 10AWG 9 AWG

* ... ...

... ... ...

... ... ...

10' I .. ...

410 350 ! ... ... I 22' ! 20' I 16

...

... 13 I ... 1 I 2 0

310 ... 25' ¡ 16 10'

20 410 ... 32' 1, 310 250 ... ... 25' I 16 13'

Alternate anstructions

29


~ ~~

KEA S-94-649-2000 DATE: 07/24/00

Table 6-3 One-third Neutral Concentric Copper Conductor

Alternate consttuctions


- - _ _ ~

ICEA S-94-649-2000

-~ ~


Part 7 JACKETS

Values

DATE: 07i24100

Tensile Strength, Minimum psi íMPaì

7.1 MATERIAL

1700 (1 1.7)

The jacket, when supplied, shall consist of a nonconducting or semiconducting thermoplastic material depending upon installation requirements. The jacket mateflal shall be compatible with all cable components it contacts. A thermosetting jacket may be supplied upon consulting the manufacturer. When tested in accordance with Part 9, the jacket shall meet the applicable requirements. There shall be no water between the insulation shield and the jacket in accordance with 9.15.

Heat Distortion at 100 OC +, 1 OC Maximum Percent

Environmental Stress Crackincf

7.1.1 Low Density and Linear Low Density Polyethylene, Black (LDPULLDPE)

30

No Cracks

This jacket shall consist of a black, low density or linear low density polyethylene compound suitable for exposure to suniight. The jacket shall meet the following requirements. Jacket irregularity inspection test shall be performed in accordance with 7.3 at Level 6 (See Tables 7-10 and 7-1 1).

Table 7-1 Low Density and Linear Low Density Polyethylene, Black (LDPULLDPE)

320 Absorption Coefficient Minimum 1 OOO(absorbance/rneter)

Base Resin Density (Dz3c,g/cm3)~ 0.910 - 0.925

Use condition A with a full strength solution of Igepal CÖ-630 or equivalent, as defined

“in lieu of testing finished cable jackets, a certification by the manufacturer of the in ASTM D 1693.

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

31


DATE: 07/24/00 ICEA S-94-649-2000

7.1.2 . Medium Density Polyethylene, Black (MDPE)

This jacket shall consist of a black, medium density polyethylene compound suitable for exposure to sunlight. The jacket shall meet the following requirements. Jacket irregularity inspection test shall be performed in accordance with 7.3 at Level B (See Tables 7-10 and 7-1 1).


Table 7-2 Medium Density Polyethylene, Black (MDPE)

Values

~~

Elongation, Minimum Percentage of Unaged Value

Heat Distortion at 110 OC f 1 O C

Maximum Percent

Environmental Stress Cracking'

Absorption Coefficient Minimum 1 OOO(absorbance/meter)

Ag i ng Requirements After Air Oven Aging at 100 OC f 1 OC for 48 hours

75

30

No Cracks

320

75 Tensile Strength, Minimum Percentage of Unaaed Value

Base Resin Density (D23c,g/cm')" 0.926 - 0.940

Use condition 6 with a full strength solution of Igepal CO-630 or equivalent, as defined in ASTM D 1693 ** In lieu of testing finished cable jackets. a certification bpthe manufacturer of the

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


DATE: 07124100


ICEA S-94-649-2000

7.1.3 High Density Polyethylene, Black (HDPE)

This jacket shall consist of a black, high density polyethylene compound suitable for exposure to sunlight. The jacket shall meet the following requirements. Jacket irregularity inspection test shall be performed in accordance with 7.3 a t Level 8 (See Tables 7-10 and 7-1 1).

Values

Table 7-3 High Density Polyethylene, Black (HDPE)

Heat Distortion at 110 O C f 1 OC Maximum Percent

Environmental Stress Crackina'

30

No Cracks

Tensile Strength, Minimum psi 1 2500

(1 7.2) i

Absorption Coefficient Minimum 1 OOO(absorbance/meter)

Base Resin Density (Dz'c,g/cm3)*


320

0.941 - 0.965

I 350

Aging Requirements After Air Oven Aging a t 100 *C f 1 "C for 48 hours

Tensile Strength, Minimum Percentage of Unaged Value

Elongation, Minimum Percentaae of Unaaed Value

75

75

* Use conwon 6 with a full srrength solution of Igepal CU-630 or equivalent. as defined in ASTh : 1693. b

polyethylene compound that this requirement has been complied with shall suffice. ** In lieu GI ?sting finished cable jackets. a certification by the manufacturer of the

33


DATE: 07124100

Tensile Strength, Minimum psi (MPa)

ICEA S-94-649-2000

7.1.4 Semiconducting Jacket Type I

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

1200 (8.27)

7.3.

Table 7 4 Semiconducting Jacket Type I

Phvsical Reauirements I Values

Elongation at Rupture, Minimum Percent 1 O0

Aging Requirements After Air Oven Aging at 100 OC f 1 OC for 48 hours


Elongation, Minimum Percentage

Heat Distortion at 90 OC 2 1 OC Maximum Percent

~ l ~ o

25

Radiai Resistivity At 25 OC f 5 OC Maximum ohmmeter

1 O0

Brittleness Temperature OC, not warmer than -1 o


ICEA S-94-649-2000


DATE: 07/24/00

Values

7.1.5 Semiconducting Jacket Type II

This jacket shall consist of a black, thermoplastic, semiconducting compound suitable for exposure to sunlight. The jacket provides more heat and distonion resistance than the Type I semiconducting jacket. The semiconducting jacket shall be clearly identified as being semiconducting. The jacket shall meet the following requirements. Jacket irregularity inspection test shall be performed in accordance with 7.3.

Table 7-5 Semiconducting Jacket Type II

Unaged Requirements

Tensile Strength, Minimum psi 1500 (MPa) (10.3)

150 Elongation at Rupture, Minimum Percent

I

Radial Resistivity At 25 OC f 5 OC Maximum ohm-meter

Brittleness Temperature OC, not warmer than

Aging Requirements After Air Oven Aging at 121 OC 2 1 OC for 168 hours



75

75

1 O0

-1 5

25 Heat Distortion at 121 O C f 1 OC Maximum Percent

I

35


DATE: 07124100


ICEA S-94-649-2000

7.4.6 Polyvinyl Chloride (PVC)

This jacket shall consist of a black, polyvinyl chloride compound suitable for exposure to sunlight. The jacket shall meet the following requirements. Jacket irregularity inspection test shall be performed in accordance with 7.3 at Level B (See Tables 7-10 and 7-11).

Values

Tensile Strength, Minimum psi (MPaì

1 O0 Elongation at Rupture, Minimum Percent

1500 (10.3)

Aging Requirements After Air Oven Aging at 1 O0 OC k 1 OC for 120 hours

Tensile Strength, Minimum Percentage of Unaaed Value 85

Heat Distortion at 121 OC t 1 OC Maximum Percent

Heat Shock at 121 OC t 1 OC

Cold Bend at -35 OC

60 Elongation, Minimum Percentage of Unaged Value

Aging Requirements After Oil Immersion Test at 70 OC f 1 OC for 4 hours

50

No Cracks

No Cracks

b

80 Tensile Strength, Minimum Percentage of Unaged Value

Elongation, Minimum Percentaae of Unaaed Value 60


DATE: 07/24/00


JCEA S-94-649-2000

7.1.7 Chlorinated Polyethylene (CPE)

This jacket shall consist of a black, thermoplastic, chlorinated polyethylene compound suitable for exposure to sunlight. The jacket shall meet the following requirements. Jacket irregularity inspection test shall be performed in accordance with 7.3 at Level A (See Tables 7-10 and 7-1 1).

Values

Table 7-7 Chlorinated Polyethylene (CPE)


Tensile Stress a t 1 O0 percent Elongation, Minimum

psi (MP4

Elongation a t Rupture, Minimum Percent

1400 (9.65)

1 O00 (6.89)

150



Heat Distortion at 121 OC 2 1 OC Maximum Percent

Cold Bend at -35 O C

85 Tensile Strength, Minimum Percentage of Unaged Value

60

60

25

No Cracks

50 Elongation, Minimum Percentage of Unaged Value

37


DATE: 07/24/00


Tensile Stress at 200 percent Elongation, Minimum

psi ( M W


ICEA 5-94-649-2000

7.1.8 Thermoplastic Elastomer (TPE)

This jacket shall consist of a black heavy duty thermoplastic elastomer compound suitable for exposure to sunlight. The jacket shall meet the following requirements. Jacket irregularity inspection test shall be performed in accordance with 7.3 at Level A (See Tables 7-10 and 7-1 1 ).

1800 (12.4)

400 (2.76)

350

Table 7-8 Thermoplastic Elastomer (TPE)



'5

75

Heat Distortion at 121 OC I 1 OC Maximum Percent I 25


DATE: 07124100


ICEA S-94-649-2000

7.1.9 Polypropylene, Black (PP)

This jacket shall consist of a black thermoplastic polypropylene compound suitable for exposure to sunlight. The jacket shall meet the following requirements. Jacket irregularity inspection test shall be performed in accordance with 7.3 at Level B (See Tables 7-10 and 7-1 1).

Table 7-9 Polypropylene, Black (PP)

Values

Tensile Strength, Minimum psi ( M W

E!ongation at Rupture, Minimum Percent

2500 (1 7.2)

350

I l

Tensile Strength, Minimum Percentage of

Elongation, Minimum

Unaged Value

Percentage of Unaged Value

Heat Distortion at 136 OC fi O C

Maximum Percent

Environmental Stress Cracking*

Absorption Coefficient Il Minimum 1 OOO(abcorbancelrneter)

75

75

15

No Cracks

320

* Use condition 6 with a full strength solution of Igepal CO430 or equivalent. as defined in ASTM D 1693.

39


ICEA S-94-649-2000 DATE: 07/24/00

7.2JACKET TYPES

7.2.1 Extruded-To-Fill Jacket

The jacket material shall cover the concentric neutral conductor and fill the spaces between the wires or straps. The jacket material shall be in contact with the insulation shield, but shall strip freely. Materials suitable for use as an extruded-to-fill jacket are specified in 7.1 .i, 7.1 -4, 7.1.5, 7.1.7, 7.1.8 and 7.1.9.

When measured over the wires or straps, the jacket thickness shall be as specified in Table 7-1 O.

7.2.2 Overlaying Jacket

The jacket material shall be applied over a separator tape which is compatible with the other components of the cable. If a nonmetallic tape is applied over the concentric neutral conductor and the jacket is semiconducting, then the tape shall be semiconducting and meet the requirements of 3.6.3. When the jacket is insulating, the tape shall be either nonconducting or semiconducting. Materials suitable for use as an overlaying jacket are specified in 7.1.1 through 7.1.9.

When measured over the wires or straps, the jacket thickness shall be as specified in Table 7-1 1.

7.3 JACKET IRREGULARITY INSPECTION

7.3.1 Nonconducting Jackets

A nonconducting jacket over the concentric neutral conductor shall withstand an alternating current spark test voltage. The test voltage for a given thickness and type of jacket shall not be less than indicated in Tables 7-1 O and 7-1 1. The voltage level for a jacket material shall be as specified in 7.1.1 through 7.1.9. The voltage shall be applied between an electrode at the outside surface of the jacket and the concentric neutral conductor. The neutral conductor shall be connected to ground during the test. The spark test shall be conducted in accordance with ICEA T-27-581/NEMA WC-53.

7.3.2 Semiconducting Jackets

The method of inspection for semiconducting jackets is visual.


K E A S-94-649-2000

Calculated Minimum Diameter Over the Concentric Neutral

Inches (mm)

DATE: 07/24/00

Extruded-To-Fill Jacket Thickness

Minimum Point Maximum Point

mils mm mils mm 1 LeveiA

AC Spark Test Voltage for Insulating Jackets

kV

Level 6

Table 7-10 Extruded-To-Fill Jacket Thickness and Test Voltage

O - 1.500 (O - 38.10)

1 SO1 and larger (38.13 and larger)

45 1 1.14 1 80 2.03 2.0 4.5 j 1

70 1.78 120 3.05 3 .O 7.0 -

Calculated Minimum Diameter Over the Concentric Neutral

Inches (mm)

O - 0.700 (O - 17.78)

0.701 - 1.500 (17.81 - 38.10)

1.501 - 2.500 (38.13 - 63.50)

Table 7-1 1 Overlaying Jacket Thickness and Test Voltage

Overlaying Jacket Thickness

Minimum Point Maximum Point

mils rnm mils mm I levei^ Level B

AC Spark Test Voltage for

insulating Jackets

kV

55 1 1.40 1 90 2.29 2.5 5.5

70 I 1.78 1 o5 2.67 3.0 7.0

100 2.54 150 3.81 4.5 10.0

1 125 1 3.18 180 2.501 and larger (63.53 and larger)

41

4.57 5.5 1 12.5


ICE A S -94-649-2000 DATE: 07/24/00

Part 8 CABLE ASSEMBLY AND IDENTIFICATION

8.1 MULTIPLEX CABLE ASSEMBLIES

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

8.2 CABLE IDENTIFICATION

8.2.1 Jacketed Cable

The outer jacket surface of the cable shall be suitably marked throughout its length by surface and/or indent print, at regular intervals with no more than 6 inches (152 mm) of unmarked space between cable identification, with the following information:

Manufacturer's Identification or trade name Size of Conductor Conductor Material Type of Insulation Voltage Rating Nominal Insulation Thickness (See Table 8-1) Power Cable Symbol (Lightning Bolt) per the NESC (Rule 350) Year of Manufacture Semiconducting Jacket (If Applicable)

8.2.1 .I Optional Cable identification

Upon request of the purchaser and with the manufacturer's agreement, the cable jacket may incorporate longitudinal red stripe (Three stripes) identification. Color retention cannot be guaranteed for the life of the cable. .The three stripes shall be extruded into the jacket. The stripe material shall be durable and compatible with the jacket material. The extruded stripe depth into the jacket shall not be greater than 25 mils (0.635 mm). The total width of all the stripes shall not exceed 50 percent of the jacket outer circumference.


ICEA 5-94-649-2000

Vo I tage, Size, 100 Percent

Level P hase-top hase AWG or kcmil

DATE: 07/24/00

133 Percent Level

8.2.2 Unjacketed Cable

In addition to marking the extruded insulation shield semiconducting, the extruded insulation shield outer surface shall be suitably marked throughout the cable length by surface print only, at regular intervals with no more than 6 inches (152 mm) of unmarked space between cable identification, with the following information:

1001-3000 (507-1520)

6-1000 (13.3-507)

1001-3000 (507-1520) 5001 -8000

2-1000 (33.6-507)

1001-3000 (507-1 520) 8001 -1 5000

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

140 I 140

115 I 140

175 ! 175

175 220

220 j 220

8.2.3 Optional Center Strand Identification

25001 -28000 I 1-3000 (42.4-1 520)

28001-35000 I 110-3000 (53.5-1520)

When center strand identification is requested by the purchaser, the center strand of each conductor shall be indented with the manufacturer's name and year of manufacture. This information is to be marked at regular intervals with no more than 12 inches (305 mm) between repetitions.

280 I 345

345 320

8.2.4 Optional Sequential Length Marking

When sequential length marking is requested by the purchaser, the information is to be marked at regular intervals of 2 feet (610 mm).

Table 8-1 Nominal Insulation Thickness

Rated Circuit 1 Conductor 1 Nominal Insulation Thickness (mils) II

1 8-1000 (8.37-507) I 90 I 115 II

1 5001 -25000 1 1-3000 (42.4-1 520) ¡ 260 i 320 II

I 1 - I ~ II 35001 -46000 I 4/0-3000 (1 07-1520) I 445 I 580 Il


~~

ICEA S-94-649-2000 DATE: 07/24/00

Part 9 TESTING AND TEST METHODS

9.1 TESTING

All cables shall be tested at the factory to detemine their compliance with the requirements given in Parts 2, 3, 4, 5, 6, and 7. When there is a conflict between the test methods given in Part 9 and publications of other organizations to which reference is made, the requirements given in Part 9 shall apply.

The tests in Part 0 may not be applicable to all materials or cables. To determine which tests are to Se made, refer to the parts in this publication that set forth the requirements to be met by the particular materiai or cable.

9.2SAMPLING FREQUENCY

Sampling frequency shall be as indicated in Table 9-5 "Summary of Production Tests and Sampling Frequency Requirements".

9.3 CONDUCTOR TEST METHODS

9.3.1 Method for DC Resistance Determination

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

Except as noted above, this test shall be performed in accordance with ICEA T-27-581/NEMA WC-53.

9.3.2 CrossSectional Area Determination

Cross-Sectional area shall be determined in accordance with ICE4 T-27-581/NEMA WC-53.

9.3.3 Diameter Detemination

Diameter shall be determined in accordance with ICEA T-27-581/NEMA WC-53.

9.4TEST SAMPLES AND SPECiMENS FOR PHYSICAL AND AGING TESTS

9.4.1 General

Physical and aging tests shall be those required by Parts 3, 4, 5, and 7

9.4.2 Measurement of Thickness

The measurement of thickness for components having no minimum removability tension requirements shall be made with either a micrometer or an optical measuring device. For all other extruded components, the measurement of thickness shall be made only with an optical measuring device. The micrometer and optical measuring device shall be capable of making measurements accurate to at least 0.001 inch (0.025 mm).


KEA S-94-649-2000 DATE: O7124100

9.4.2.1 Micrometer Measurements

When a micrometer measuring device is used, the component shall be removed and the minimum and maximum thickness determined.

9.4.2.2 Optical Measuring Device Measurements

When an optical measuring device is used, the maximum and minimum thickness shall be determined from a specimen cut perpendicular to the axis of the sample so as to expose the full cross-section.

9.4.3 Number of Test Specimens

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

Table 9-1 Test Specimens for Physical and Aging Tests

Total Number of Test Specimens

For determination of unaged properties

Tensile strength and ultimate elongation

Permanent set

For accelerated aging tests

For oil immersion

Heat shock

Heat distortion

Cold bend

Strippinci

3t

3t

3t

3t

1

3t

1

1

tone test speamen out of three shall be tested and the other two speamens h.ld in reserve, except that when only one sample IS

selected. then all three test speamens shall be tested and the average of ttie results reponed.

9.4.4 Size of Specimens

The test specimens shall be prepared using either ASTM D 412 Die 6, E, C or D. In the case of wire and cable smaller than size 6 AWG having an insulation thickness of 90 mils (2.29

mm) or less, the test specimen shall be permitted to be the entire section of the insulation. When the full cross-section is used, the specimens shall not be cut longitudinally. In the case of wire and cable size 6 AWG and larger, or in the case of wire and cable smaller than size 6 AWG having an insulation thickness greatetthan 90 mils (2.29 mm), specimens rectangular in section with a cross-section not greater than 0.025 square inch (16 mm’) shall be cut from the insulation. In extreme cases, it may benecessary to use a segmental specimen.

45


ICEA S-94-649-2000 DATE: 07124100

Specimens for test on jacket compounds shall be taken from the completed cable and cut parallel to the axis of the cable. The test specimen shall be a segment cut with a sharp knife or a shaped specimen cui out with a die and shall have a cross-sectional area not greater than 0.025 square inch (16 mm2) after irregularities, corrugations, and wires have been removed.

9.4.5 Preparation of Specimens of insulation and Jacket

The test specimen shall have no surface incisions and shall be as free as possible from other imperfections. Where necessary, surface irregularities such as corrugations due to stranding shall be removed so that the test specimen will be smooth and of uniform thickness. If a jacket specimen passes the minimum requirement with irregularities, then their removal is not required.

9.4.6 Specimen for Aging Test

Specimens shall not be heated, immersed in water, nor subjected to any mechanical or chemical treatment not specifically described in this Standard.

9.4.7 ’ Calculation of Area of Test Specimens

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

9.4.7.2 Where a slice cut from the insulation by a knife held tangent to the wire is used and when the cross- section of the slice is a segment of a circle, the area shall be calculated as that of the segment of a circle whose diameter is that of the insulation. The height of the segment is the wall of insulation on the side from which the slice is taken.

When the cross-section of the slice is not a segment of a circle, the area shall be calculated from a direct measurement of the volume or from the specific gravity and the weight of a known length of the specimen having a uniform cross-section.

The values may be obtained from a table giving the areas of segments of a unit circle for the ratio of the height of the segment to the diameter of the circle.

9.4.7.3 When the conductor is large and the insulation thin and when a portion of a sector of a circle has to be taken, the area shall be calculated as the thickness times the width.

This applies either to a straight test piece or to one stamped out with a die and assumes that corrugations have been removed.

9.4.7.4 When the conductor is large and the insulation thick an! when a portion of a sector of a circle has to be taken, the area shall be calculated as the proportional part of the area of the total cross-section.

9.4.7.5 The dimensions of specimens to be aged shall be determined before the aging test.

9.4.8 Unaged Test Procedures

9.4.8.1 Test Temperature

Physical tests shall be made at room temperature. The test specimens shall be kept at room temperature for not less than 30 minutes prior to the test.

-


ICEA S-94-649-2000 DATE: O7124100

9.4.8.2 Type of Testing Machine

The testing machine shall be in accordance with ASTM D 412.

9.4.8.3 Tensile Strength Test

The tensile strength test shall be made with specimens prepared in accordance with 9.4.3 and 9.4.4. The length of all of the specimens for the test shall be equal. Gauge marks shall be 2 inches (50.8 mm) apart when using ASTM B or E Die size and 1 inch (25.4 mm) apart when using ASTM C or D Die size except that 1 inch (25.4 mm) gauge marks shall be used for polyethylene regardless of the die size. Specimens shall be placed in the jaws of the testing machine with a maximum distance between jaws of 4 inches (101.6 mm) except 2.5 inches (63.5 mm) for polyethylene. The specimen shall be stretched at the rate of 20 inches (508 mm) per minute jaw speed until it breaks.

The tensile and elongation determinations for compounds for which the compound manufacturer certifies that the base resin content is more than 50 percent by weight of high density polyethylene (having a density of 0.926 g/cm3 or greater), or total base polyethylene resin content (having a density of 0.926 g/cm’ or greater), shall be permitted to be tested at a jaw separation rate of 2 inches (51 mm) per minute as an alternate to 20 inches (508 mm) per minute.

Specimens shall break between the gauge marks to be a valid test. The tensile strength shall be calculated based on the area of the unstretched specimen. Specimen length, gauge mark distance, and jaw speed shalt8e recorded with the results.

9.4.8.4 Elongation Test

Elongation at rupture shall be determined simultaneously with the test for tensile strength and on the same specimen.

The elongation shall be taken as the distance between gauge marks at rupture less the original gauge length of the test specimen. The percentage of elongation at rupture is the elongation in inches divided by the original gauge length and multiplied by 100. Specimen length, gauge mark distance, and jaw speed shall be reported with results.

9.4.9 Aging Tests

9.4.9.1 Aging Test Specimens

Test specimens of similar size and shape shall be prepared from each sample selected, three for the determination of the initial or unaged properties, and three for each aging test required for the insulation or jacket being tested. Simultaneous aging of different compounds should be avoided. One specimen of each three shall be tested and the other two held as spares except that, where only one sample is selected, all three specimens snail be tested and the average of the results repoded.

In the case of wire and cable 6 AWG and larger or with an insulation thickness of 90 mils (2.29 mm) or greater, samples shall be cut from the insulation with a cross-section not greater than 0.025 square inch (16 mm2).

Die-cut specimens shall be smoothed before being subjected to the accelerated aging tests wherever the thickness of the specimen will be 90 mils (2.29 mm) or greater before smoothing.

The test specimens shall be suspended vertically in such a manner that they are not in contact with each other or with the side of the oven.

The aged specimens shall have a rest period of not less than 16 hours nor more than 96 hours between the completion of the aging tests and the determination of physical properties. Physical tests on both the aged and unaged specimens shall be.maae at approximately the same time.

47


ICEA S-94-649-2000 DATE: O7124100

9.4.9.2 Air Oven Test

The test specimens shall be heated at the required temperature for the specified period in an oven having forced circulation of fresh air. The oven temperature shall be controlled to i 1 OC.

9.4.9.3 Oil Immersion Test for Polyvinyl Chloride Jacket

The test specimens shall be immersed in ASTM No. 2 or IRM 902 oil, described in ASTM D 471, at 70 OC 2 1 OC for 4 hours. At the end of this time, the specimens shall be removed from the oil, blotted to remove excess oil, and allowed to rest at room temperature for a period of 16 to 96 hours. The tensile strength and elongation of the specimens snail then be aerermined in accordance with 9.4.8 at the same time that the original properties are determined.

9.4.1 O Hot Creep Test

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

9.4.1 1 Solvent Extraction

The solvent extraction shall be determined in accordance with ASTM D 2765.

9.4.12 Wafer Boil Test for Conductor and Insulation Shields

Any outer covering and the conductor shall be removed. A representative cross section containing the extruded conductor shield and insulation shield, shall be cut from the cable. The resulting wafer shall be at least 25 mils (0.64 mm) thick. The wafer may be further separated into concentric rings by careful separation of the shield from the insulation. This may include the use of a punch to separate the conductor shield or insulation shield from most of the insulation.

The resulting wafer@) or rings shall then be immersed in boiling decahydronaphthalene with 1 percent by weight Antioxidant 2246 (or other reagents specified in ASTM D 1,765, such as xylene) for 5 hours using the equipment specified in ASTM D 2765. (This solution may be reused for subsequent tests provided that it works as effectively as a fresh solution). The wafer(s) shall then be removed from the solvent and examined for shield/insulation interface continuity with a minimum 15-power magnification.

Total or partial separation of the semiconducting shields from the insulation is permissible. Partial loss of the shields is also permissible provided each shield is a continuous ring. If the conductor shield dissolves or cracks such that it does not maintain a continuous ring, the cable lot shall be rejected. If the insulation shield dissolves or cracks such that it does not maintain a continuous ring, the cable lot shall either be rejected by the manufacturer or a sample of insulation shield from the Sam) lot shall be subjected to the requirements of 9.4.12.7 as a referee test.

9.4.12.1 Insulation Shield Hot Creep Properties

Hot creep and set properties shall be determined at 150 OC 2 2 OC in accordance with ICEA T-28-562 with the sample removed from the cable core. The degree of cross-linking shall be adequate to limit elongation and set to the values in Table 9-2.


ICEA S-94-649-2000

Maximum set

Table 9-2 Insulation Shield Hot Creep Requirements

5%

DATE: 07/24/00

Physical Requirements I Shield Extruded

9.4.1 3 Amber, Agglomerate, Gel, Contaminant, Protrusion, Indent, Irregularity and Void Test

9.4.13.1 Sample Preparation

Samples snall be prepared by cutting a suitable length of cable helically or in some other convenient manner to produce 20 consecutive thin wafers consisting of the conductor shield, insulation and insulation shield. Wafers shall be approximately 25 mils (0.64 mm) thick. The cutting blade shall be sharp and shall produce wafers with uniform thickness and with very smooth surfaces. The sample shall be kept clean and shall be handled carefully to prevent surface damage and contamination.

9.4.1 3.2 Examination

The wafers shall be examined with 15 power magnification for voids, contaminants, gels, agglomerates, and ambers, as applicable, in the insulation. They shall also be examined for voids and protrusions between the insulation and the conductor and insulation shields and conductor shield irregularities. Unfilled insulations shall be examined using transmitted light. An opiicai coupling agent such as mineral oil, glycerin or silicone oil shall be used to enhance the observation of imperfections within the wafers. For mineral-filled cross-linked polyethylene insulation, EPR, and extruded shields, a reflected light method shall be used. For void count, as applicable, the volume of the insulation examined shall be calculated using any convenient technique. The results of this examination shall be recorded as pass or fail in the production test report.

9.4.1 3.3 Resampling for Amber, Agglomerate, Gei, Contaminant, Protrusion, Irregularity and Void Test

If after examination according to 9.4.13.2, the size andlor number (as applicable) of voids, contaminants, agglomerates, gels, ambers, irregularities or protrusions exceeds thespecified limits, the lot shall be divided into shipping lengths. One sample shall be taken from the beginning and end of each shipping length. For the shipping length to pass, both samples shall meet the requirements of this section. If either of the two samples from the shipping length fails, the shipping length shall be rejected.

9.4.1 3.4Protrusion, Indentation and Irregularity Measurement Procedure

To measure the size of protrusions, indentations and conductor shield irregularities in wafers examined in 9.4.13.2, the wafers shall be viewed in an optical compararor or similar device which displays the wafer so that a straight edge can be used to facilitate the measurement. Protrusion and indentations shall be measured as shown in Figure 9-1. Conductor shield irregularities shall be measured as shown in Figure 9-2. This procedure is used on cable wafers with the conductor, jacket and metallic shield removed.


ICEA S-94-649-2000 DATE: 07/24/00

Figure 9-í Procedure to Measure Protrusions and Indentations

Protrusion of ~ insulation

Con centric Neutra 1 -0

Insulation Shield

Protrusion of shield into insulation

Figure 9-2 Procedure to Measure irregularities

/- Convolutions

Insulation Shield

9.4.14 Physical Tests for Semiconducting Material Intended for Extrusion

9.4.14.1 Test Sample

One test sample shall be molded from each lot of semiconducting material intended for extrusion on the cable.

9.4.1 4.2Test Specimens

For each test, three test specimens, each approximately 6 inches (152 mm) long and not greater than 0.025 square inch (16 mm') in cross-section, shall be cut out of the test sample with a die. All three test specimens shall be tested and the results averaged.


ICEA S-94-649-2000 DATE: 07/24/00

9.4.14.3 Elongation

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

9.4.15 Retests for Physical and Aging Properties and Thickness

If any test specimen fails to meet the requirements of any test, either before or after aging, that test shall be repeated on two additional specimens taken from the same sample. Failure of either of the additional specimens shall indicate failure of the sample to conform to this Standard.

If the thickness of the insulation or of the jacket of any reel is found to be less than the specified value. that reel shall be considered as not conforming to this Standard, and a thickness measurement on each of the remaining reels shall be made.

When ten or more samples are selected from any single lot, all reels shall be considered as not conforming to this Standard if more than 10 percent of the samples fail to meet the requirements for physical and aging properiies and thickness. If 10 percent or less fail, each reel shall be tested and shall be judged upon the results of such individual tests. Where the number of samples selected in any single lot is less than ten, all reels shall be considered as not conforming to this Standard if more than 20 percent of the samples fail. If 20 percent or less fail, each reel, or length shall be tested and shall be judged upon the results of such individual tests.

9.5 DIMENSIONAL MEASUREMENTS OF THE METALLIC SHIELD

Metallic shielding wire or strap shall be removed from no less than 6 inches (152 mm) of the insulated conductor. Measurements shall be made with a micrometer or other suitable instrument readable to at least 0.0001 inch (0.002 mm).

Round wires shall be measured at each end of the sample and near the middle of the sample. The average of the three measurements shall be taken as the diameter.

Flat straps shall be measured for width and thickness at each end of the sample and near the middle of the sample. The average of the three measurements for each dimension shall be taken as the width and thickness.

9.6 DIAMETER MEASUREMENT OF INSULATION AND INSULATION SHIELD

Measurement of the diameter over the insulation and the insulation shield shall be made with a diameter tape accurate to 0.01 inches (0.25 mm).

When there are questions regarding compliance to this Standard, measurements shall be made with an opticai measuring device or with calipers with a resolution of 0.0005 inch (0.013 mm) and accurate to 0.001 inch (0.025 mm). At any given cross-section, the maximum diameter, minimum diameter, and two additional diameters which bisect the two angles formed by the maximum and mmimum diameters shall be measured. The diameter for the cross-section shall be the average of the four values. This average diameter value shall be used to determine if the cable meets the minimum and maximum limits given in Appendix C. All diameter measurements shall be made on cable samples that contain the conductor.

9.7TESTS FOR JACKETS

9.7.1 Heat Shock

Samples of polyvinyl chloride jacketed cable shall be wound tightly around a mandrel having a diameter in accordance with Table 9-3, held firmiy in place, and subjected to a temperature of 121 OC 2 1 OC for 1 hour. At the end of the test period, the sample shall be examined without magnification.

51


ICEA S-94-649-2000

(D'- d z ) p= 100L

DATE: O7124100

Where: p = Volume resistivity in ohm-meters. R = Measured resistance in ohms. D = Diameter over the conducior stress control layer in inches. d = Diameter over the conductor in inches. L = Distance between potential electrodes in inches.

9.8.2 Insulation Shield

' Four annular-ring electrodes shall be applied to the surface of the insulation shield layer. The two potential electrodes shall be at least 2 inches (50.8 mm) apart. A current electrode shall be placed at least 1 inch (25.4 mm) beyond each potential electrode. When a high degree of accuracy is not required, this test may be made with only two electrodes spaced at least 2 inches (50.8 mm) apart.

The power of the test circuit shall not exceed 100 milliwatts. The test shall be made at the specified temperature with either ac or dc voltage.

The volume resistivity shall be calculated as fallows:

2 R ( D 2 - d 2 ) p= IOOL

Where: p = Volume resistivity in ohm-meters. R = Measured resistance in ohms. D = Diameter over the insulation shield layer in inches. d = Diameter over the insulation in inches. L = Distance between potential electrodes in inches.

9. 3 Semiconducting Jacket Radial Resistivity Test I

This procedure is designed for testing short samples of cable hating semiconducting jackets in contact with concentric wire neutrals.

The resistance of the jacket is obtained from measuring the voltage drop across the sample at room temperature. This is created by passing a constant dc or 60 Hz ac current through the sample in a radial direction. The apparent resistivity of the jacket is calculated from the electrical measurement and geometry of the cable.

9.8.3.1 Sample Preparation

A sample of cable at least 6 inches (152 mm) long will be prepared as shown in Figure 9-3. The concentric wires form one measuring electrode and a 2-inch (50 mm) band of conducting paint covering the surface of the jacket provides the second measuring electrode. Two separate bands of conducting paint 112 incn (13 rnm) wide and covering the suriace of the jacket form the guard electrodes. The bands are separated approximately 118 inch (3.2 mm) from the measuring electrode.


KEA S-94-649-2000 DATE: 07/24/00

G Semi- \ t

Conducting Jacket

G t ,-- Oedmde

- I I /

C on œnt ric Neu trai

Figure 9-3 Sample preparation for radial resistivity measurement

of semiconducting jackets

Legend: E, - Measuring electrode, conducting paint on the surface of the jacket

E2 - Measuring electrode, concentric neutral wires tied together

G - Guard electrode, conducting paint on the surface of the jacket

The sample shall be tested in air at room temperature.

9.8.3.2 Test Equipment Setup

The equipment needed to perform the test consists of two high input impedance (>1 megohm) voltmeters, an ammeter, an adjustable resistor and an adjustable voltage dc or 60 Hz ac power supply. The measuring circuit is connected as shown in Figure 94.

Adjustable resistor R, is used to control the potential of the guard electrodes to the same value as E,. This is done to prevent surface current from affecting the measurement. As it is adjusted, the measured voltage Vi may go through a minimum point. The voltage V2 and current measurements shall be made with R, adjusted such that V, is as close to zero as possible.


IC €A S -94-649-200 O DATE: 07/24/00

Current density through the sample should be limited to lmAlcm2. Higher current density may cause inconsistency in the measurements due to heat generated in the semiconducting material.

! l l l I I

i i Return I I

r n

Volt Meters

Ammeter

Guard

Figure 9-4 Circuit for Radial Resistivity Measurement

of Semi-Conducting Jackets

Legend: E,, E2 and G are the same notations used in Figure 9-3.

9.8.3.3 Calculation

Calculate the resistance R of the cable jacket from the measurements of voltage V2 and current obtained using the circuit in Figure 9-4 (R = V2/1). Using the value R and the appropriate dimensions of the cable sample, caiculate the apparent resistivity as follows:

Where:

pv = apparent resistivity in ohm-meters R = calculated resistance in ohms L = electrode length in meters D = diameter over the semiconducting jacket in mm d = pitch diameter* of the concentric wires in mm

The pitch diameter d is measured from center to center of two concentric wires which are diametrically opposite from each other.

55


DATE: 07/24/00 ICEA S-94-649-2000

9.9 ADHESION (INSULATION SHIELD REMOVABILITY) TEST

Adhesion test shall be performed in accordance with ICEA T-27-5811NEMA WC-53 (Adhesion).

9.10 SHRINKBACK TEST PROCEDURE

9.10.1 Sample Preparation

Five samples, each 1.5 feet (0.45 m) are required for the test. A length of the specimen cable 17.5 feet (5.25 m) long is to be laid out and straigntened. The sample is to be marked at a point 5.0 feet (1.5 m) from one end and then marked at 1.5 foot (0.45 rnj intervals for a distance of 7.5 feet (2.25 m). The cable is to be cut using a fine tooth saw at the 1.5 foot (0.45 m) intervals marked on the sample. The two 5.0 foot (1.5 m) end pieces from the original cable length are to be discarded.

9.10.2 Test Procedure

The five 1.5 foot (0.45 m) long cable samples shall be placed in a forced air convection oven at a temperature of 50 OC 11 OC for a period of 2 hours. After the 2 hour period, the samples shall be removed from the oven and allowed to cool for 2 hours at room temperature. The heating and cooling cycle shall be performed three times, if required.

9.10.2.1At the end of each cooling period, the samples shall be measured for shrinkback using a micrometer, or preferably an optical measuring device. The selected measuring device shall have a minimum resolution of 0.001 inch (0.025 mm).

9.10.2.20ne reading is to be made from each end of each sample between the end of the conductor and the edge of the conductor shield interface at the point of circumference of the conductor where shrinkback is maximum.

9.1 0.3 PasslFail Criteria and Procedure

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

9.1 1 RETESTS ON SAMPLES

Except for physical and aging properties and thickness tests See 9.4.15

s

Except for Amber, Agglomerate, Gel, Contaminant, Protrusion, Indent, Irregularity and Void Test See 9.4.1 3.3

9.11.1 If all of the samples pass the applicable tests described in 9.5 through 9.10 and 9.14, the lot of cable that they represent shall be considered as meeting the requirements of this Standard.

9.1 1.2 If any sample fails to pass these tests, the length of cable from which the sample was taken shall be considered as not meeting the requirements of this Standard and another sample shall be taken from each of the two other lengths of the cable in the lot of cable under test. If either of the second samples fails io pass the test, the lot of cable shall be considered as not meeting the requirements of this Standard. If both such second samples pass the test, the lot of cable (except the length represented by the first sample), shall be considered as meeting the requirements of this Standard.


ICE4 S-94-649-2000 DATE: O7124100

9.1 1.3 Failure of any sample shall not preclude resampling and retesting the length of cable from whicn the original sample was taken.

9.12 VOLTAGE TESTS

9.12.1 General

These tests consist of voltage tests on each shipping length of cable. The voltage shall be applied between the conductor and the metallic shield with the metallic shield grounded. The rate of increase from the initially applied voltage to the specified test voltage shall be approximately uniform and shall be not more than 1 O0 percent in 1 O seconds nor less than 1 O0 percent in 60 seconds.

9.12.2 AC Voltage Test

This test shall be made with an alternating potential from a transformer and generator of ample capacity but in no case less than 5 kVA. The frequency of the test voltage shall be nominally between 25 and 60 Hz and shall have a wave snape approximating a sine wave as dosely as possible.

The initially applied ac test voltage shall be not greater than the rated ac voltage of the cable under test. The duration of the ac voltage test shall be 5 minutes.

9.1 3 PARTIAL-DISCHARGE TEST PROCEDURE

Partial-discharge test shall be performed in accordance with ICEA Publication T-24-380. The manufacturer shall wait a minimum of 7 days after the insulation extrusion process before the tests are performed. The 7 day waiting period may be reduced by mutual agreement between the purchaser and manufacturer when effective de-gassing procedures are used.

9.14 METHOD FOR DETERMINING DIELECTRIC CONSTANT AND DIELECTRIC STRENGTH OF EXTRUDED NONCONDUCTING POLYMERIC STRESS CONTROL LAYERS I

l

Determination of dielectric constant and dielectric strength shall be performed in accordance with ICEA T-27-58 1lNEMA WC-53.

9.15 MOISTUF 2 CONTENT

Each end of each shipping length shall be examined for moisture under the jacket (if the cable is jacketed) and for moisture in the conductor (if cable does not have a sealanr and is stranded).

9.15.1 Moisture Under the Jacket

If the cable is jacketed, 6 inches (152 mm) of the jacket shall be removed and the area under the jacket shall be visually examined for the presence of moisture. If water is present, or there is an indication that it was in contact with moisture, effective steps shall be taken to assure that the moisture is removed or that the length of cable containing moisture under the jacket is discarded.

9.1 5.2 Moisture in the Conductor

If the cable has an unsealed, stranded conductor, 6 inches (1 52 mm) of the conductor shall be exposed on each end. The strands shall be individually separated and visually examined. If water is present, the conductor shall be subjected to 9.1 5.4.

.57


ICEA C-94-649-2000 DATE: 07/24/00

9.1 5.3 Water Expulsion Procedure

A suitable method of expelling water from the strands shall be used until the cable passes the Presence of Water Test. As soon as possible after the procedure, both ends of the cable shall be sealed to prevent the ingress of water during shipment and storage.

9.15.4 Presence of Water Test

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

9.15.4.1 Each length of cable to be tested shall be sealed at one end OVE- the insulation shield using a rubber cap filled with anhydrous calcium sulphate granules. The rubber cap shall be fitted with a vaive.

9.15.4.2Dry nitrogen gas or dry air shall be applied at the other end until the pressure is 15 psi (100 kPa) gauge. The valve on the rubber cap shall then be opened sufficiently to hear a flow of gas.

9.15.4.3After 15 minutes, a check of the change of color of the granules in the rubber cap shall be made.

9.15.4.4If the color has not completely changed to pink after 15 minutes, it is an indication that a tolerable amount of moisture is present in the strands. In the case of complete change in color of all granules, the water shall be expelled from the conductor per 9.1 5.3.

9.15.4.5This procedure shall be repeated after placing new granules in the cap.


ICEA S-94-649-2000

9.16 PRODUCTION TEST SAMPLING PLANS

STANDARD REFERENCE TEST

DATE: O7124100

TEST METHOD MINIMUM REFERENCE FREQUENCY

dc Resistance

Diameter

Part 2 9.3.1 and ICEA T-27-581

Part 2 ICEA T-27-581

Temper

Elongation After Aging

Volume Ressüvity

Thiciwess

Part 2

Part 3 1 9.4.14 Plan H

Part 3 9.8.1 Plan H

Pari 3 9.4.2 Plan'E .

ASTM

Voids, Protrusions and Irregularities

Pian A I

Part 3 9.4.13 Plan A

Manufadurer certification that required values are met

Wafer Boil I part3 9.4.12 I Pian B

1 Part3 Spark Test (Nonanduaing Layer Only)

ICEA T-27-581 100%

1 Part4 Unaged and Aged Tensile and Elongation

I I i Insulation

9.4.8 and 9.4.9 I Pian c

Hot Creep I Pian Part 4 ICEA 1-28-562

Voids and Contaminants 'I Pian A I

Part 4 9.4.13

ll Diameter 1 AppendixC I 9.6 I Pian A

Shnnkback Test (XLPWRXLPE Only) I Part 4

Thickness Part 4

9 10 I Pian c

9.4 2 e Plan E

59

Elongation After Aging

Volume Resistivity

Thickness

Indent (Under Concentnc Neutrals)

Voids and Prohsions

Stnpping Tension

Wafer Boil

Diameter

Part 5 9 4 14 Plan H

Part 5 9 8 2 Plan H

Part 5 9 4 2 Plan E

Part 5 9 4 13 Plan D

Part 5 9.4.13 Plan A

Part 5 9.9 - Pian B

Part 5 9 4 12 Plan B

Appendix C 9.6 Plan A


DATE: 07/24/00 KEA S-94-649-2000

I ! STANDARD TEST METHOD MINIMUM REFERENCE REFERENCE FREQUENCY TEST

Metallic Shields

Dimensional Measurements Part 6 9.5 Plan E

Unaged and Aged Tensile and Part 7 9.4.8 and 9.4.9 Elongation

Thickness Part 7 9.4.2

I Plan D

Plan E

Heat Distortion

Heat Shod< li Part 7 ICEA T-27-581 I Pian H

Part 7 9.7.1 Plan H ! Cold Bend

Oil Immersion

Part 7 ICEA T-27-581 Plan F

Part 7 9.4.9.3 Plan H I Radial Resistivity i Part7

Plan A

One sample from each end of a manufacturer's master length. One sample from the outer end of each length is sufficient if at least one sample IS taken every 10,000 feet (3,000 m).

Plan 6

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

Plan C

One test for each 50,000 feet (15,000 m) of cable or at least once per cable core-extruder run.

9.8.3 Plan D

60

ac Withstand Test

Partial Discharge Test U Part 4 I 9.12 Plan G

Part 4 ICEA T-24-380 Plan G

Jacket Spark Test Part 7 ICEA T-27-581 100% I 1 Other Tests

Moisture in Conductor I part2 9.15 Plan G

Moisture Under Jacket Part 7 I 9.15 Plan G

-


ICEA S-94-649-2000

Plan D

1 - 2

3 - 19

20 and greater

One test for each 50,000 det (1 5,000 m) or at least once per jacket extruder run.

each shipping length

2

10% of shipping lengths (Fractions shall be rounded to the

next higher integer value)

Plan E

Jacket Extruder Run Length-feet (meters)

Table 9-6 Plan E

Conductor Size kcmil (mm2) Number of Samples

Number of Tests Quantity of Shipping Lengths Per Extruder Run

1

1,000 to 25,000 (300 to 8,000) 1 250 (1 27) and larger I 1

each additional 25,000 (8,000) 1 250 (127) and larger I 1 I

Plan F

Table 9-7 Plan F

DATE: 07/24/00

I /I each additionai 50,000 (I 5,000) less than 250 (127) I

Plan G

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

Plan H

Each lot of material used for extrusion on the cable.


ICEA S-94-649-2000 DATE: 07/24/00

Part 10 QUALIFICATION TESTS

10.0 GENERAL

Qualification tests included in this Standard are intended to demonstrate the capability of materials to be used in high quality cable with the desired performance characteristics.

It is intended that the product furnished under this Standard shall consistently comply with all of the qualification test requirements.

The tests are divided into five categories. The first is Core Material Qualification, which is divided into two sections: Conductor Shield/insulation Qualification and Insulation Shield Qualification. The second is Thermomechanical Qualification. The third is Jacket Material Qualification. The fourth is CV Extrusion Qualification. The fifth is Other Qualification Tests.

If requested by the purchaser at the time of inquiry, the manufacturer shall furnish the purchaser with a certified copy of the qualification tests that represents the cable being purchased.

If a conductor shield/insulation combination, insulation shield or a completed cable design was qualified in accordance with AEIC CS5-94 or AEIC CS6-96 specification, then it does not need to be requalified under the conductor shield/insulation, insulation shield or thermomechanical qualification test, as applicable, in this Standard. Additional qualification tests in 10.3, 10.4 and 10.5 are required to be performed, as applicable, in accordance with this Standard.

10.1 CORE MATERIAL QUALIFICATION TESTS

These tests evaluate core (conductor shield, insulation and insulation shield) materials only. The Core Material Qualification Report can be used by ail cable producers who propose to use the materials contained in the report. The Core Material Qualification Report is valid until one of the compounds change (change in any of the compound composition). Unless otherwise noted, samples of unjacketed 15kV rated cable with a 100% insulation level wall thickness in accordance with Table 4-1 1, and a 1/0 AWG compressed Class B unfilled stranded aluminum or copper conductor which successfully complete this qualification test program, qualify that aesign for cables rated 5 through 46kV.

10.1 .I Conductor Shieldllnsulation Qualification

Seven combinations of the electrical tests 1 O. 1.3 and 1 O. 1.4 and conditioning procedures 1 O. 1.5 and 10.1.6 are required for this qualification. They are presented as Test Nos. 1-7 in the Flow Chart for Qualification Tests. The tests may be performed with any commercially used insulation shield material. Additionally, the Resistance Stability Test 10.5.3 shall be performed on every shield material.

Note: Insulation Resistance Test 10.5.1, Accelerated Water Absorption Test 10.5.2 and Dissipation Factor Characterization Test 10.5.7 shall be performed on each insulation material. The Dry Electrical Test 10.5.5 shall be performed on EPR insulation Class Ill. The Discharge Resistance Test 10.5.6 shall be performed on EPR insulation Class IV. The Brittleness Test 10.5.4 shall be performed on every shield material. The results shall be on file with the manufacturer and are not required to be reported on the Conductor Shield/lnsulation Qualification Test report unless specifically requested.


ICEA S-94-649-2000 DATE: 07/24/00

10.1.2 Insulation Shield Qualification

All combinations of insulation and insulation shield material must be subjected to test Nos. i, 2, 3 and 4 of the Flow Chart for Qualification Tests. If a given combination of these materiais was qualified under the Conductor Shield/lnsulation Qualification, it will be considered as qualified. Additionally, the Resistance Stability Test 10.5.3 shall be performed on every shield material.

Note: The Brittleness Test 10.5.4 shall be performed on every shield material. The results shall be on file with the manufacturer and are not required to be reported on the Insulation Shield Qualification Test report unless specifically requested.


ICEA S-94-549-2000

I Electrical Measurements

DATE: 07/24/00

120-Day Accelerated Water Treeing Test (AWTT)

Samples 13-21 Para. 1 O. 1.6

FLOW CHART FOR QUALIFICATION TESTS

Para. 10.1.7 Sample 13 c a

1 I

I

I Electrical Measurements I Para. 10. I .7 Sample 1

Test No. I High Voltage Time Test

Samples 1, 7 ,3 Para. 10.1.3

Hot Impulse Test Samples 4, 5,6

Physical Measurements

Samples 7-21 Para. 10.1.5

1 Electrical Measurements I Para. 10.1.7 Sample 7

Test No. 3 High Voltage Time Test

Samples 7, 8 , 9 Para. 10.1.3

1

I Physical Measurements 1 Para. 1 O. 1.8 Sample 7

Hot Impulse Test Samples 10, 1 I , 12

Para. 1 O. 1.4

I

I Test No. 5

High Voltage Time Test Samples 13, 14, 15

Para. 1 O. 1.3

Physical iMeasurernents

I Test No. 6

Continue AWTT For Total of I80 Days

High Voltage Time Test Para. 10.1.3

Samples 16, 17, 18

I Test No. 7

Continue AWTT For Total of 360 days

High Voltage Time Test Para. 1 O. i .3

Samples 19,20,2i


ICEA S-94-649-2000 DATE: 07/24/00

10.1.3 High Voltage Time Test (HVTT) Procedure

A high voltage time test shall be made on samples of cable as shown in Flow Chart; Test Nos. 1, 3, 5, 6, 8 7 or when required in other sections of this specification. The voltage test frequency shall be 49-61 Hz. The test snail be performed with the cable at room temperature. Test samples shall have a minimum active length of 15 feet (4.5 m) or as otherwise specified. A test voltage equal to 100 V/mil (3.9 kVlmm) shall be applied under the conditions stated in Part 9 and held for a period of 5 minutes. The voltage shall then be increased in 40 V/mil (1.6 kV/mm) steps and heid for 5 minutes at each value, continuing to cable breakdown. The V/mil (kV/mm) stress is calculated based on the nominal thickness in Table 8-1.

A sample which fails to withstand the following voltage step for test Nos. 1 & 3 shall be considered to have faiied to meet the qualification test requirements:

- 620 V/mil (24.4 kVlmm)

- 500 V/mil(19.7 kV/mm)

The results of each cable test, cable failure dissection, wall thickness at failure site, and examination shall also be recorded and reported.

When testing samples removed from the accelerated water treeing test, the HVIT shall be performed within 24 hours after the termination of the treeing test. The water in the conductor shall not be drained before the HVTT is performed. If the test is not performed within 24 hours of completing the water !reeing test, the samples shall be stored in water with the same characteristics as the water used during the test until the H W can be completed.

If a termination failure occurs, the test shall be considered finished only if the 1100 V/mil (43.3 kV/mm) step has been completed. A termination failure is aefined as a failure outside of the active length.

If a termination failure occurs and the 1100 Vlmil (43.3 kV/mm) step has not been completed, the sample may be. reterminated and retested. To retest, the sample shall have a minimum shielded length of 10 feet (3.1 m) after reterminating. The voltage shall be reapplied starting at 100 V/mil (3.9 kV/mm) for 30 seconds. It shall be increased in 40 V/mil (1.6 kV/mm) steps and held for 30 seconds at each step, continuing to the step at which the terminal failure occurred. The voltage shall be held for 5 minutes at this step and then increased in 40 V/mil (1.6 kV/mm) steps and held for 5 minutes at each step until breakdown occurs.

10.1.4 Hot Impulse Test Procedure

To establish impulse performance characteristics, a hot impulse test shall be made in accordance with IEEE Standard No. 82, "Test Procedure for Impulse Voltage Tests on Insulated Conductors," on sampies of cable as shown in Flow 'Chart; Test Nos. 2 8 4. The minimum active length is 8 feet (2.4 m). Hot impulse tests shall be made with the sample placed in a 3-inch nominal diameter polyethylene or PVC conduit with a minimum length of 6 feet (1.8 m). The conduit ends shall be closed toprevent air circulation into or out of the conduit.

For hot impulse tests, the temperature of the conductor shall be equal to the rated emergency overload temperature of the cable +O/-5 OC. The temperature shall be achieved by circulating current in the conductor with no current in the metallic shield.

Ten impulses of each polarity with magnitude equal to the BIL shown in Table 4-10 shall be applied. The voltage shall then be raised over the BIL values listed in steps of approximately 25% of BIL with three impulses of negative polarity applied at each step and continuing to cable breakdown outside the terminals.

Impulse breakdown sites shall be dissected and the results shall be recorded and reported in the qualification test report.

10.1.5 . Cyclic Aging

Cyclic aging is conducted to provide thermal conditioning (to remove a large amount of the VOlatileS found in freshly manufactured cable) for Test Nos. 3 through 7 as listed in Flow Chart.


ICEA S-94-649-2000 DATE: 07/24/00

10.1 S.1 Cable Length

Sufficient sample length is required to provide aged cable for Test Nos. 3 through 7 in Flow Chart.

10.1.5.2Sample Preparation

Prior to the application of current, the overall jacket, if any, shall be removed. A minimum of seven days must pass from the time the cable is insulated until these tests are performed.

10.1 S.3 Conduit

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

10.1 S.4 Load Cycle

The cable shall be subjected to 14 thermal load cycles. A load cycle is defined as a 24-hour period during which the current is on for the flrst 8 hours and off for the remaining 16 hours. The conductor temperatwe inside the conduit shall be equal to the rated emergency overload temperature of the cable during the last 4 hours of the current on period. During the current-off period, the cable conductor shall fall to within 5 OC of the ambient temperature. No voltage is applied during the load cycle. Temperatures shall be established before the test is performed by placing a thermocouple on the conductor of a "dummy" cable which is load cycled in a manner similar to a test sample.

10.1.6 Accelerated Water Treeing Test ( A m ) Procedure

10.1.6.1 General

The cable conditioned in 10.1.5 is used for this test. Each cable is aged at the test voltage with the cable placed in a tap water filled, 3-inch nominal diameter polyethylene or PVC conduit and with the conductor interstices filled with tap water throughout the test.

10.1.6.2Sample Preparation

Sufficient cable shall be aged to perform Test Nos. 5 through 7 listed in Flow Chart. Each sample in Test Nos. 5 through 7 shall have a minimum metallic shielded length of 12 feet (3.7 m) inside the water-filled conduit plus enough cable to provide for sufficient test terminati?ns. The aging test may be conducted with individual samples or in one continuous length which is subsequently cut into individual samples.

10.1.6.3Aging Time

Three samples are aged for 120 days then subjected to a series of tests (Test No. 5). An ac withstand of 300 Vlmil (1 1.8 kV/mm) minimum is required for the samples aged for 120 days. Three samples are aged for 180 days and subjected to a HVTT (Test No. 6). The remaining three samples are aged for 360 days and subjected to a HVTT (Test 7). If the cable meets the requirements of Test No. 5, it has met the requirements for AWTT. However, the manufacturer is required to continue the test to obtain data for cables aged 180 days and 360 days. The 180-day and 360-day data is obtained for engineering information only. -


ICEA 5-94-649-2000

10.1.6.4Test Procedure

The aging parameters for the accelerated water treeing test are outlined as follows:

DATE: 07/24/00

Test Voltage:

150 Vlmil f 5 Vlmil (5.9 kV/mm t 0.2 kV/mm) average stress, based on the nominal thickness in Table 8-1.

Test Frequency:

49-61 Hz (report nominal frequency utilized)

Test Cycle:

The cables shall age with voltage applied continuously 7 days a week (except during equipment or sample maintenance). During each week, the cables shall experience 5 consecutive 24-hour load cycle periods followed by 2 consecutive non-load cycle periods.

Dummy Load Cycle:

To establish the 24-hour temperature profile for the 5 consecutive load cycle periods, a sample of dummy cable shall be installed in a conduit exactly as it will be installed in the aging test. To monitor the temperature of the sample, thermocouples shall be placed on the conductor in air, on the conductor in water (near the center of the conduit) and on the insulation shield in water (also near the center of the conduit). Current shall be induced in the conductor for 8 hours followed by 16 hours with no current (one load cycle period). No voltage is applied to the dummy cable. The current magnitude shall be sufficient to acnieve an in-water insulation shield temperature of 45 OC k3 OC by the end of ihe current on period. To achieve the required in-water insulation shield temperature requirements may require the use of a thin blanket of thermal insulation around the conduit. The 24-hour time-temperature profile for the conductor in air and water and the insulation shield in water shall be reported graphically in the qualification test report. The 24-hour load cycle temperature profile for the insulation shield in water shall be followed during the cable aging load cycle.

Aging Load Cycle:

Thermocouples shall be attached to the in-water insulation shield of several samples (near the center of the conduit) to verify that the cables achieve the correct temperature. Conductor current shall be induced 8 hours on and 16 hours off (one load cycle period) for 5 consecutive days a week. During each load cycle, the in-water insulation shield temperature profile e<tablished for the dummy cable shall be followed. Generally, the current magnitude established during the dummy cable test is used during the aging test. However, the conductor current may be adjusted to achieve the correct temperature if the thermal environment of the test facility changes during the test. The current shall be off for 2 consecutive days during each week. Voltage shall be applied continuously (7 days a week) during the aging period except when replenishing water in the conductor or the conduit or for general maintenance. One day of aging equals 24 hours of continuous voltage application if the temperature requirements are met and the voltage IS within the specified limits. If the temperature or voltage falls below the specified value during a 24-hour test period (load cycle or non-load cycle), that period shall be repeated. The test may be interrupted between load cycles for equipment or sample maintenance.

A

10.1.6.5Water pH

The pH of the water in the conduit shall be measured at O, 120, and 360 days of aging. The values shall


DATE: 01/24/00 IC EA S -94-649-20 O O

be reported in the certified qualification test report.

10.1.7 Qualification Test Electrical Measurements

To monitor changes in the electrical characteristics of the cable during aging, partial discharge (unless otherwise specified), capacitance and dissipation factor shall be measured. The capacitance and dissipation factor test shall be made at rated voltage at room temperature. These tests shall be conducted on Samples 1, 7 and 13. The results from Sample 1 shall meet the limits in the appropriate Parts of this Standard and shall be reported. If limits are exceeded, the test shall be terminated and the cable design rejected. The results from Samples 7 and 13 shall be reported in the qualification test report for engineering information only.

10.1.8 Qualification Test Physical Measurements

To monitor changes in the physical characteristics of the cable durinç aging the conductor shield thickness, insulation thickness, insulation shield thickness, insulation shield stripping tension shall be measured on Samples 1, 7 and 13. The results from Sample 1 shall meet the limits in the appropriate Parts of this Standard and shall be reported. The insulation shield stripping tension on Sample 7 shall be not less than 3 pounds (13.4 N). If limits are exceeded, the test shall be terminated and the cable design rejected. All remaining results from Sample 7 and all results from Sample 13 snail be reported in the qualification test report for engineering information only.

10.2 THERMOMECHANICAL QUALIFICATION TEST - Optional

The user may request a Thennomechanical Qualification Test if the cable purchased is expected to operate near the rated emergency overload conductor temperature.

10.2.1 Scope

The manufacturer shall conduct the test on a generic cable design in accordance with Tables 10-1 and 10-2, which represents the cable design being purchased. Tests on the identical materials or design are not necessary to demonstrate the desired performance results.

10.2.2 Procedure

10.2.2.1 Fixture

A 3-inch nominal diameter conduit shall be used for cables up to 1.5 inches (38.1 mm) in diameter, and a 4-inch nominal diameter conduit shall be used for cables larger than 1.5 inches (38.1 mm) in diameter. The test fixture shall consist of two pieces of conduit, each 15 feet (4.6 m) long, joined together at one end by a U-bend.with a radius of 13 inches (330 mm) for the 3-inch nominal conduit and a radius of 16 inches (406 mm) for the 4-inch nominal conduit.

10.2.2.2 Load Cycling

The cable shall be subjected to 14 load cycles. Each load cycle is defined as a 24-hour time span with a current-on period and a current-off period. During the current-on period, sufficient alternating current shall be passed through the conductor to achieve a cable conductor temperature equal to the rated emergency overload temperature +Ob5 OC for a period of 6 hours. There shall be no current in the cable metallic shield. Voltage on the conductor is not required during load cycling. When the condktor is at the required temperature, the temperature gradient shall be within the limits outlined in Table 10-1. The reference location for all conductor temperature requirements is the longitudinal center of the cable inside the conduit (in center of U-bend). These temperatures shall be established before the test is performed by placing a


I C I 3 5-94-649-2000 DATE: 07124100

thermocouple on the conductor of a "dummy" cable which is load cyded in a manner similar to a test sample. During the current-off period, the cable conductor temperature should drop to within 5 OC of the ambient

air temperature. If this condition cannot be met, the test shall be interrupted at the end of the fifth and tenth cycle. During this intemption, the current shall remain off for a period of at least 24 hours to allow the cables to cool to ambient temperature. The load cycle shall be resumed at the end of the intemption penod. This interrupted procedure may also be followed even if the temperature drop requirement during the current-off period can be met.

The test specimens must complete 14 load cycles. The 24-hour interruption periods are not considered part of a load cycle.

If, for any reason, the temperature falls below the speciñed level during any given load cycle, that load cycle must be repeated. Load cycles may be contiguous or there may be periods with no current between load cycies to accommodate schedule variations or equipment failures or maintenance.

10.2.2.3 Electrical Measurements

Initially and after 14 test cycles partial discharge (unless otherwise specified) and dissipation factor measurements shall be made with the cable conductor at room temperature and at the emergency overioad temperature f 5 OC. l ñ e dissipation factor shall be measured at rated voltage to ground.

Unless there is specific agreement by purchaser and manufacturer on other values, the dissipation factor at room temperature and partial discharge shall meei the limits in the appropriate Parts of this Standard and shall be reported.

If the partial discharge or the dissipation factor limits are exceeded, the test shall be terminated and the cable design rejected.

10.2.2.4 Physical Measurements Before and After the Thennomechanical Design Test

At the end of the test, a sample of cable from the center of the bend will be removed for measuring. Measure the thickness of the conductor shield, insulation, insulation shield, and jacket as outlined in 9.4.2.2. These measurements shall also be made on an unaged sample of the same cable. If the jacket cracks or develops holes during the test, the cable design shall be rejected.

Table 10-1 Maximum Temperature Gradient for Thermal Aging

Conductor Size,

500 (253) or

less than

500 (253) or

I ( less than 1 500(253)

Insulation Maximum Thickness Temperature Conductor

Gradient between Sizes Qualified Conductor & Cable

Outer Surface

Qualified mils (mm)

that size and all smaller sizes ail 1 40°C 345 (8.76)

or mcre

less than that voltage 345 (8.76) class & lower

less than that vol tage 345 (8.76) class & lower

30 OC all

that size and all smäiier sizes 30 O C

6 9


KEA S-94-649-2000 DATE: 07/24/00

Table 10-2 Generic Groupings of Cable Components

Insulations:

Crosslinked polyethylene

Ethvlene oromiene rubber

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

Extruded Shielding:

4 Thermoplastic

b\ Thermoset -

Metallic Shielding:

a) Round wire

b) Flat strap

Nonconductina Jackets:

b)

c) High dencity polyethylene

d) CPE

e) TPE

f) PP

Serniconductina Jackets:

Low, medium and linear low density polyethylene

a)

Notes:

1)

2)

Type I and Type I I

Only one conductor metal needs to be tested, !.e.. aluminum qualifies copper

A change in any one of the items listed requires a new thennomechanical and vice versa.

qualification test.

* 10.3 JACKET MATERIAL QUALIFICATION TESTS

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

10.3.1 Polyethylene Jackets

10.3.1.1 Environmental Stress Cracking Test

Except as otherwise specified in 10.3.1.1.1 and 10.3.1.1.2, this test shall be made in accordance with ASTM D 1693.


ICEA 5-94-649-2000 DATE: 07/24/00

10.3.1.1 .l Test Specimen

Three test specimens approximately 1.5 inches (38.1 mm) long, 0.5 inch (12.7 mm) wide, and 0.125 inch (3.18 mm) thick from the sample shall be molded from material intended for extrusion. The temperature of the molded specimens shall be lowered at any suitable rate. A slit made with a razor blade, approximately 0.75 inch (19.0 mm) long and from 0.020 to 0.025 inch (0.51 to 0.64 mm) deep, shall be centrally located on one of the 1.5 inch by 0.5 inch (38.1 mm by 12.7 mm) surfaces.

10.3.í.1.2 Test Procedure

The specimens shall be bent with the slit on the outside and placed in a test tube 200 mm long and 32 mm in outside diameter. The cracking agent (Igepal CO-630, made by the GAF Corporation, or its equivalent) shall be added to completely cover the specimen. The test tube, suitably closed by means such as foil-covered cork, shall be placed in an oven at 50 OC I 1 OC for 48 hours. At the end of this period, the specimens shall be removed, allowed to cool to room temperature, and inspected for cracking.

10.3.1.2Absorption Coefficient Test

The absorption coefficient of polyethylene jacket compound shall be determined in accordance with ASTM D 3349, Three test specimens shall be tested and the average of the results reported.

10.3.2 Semiconducting Jackets

10.3.2.1 Brittleness Test (See 10.5.4)

10.3.3 Polyvinyl Chloride and Chlorinated Polyethylene Jackets

10.3.3.1 Sunlight Resistance

10.3.3.1.1 Test Samples

Five samples shall be prepared from material intended for extrusion or from completed cable.

10.3.3.1.2 Test Procedure

The test may be performed using either a carbon-arc or xenon-arc apparatus. For a carbon-arc apparatus, five sampies shall be mounted vertically in the specimen drum of the carbon-arc-radiation and water-spray exposure equipment similar to the Type D apparatus in ASTM G-23. For the xenon-arc apparatus, five campies shall be mounted, top and boitom, on a rack of the xenon-arc-radiation and water- spray exposure equipment similar to the apparatus in ASTM G-26. The test method shall also be in accordance with ASTM G-23 or ASTM G-26 respectively. The exposure time shall be 720 hours. Five die-cut specimens shall be prepared and tested for tensile and elongation from (1) unaged section of the cable jacket and (2) the conditioned samples, one specimen from each sample. The respective averages shall be calculated from the five tensile strength and elongation values obtained for the conditioned samples. These averages shall be divided by the equivalent averages of the five tensile and elongation values obtained for the unaged specimens. This provides the tensile and elongation ratios for the jacket. The jacket is not sunlight resistant if an 80 percent or greater retention for either the tensile or elongation after the 720 hours of exposure is not maintained.

10.4 CV EXTRUSION QUALIFICATION TEST

'

I

CV extrusion qualification is required for 15 - 46 kV rated cables. Once a month, a cable core sample


ICEA 5-94-649-2000 DATE: 07/24/00

Filled XLPE or TRXLPE

shall be obtained from each extrusion line and subjected to this test. The cable core design tested will likeiy vary from month to month and will be rated 15 through 46 kV. The test consists of thermal conditioning followed by a High Voltage Time Test. If an extrusion line did not produce any cable for a shipping length during a calendar month, a test is not required.

If a Core Material Qualification Report on cable not produced by the manufacturer is used in accordance with 10.1, then the manufacturer must perform a CV extrusion qualification test on the materials in the report (conductor shield, insulation and insulation shield) prior to producing a shipping length.

500 (1 9.7) I 380 (1 5.0)

10.4.1 Thermal Conditioning

EPR

Conditioning may be accomplished using an air oven or by circulating current in the conductor. If an oven is used, the sample shall be placed in the oven for 72 hours at a temperature of 75 OC. If conductor current is used, ac current shall be applied or induced to obtain a conductor temperature of 90 OC for 72 hours. The sample shall be supported in air (no conduit and not lying on the floor), with no test voitage applied.

The sample selected for this test shall have a minimum active length of 20 feet (6.1 m) with sufficient additional length to apply terminations for the High Voltage Time Test.

300 (1 1.8) I 300 (1 1.8)

10.4.2 Dissipation Factor Verification

The dissipation factor of the sample shall be measured at room temperature at the rated phase to ground voltage. Any appropriate metallic shield may be used for this test. The dissipation factor shall meet the requirements of Part 4. The actual value shall be recorded.

10.4.3 AC Withstand Verification

After the thermal conditioning is complete, the sample shall be subjected to the High Voltage Time Test outlined in 10.1.3. The minimum withstand voltage requirement is provided in Table 10-3. The V/mil (kV/mm) step increases are calculated based on the nominal thickness in Table 8-1.

The CV Extrusion Qualification Test report shall indicate the appropriate minimum withstand value for the cable under test and shall certiv that the cable tested withstood this value. The report does not need to include the ac breakdown value. Test results for 46 kV cables shall be recorded for engineering information only.

Table 10-3 AC Withstand Voltage Requirements

15-35 kV Rated Cables

Withstand Voltage - Vlmil (kV/mm) O.D. Over Insulation Insulation Type

I I 1.2" (30.5 mm) I > 1.2" (30.5 mm) i/

10.5 OTHER QUALIFICATION TESTS

10.5.1 Insulation Resistance

-

Insulation resistance test shall be performed in accordance with ICEA T-27-581/NEMA WC-53.


ICEA 5-94-649-2000

I The capacitance and dissipation factor shall be measured initially at room temperature, 105 OC and 140 "C. After the test has been completed, the same propdrties shall be measured at the three temperatures. The dissipation factor shall not increase by more than 10% at each of the three test temperatures.

The partial discharge shall be measured on the initial specimens and after the current loading test has been completed. The value shall meet the limits in Part 4 of this Standard and shall be reported. If limits are exceeded, the test shall be terminated and the cable design rejected.

DATE: 07124100

10.5.2 Accelerated Water Absorption Tests

Accelerated water absorption test shall be performed in accordance with ICEA T-27-581 /NEMA WC-53.

10.5.3 Resistance Stability Test

The requirements described in Parts 3 and 5 of this Standard and in ICEA T-2-25 shall be met.

10.5.4 Brittleness Test for Semiconducting Shields

10.5.4.1 Test Samples

A plaque shall be molded from material intended for extrusion. Three test samples, each approximately 6 inches (152 mm) long and not greater than 0.025 square inch (16 mm') in cross-section, shall be cut out of the plaque with a die. NI three samples shall be tested and the results averaged.

1 0.5.4.2Test Procedure

This test shall be conducted in accordance with ASTM D 746, using Specimen A.

10.5.5 Dry Electrical Test for EPR Class 111 Insulation Only


At least three samples shall be tested. A sample shall consist of a 110 AWG Aluminum or Copper 15kV cable utilizing a 100% insulation level wall thickness in accordance with Table 4-1 I along with a conductor shield and an outer insulation shield with any suitable metallic shield. The samples shall be 30 feet (9.1 m)long.

10.5.5.2Test Procedure

The test shall be performed with the sample cable in a 3 inch nominal diameter polyethylene or PVC conduit. The effective length between terminals shall be at least 20 feet (6.1 m). The sample shall be current loaded at 140 OC at rated phase-to-ground voltage for three weeks continuously. The loading may be interrupted, if necessary, for equipment or sample maintenance provided the total time is achieved.

10.5.5.3 Electrical Measurements

10.5.6 Discharge Resistance Test for EPR Class IV Insulation Only

Compound mixing qualification of the insulation used for discharge-resistant cable designs is required. Once per month a sample of each qualified insulation shall be obtained from each compeund mixing line and subjected to this test.

The test shall be performed in accordance with ASTM D 2275 using the following standard specimens and conditions.

73


ICEA S-94-649-2000 DATE: 07/24/00

10.5.6.1 Test Specimens

From each test sample, three test specimens, each having a minimum diameter of 4 inches (101.6 mm) and a thickness of 0.060 inch i- 0.004 inch (1.52 mm f 0.10 mm), shall be molded and suitably cured. The prepared specimens shall be held for a minimum of 72 hours at room temperature followed by 16 hours minimum in the same environment as the electrical discharge test.

10.5.6.2Test Environment

The discharge test shall be performed in an area provided with a controlleddraft flow of conditioned air to maintain the required relative humidity and temperature and with suitable venting to remove ozone and other gasses.

10.5.6.3Test Electrodes

The electrodes shall be of stainless steel Type 309 or 310, with a surface finish of 16 pin (0.406 pm). Each upper electrode, to which the test voltage is applied, shall be a cylindrical rod having a diameter of 0.250 inch f 0.010 incn (6.35 mrn f 0.254 mm) and a length adjusted to provide a contact weight of 30 grams i- 3 gams when positioned vertically atop the center of the insulation specimen. The contacting end shall be flat except for edges rounded to a radius of 0.035 inch i: 0.005 incn (0.89 mm 10.127 mm). The lower electrode(s) shall be electrically groundea and may be either (1) a common plate under, and extending at least 2 inches (50.8 mm) beyond, the array of upper electrodes or (2) individual flat discs of 1.25 inch (31.75 mm) minimum diameter, centered under each upper electrode.

10.5.7 . Dissipation Factor Characterization Test

A dissipation factor test shall be performed to demonstrate the insulation material utilized shall comply with the maximum room temperature requirements of this Standard. In addition, an elevated temperature dissipation factor measurement shall also be performed in order to characterize the specific insulation compound. This test shall be performed once for each insulation which has been qualified to this Standard. When an insulation compound requires requalification within the context of this Standard, the Dissipation Factor Characterization Test shall also be performed.


Samples for this test shall be rated 15 kV with a 100% insulation level wall thickness in accordance with Jable 4-1 1. They shall have a #1/0 AWG compressed, Class E, stranded aluminum or copper conductor and be unjacketed with a concentric neutral. s

10.5.7.2Thermal Conditioning

Conditioning may be accomplished using an air oven or by circulating current in the conductor. If an oven is used, the sample shall be placed in the oven for 72 hours at a temperature of 75 OC. If conductor current is used, ac current shall be applied or induced to obtain a conductor temperature of 90 OC for 72 hours. The sample shall be supported in air (no conduit and not lying on the floor), with no test voltage applied. Alternatively, conditioning may consist of the 14 day cycling aging test as defined in 10.1.5 taken from a length of cable which is being load cycled for conductor shield/insulation qualification or insuiation shield qualification.

The sample selected for this test shall have a minimum active length of 20 fe-et (6.1 m) with suificient additional length to apply terminations.


IC EA S-94-649 -200 O DATE: O7124100

10.5.7.3 Dissipation Factor Testing

The dissipation factor of the sample shall be measured at the rated phase to ground voltage using the following sequence of conductor temperatures:

1. Rated emergency temperature of the insulation. 2. Room Temperature

The conductor temperature shall be achieved by inducing ac current in the conductor. The sample shall be supported in air (no conduit and not lying on the floor). The dissipation factor shall be measured after the temperature has stabilized at the required temperature. The time to elevated temperature should be minimized.

The dissipation factor measured at room temperature shall be less than or equal to the appropriate values listed in 4.3.1.2.5 or 4.3.2.2.5. The dissipation factor measured at the emergency temperature is taken for characterization of the insulation material.

75


~ ~~

ICEA S-94-649-2000 DATE: 07/24/00

Part 11 APPENDICES

APPENDIX A NEMA, ICEA, IEEE, ASTM AND ANSI STANDARDS

Al NEMA PUBLICATIONSt

WC 26iEEMAC 201 (2000) Binational Wire and Cable Packaging

WC 53/ICEA T-27-581 (1 990)

Standard Test Methods for Extruded Dielectric Power, Control, Instrumentation & Portable Cables for Test

A2 ICEA PUBLICATIONSt

P-32-382-? 994 Short Circuit Characteristic of Insulated Cable

P-45-482-1994 Short Circuit Performance of Metallic Shields and Sheaths on Insulated Cable

T-24-380-1994 Guide for Partial-Discharge Test Procedure

T-25-425, (02/81)

T-28-562-1995

T-31-620-1994

T-32-645-1993

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

Test Method for Measurement of Hot Creep of Polymeric Insulation

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

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

T-34-664-1996 Guide for Conducting Longitudinal Water Penetration Resistance Tests on Longitudinal Water Blocked Cables

A3 IEEE STANDARDS$

IEEE Std 82-1994

IEEUANSI C2-1997

IEEE Standard Test Procedure for Impulse Voltage Tests on Insulated Conductors

National Electrical Safety Code (NESC)

A4 ASTM STANDARDS* -

B 3-95

B 5-89

Soft or Annealed Copper Wire, Specification for

Tough-Pitch Electrolytic Copper Refinery Shapes, Specification for


ICEA S-94-649-2000 DATE: 07/24/00

B 8-95

B 33-94

B 193-95

B 230-89

B 231-95

B 233-92

B 400-94

B' 496-92

B 609-91

B 784-94

B 785-93

B 786-93

B 787-93

B 800-94

B 801-95

B 835-93

B 836-93

D 412-92

D 471 -95

D 746-79

D 1693-70

D 2275-89

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

Tinned Sofi or Annealed Copper Wire for Electrical Purposes, Specification for

Resistivity of Electrical Conductor Materials, Test Method for

Aluminum 1350-H19 Wire, for Electrical Purposes, Specification for '

Concentric-Lay-Stranded Aluminurn 1350 Conductors, Specification for

Aluminum 1350 Drawing Stock for Electrical Purposes, Specification for

Compact-Round Concentric-Lay-Stranded Aluminum 1350 Conductors, Specification for

Compact Round Concentric-Lay Stranded Copper Conductors, Specification for

Aluminum 1350 Round Wire, Annealed and Intermediate Tempers, for Electrical Purposes, Specification for

Modified Concentric-Lay-Stranded Copper Conductor for Use in Insulated Electrical Cables, Specification for

Compact Round Modified Concentric-Lay-Stranded Copper Conductor for Use in insulated Electrical Cables, Specification for

19 Wire Combination Unilay-Stranded Aluminum 1350 Conductors for Subsequent Insulation, Specification for

19 Wire Combination Unilay-Stranded Copper Conductors for Subsequent Insulation, Specification for

8000 Seties Aluminum Alloy Wire for Electrical Purposes - Annealed and Intemediate Tempers, Specification for

Concentric-Lay-Stranded Conductors of 8000 Series Aluminum Alloy for Subsequent Covering or Insulation, Specification for

Compact Round SIW Stranded Copper Conductors, Specification for

Compact Round SIW Stranded Aluminum Conductors, Specification for

Vulcanized Rubber and Thermoplastic Rubbers and Thermoplastic Elastomers - Tension, Test Methods for

Rubber Property - Effect of Liquids, Test for

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

Environmental Stress - Cracking of Ethylene Plastics, Test Methoa for -

Voltage Endurance of Solid Insulating Materiais Subjected to Partial Discharges (Corona) on the Surface, Test Method For

b


ICEA S-94-549-2000 DATE: 07/24/00

D 2765-90 Determination of Gel Content and Swell Ratio of Crosslinked Ethylene Plastics, Test Methods for

D 3349-93 Absorption Coefficient of Ethylene Polymer Material Pigmented with Carbon Black, Test Method for

D 4496i87 DC Resistance or Conductance of Moderately Conductive Materials, Test Method for

G 23-93 Operating Light -Exposure Apparatus (Carbon-Arc Type) With and Without Water for Exposure of Nonmetallic Materials, Practice for

G 26-94 Operating Light -Exposure Apparatus (Xenon-Arc Type) With and Without Water for Exposure of Nonmetallic Materials, Practice for

A5 ANSI STANDARDS$

C2-1997 National Electrical Safety Code (NESC)

--

7 Copies may be obtained from Global Engineering Documents, 15 Inverness Way East; Englewood, CO 801 12, USA.

$ Copies may be obtained from IEEE Service Center, 445 Hoes Lane, Piscataway, NJ 08854, USA.

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


~

ICEA S-94-649-2000 DATE: 07/24/00

APPENDIX B EMERGENCYOVERLOADS

Operations at the emergency overload temperature of 130 OC for insulations rated 90 OC continuous and 140 OC for insulations rated 105 OC continuous shall not exceed 1500 hours cumulative during the lifetime of the cable.

Lower temperatures for emergency overioad conditions may be required because of the type of material used in the cable, joints, terminations and separable connectors or because of cable environmental conditions.

79


ICEA S-94-649-2000 DATE: 07l24100

APPENDIX C PROCEDURE FOR DETERMINING DIAMETERS OF CABLE

C1 The minimum and maximum diameter limits are calculated average values. Conformance with these limits shall be determined in accordance with 9.6 (Diameter Measurement of Insulation and Insulation Shield).

C2 Diameters shall be computed by the following method:

A. To determine the minimum and maximum diameters over the insulation, use the formula shown in Table C-1

Table C-1 Insulation Diameter Calculation

Diameters Over Insulation (mils) Conductor Size (AWG or kcmil) Minimum Maximum

II 8 - 1000’ I C+2CS+2T 1 C + 2.5CS + 2.1T + 60 II ‘Consult manufacturer for condudor sizes larger than 1000 kcmil.

Where:

C - - Applicable nominal conductor diameter from Part 2 cs = T - - Minimum point insulation thickness from Part 4

Minimum point extruded conductor shield thickness from Part 3

All dimensions are in mils

If stated by the manufacturer at time of quotation that a conductive tape and subsequent shield is to be applied over the conductor, the diameter over the insulation will be supplied by the manufacturer.

B. To determine the minimum diameter over the insulation shield for a cable, add the appropriate value shown in Table C-2 to the minimum diameter over the insulation as calculated from Table C-l.

To determine the maximum diameter over the insulatiortshield for a cable, add the appropriate value shown in Table C-2 to the maximum diameter over the insulation as calculated from Table C-I .

Calculated diameters over the insulation and insulation shield shall be rounded to the nearest 5 mils.


- ~~

ICEA 5.-94-ú49-2000

Calculated ~~~i~~~ Diameter over Insulation - mils

o - 1000

DATE: 07124100

insulation Shield Adders - mils

Minimum Maximum

60 1 O0

1001 - 1500 I 80

1501 - 2000 110

Example:

class cable with a 133% level insulation wall thickness, and a concentric neutral. 4/0 compressed (Class 9) stranded conductor with extruded conductor shield and insulation shield, 15kV

120

150

C 2 x c s 2T Sub Total

955

C 2.5 x CS 2.1 x T Plus Sub Total

1045

= 512 mils = 24 mils (CS = 12 from Part 3) = mils (T = 210 from Part 4) = 956 mils (round to 955 for minimum diameter over insulation)

mils minimum diamerer over insulation

= 512 mils = 30 mils (CS = 12 from Part 3) = 441 mils (T = 210 from Part 4) = _Sa mils per equation in Table C-1 = 1043 mils (round to 1045 for maximum diameter over insulation)

mils maximum diameter over insulation

To calculate the diameters over the extruded insulation shield:

From Above = 955 mils minimum diameter over insulation Plus = Bn minimum value from Table C-2 Sub Total = 1 O1 5 mils minimum diameter over bsulation shield

From Above Plus Sub Total

= 1045 mils maximum diameter over insulation = 11112 maximum value from Table C-2 = ? 145 mils maximum diameter over insulation shield

Tables C-3 through C-5 give caiculated values for some commonly used cables. Diameters for other constructions may be calculated using Tables C-1 and C-2.

8 1 COPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling ServicesCOPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling Services

1 I II . . . . . . . . . . . .

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

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

. . . . . . . . . . . . i

O O d (Y

)c O

W

P

- \

.. à

I

3 s : N Z W h h h


U al m 13 U m o

c - -

C O

i!

C O '3

8': E -

C C L .:

g; E - I 1

I I I 1 il

I I I l il I

I 1 I 1 I l

I

I I

I

I I I ! I il

I l I I I

I il

I ! I I I I il I

I l I l I

I I I l l 1


o o m o N W O W r r W N 7 - r -

. . . . . .

o o m o c y < D O $

f f Z , . . . . * .

a( i c m

O

l - r , r ,

o o m o w r - r - m m n r - c )

I I

0 0 0 0 0 m m o o o ~ p i m w r -

N r


ICEA S-94-649-2000 DATE: 07124100

APPENDIX D SHIELDING

D I DEFINITION OF SHIELDING

Shielding of an electric power cable is the practice of confining the dielectric field of the cable to the insulation of the conductor or conductors. It is accomplished by means of a conductor stress control layer and an insulation shield.

D2 FUNCTIONS OF SHIELDING

D2.1 A conductor stress control layer is employed to preclude excessive voltage stress on voids between conductor and insulation. To be effective, it must adhere to or remain in intimate contact with the insulation under all conditions.

D2.2 An insulation shield has a number of functions:

a. To confine the dielectric field within the cable. b. To obtain symmetrical radial distribution of voltage stress within the dielectric, thereby minimizing the

possibility of surface discharges by precluding excessive tangential and longitudinal stresses. c. To protect cable connected to overhead lines or otherwise subject to induced potentials. d. To limit radio interference. e. To reduce the hazard of shock. This advantage is obtained only if the shield is grounded. If not

grounded, the hazard of shock may be increased.

D3 USE OF INSULATION SHIELDING

D3.1 The use of shielding involves consideration of installation and operating conditions. Definite rules cannot be established on a practical basis for all cases, but the following features snould be considered as a working basis for the use of shielding.

D3.2 Where there is no metallic covering or shield over the insulation, the electric field will be partly in the insulation.and partly in whatever lies between the insulation and ground. The extemal field, if sufficiently intense in air, will generate surface discharge and convert atmospheric oxygen into ozone, which may be destructive to insulations and to protective jackets. If the surface of the cable is separated from ground by a thin layer of air and the air gap is subjected to a voltage stress that exceeds the dielectric strength of air, a discharge will occur, causing ozone formation.

D3.3 The ground may be either a metallic conduit, a damp nonmetallic conduit, or a metallic binding tape or rings on an aerial cable, a loose metallic sheath, etc. Likewise, damage to nonshieided cable may result when the surface of the cable is moist or covered with soot, soapy grease or other conducting film and the external field is partly confined by such conducting film so that the charging current is carried by the film to some spot where it can discharge to ground. The resultant intensity of discharge may be sufficient to cause burning of the insulation or jacket.

*

D3.4 Where nonshielded cables are used in underground ducts containing several circuits that must be worked,on independently, the external field, if sufficiently intense, can cause shocks to those who handle or contact energized cable. In cases of this kind, it may be advisable to use shielded cable. Shielding used to reduce hazards of shock should have a resistance low enough to operate protective equipment in case of fault. In some cases, the efficiency of protective equipment may require proper size ground wires as a supplement to shielding. The same considerations apply to exposed installations where cables may be handled by personnel who may not be acquainted with the hazards involved.


KEA S-94-649-2000 DATE: 07/24/00

D4 GROUNDING OF THE INSULATION SHIELD

D4.1 The insulation shield must be grounded at least at one end and preferably at two or more locations. It is recommended that the shield be grounded at cable terminations and at splices and taps. Stress relief devices should be applied at all shield terminations.

D4.2 The shield should operate at or near ground potential at all times. Frequent grounding of shields reduces the possibility of open sections on nonmetallic covered cable. Multiple grounding of shields is desirable in order to improve the reliability and safety of the circuit. Ail grounding connections should be made to the shield in such a way as to provide a permanent low resistance bond. Shielding that does not have adequate ground connection due to discontinuity of the shield or to improper termination may be more dangerous than nonshielded nonmetallic cable and hazardous to life.

D5 SHIELD MATERIALS

D5.1 Two distinct types of materials are employed in constructing cable shields.

D5.l.l Nonmetallic shields may consist of a conducting tape or a layer of conducting compound. The tape may be conducting compound, fibrous tape faced, or filled with conducting compound or conducting fibrous tape.

D5.1.2 Metallic shields should be nonmagnetic and may consist of tape, braid, wires, or a sneath.

D6 SPLICES AND TERMINATIONS

D6.1 To prevent excessive leakage current and flashover, metallic and nonmetallic insulation shields, including any conducting residue on the insulation surface, must be removed completely at splices and terminations.

D6.2 An outer extruded insulation shield shall be removable without damaging or imparting conductivity to the underlying insulation. This may be accomplisned by the aid of heat (air or flame) or by the use of a suitable solvent.


ICEA S-94-649-2000 DATE: 07/24/00

APPENDIX E HANDLING AND INSTALLATION PARAMETERS

E l INSTALLATION TEMPERATURES

All cable manufactured to this Standard can be safely handled if not subjected to temperatures lower than -10 OC in the twenty four hour period preceding installation. For installations during colder temperatures contact the cable manufacturer for cable suitability or recommended practices.

E2 RECOMMENDED MINIMUM BENDING RADIUS

The minimum bend radius to which insulated cables may be bent for permanent training during installation is eight times the overall diameter for single conductor cable. For multiplexed single conductor cables, the minimum benaing radius is eight times the diameter of the individual conductor or five times the overall diameter, whichever is greater. These limits may not be suitable for conduit bends, sheaves, or other curved surfaces around which the cable may be pulled under tension while being installed due to sidewall bearing pressure limits of the cable. The minimum radius specified refers to the inner radius of the cable bend and not to the axis of the cable.

E3 DRUM DIAMETERS OF REELS

See NEMA Publication No. WC 26, Binational Wire and Cable Packaging.

E4 MAXIMUM TENSION AND SIDEWALL BEARING PRESSURES

Consult the cable manufacturer for recommended maximum pulling tensions and maximum sidewall bearins ?ressures.

E5 TESTS DURING AND AFTER INSTALLATION

€5.1 During Installation

At any time during installation, a dc proof test may be made at a voltage not exceeding the dc test voltage specified in Table E-1 under the DuringiAfter Installaiion column, applied for 5 consecutive minutes.

E52 After Installation s

After installation and before the cable is placed in regular setvice, a high voltage dc test may be made at a voltage not exceeding the dc test voltage specified in Table E-1 under the Ouring/After Installation column, apptied for 15 consecutive minutes.

E5.3 In Service

After the cable has been completely installed and placed in service, a dc proof test may be made at any time within the first five years at a voltage not exceedin5 :he dc test voltage specified in Table E-i under the First 5 Years column, applied for 5 consecutive minutes. After that time, dc testing is not recommended.

a7 COPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling ServicesCOPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling Services

DATE: 07124100 ICEA S-94-649-2000

Conductor Size AWG or kcmii (mm2)

DC test voltages are applied to discover gross problems such as improperly installed accessories O r mecnanicai damage. DC testing is not expected to reveal deterioration due to aging in service. There iS some evidence that dc testing of aged cross-linked polyethylene cables can lead to early cable failures. Infomiation on this subject is available in EPRI project report TR-101245, "Effect of DC Testing on Extruded Cross-Linked Polyethylene Insulated Cables."

The dc field test voltages listed in Table E-1 are intended for cable designed to meet this Standard. When older cables or other typedclasses of cables or accessories are connected to the system, voltages lower than those shown may be necessary. Consult the manufacturers of the cables and/or accessories before applying the test voltage.

Maximum dc Field Nominal Test Voltages-kV

mils (mm) DuringlAfîer First Installation 5 Years

A 6 A [ B I A I B

insulation Thickness

Table E-1 DC Field Test Voltages

8-1000 (8.4-507) AbovelOOO(507)

6-1000 (13.3-507) Above 1000 (507)

Above 1000 (507)

1-2000 (42.4-1013)

2-1000 (33.6)-507)

Rated Voltage Phase to Phase kV

90 (2.29) 115 (2.92) 28 36 11 140(3.56) 140(3.56) 1 28 I 36 1 11

115 (2.92) 140 (3.561 36 I 44 11 14 175 (4.45) 175 (4.45) 36 4 11 14

220 (5.59) 220 (5.59) 56 64 18 20

260 (6.60) 320 (8.13) ¡ 80 96 ¡ 25 30

175 (4.45) 220 (5.59) 56 64 18 20

5

1-2000(42.4-1013) I 280 (7.11)

1/0-2000(53.5-1013) 1 345(8.76)

4/0-2000(107.2-1013) 445 (11.3)

8

345 (8.76) 84 100 I 26 I 31

420 (10.7) 100 124 31 39

580 (14.7) 132 172 41 54

15

25

28

35

46

Column A - 100% Insulation Level Column B - 133% Insulation Level


~

ICEA S-94-649-2000

Conductor sire,

AWG or kcmii imm')

Rated Circuit Voltage,

Phase-tophase Voltage

APPENDIX F OPTIONAL FACTORY DC TEST

Insulation Thickness mils (mm)

dc Test Voltage, kV

100 Percent Level [ 133 Percent Level 100 Per- 133 Per- cent In- cent in-

Level Level Minimum Maximum Minimum Maximum ---

DATE: 07l24100

l

A factory dc voltage test may be performed with prior agreement between the manufacturer and the purcnaser.

The equipment for the dc voltage test shall consist of a battery, generator or suitable rectifying equipment and shall be of ample capacity. The initially applied dc voltage shall be not greater than 3.0 times the rated ac voltage of the cable. The duration of the dc voltage test shall be 15 minutes.

I

Table F-l DC Test Voltages

8 1 O00 (8.37-506.7)

1001-3000 (506.8-1 520)

6-1 o00 (1 3.3-506.7)

1001-3000 (506.8-1 520)

2- 1 O00 (33.6506.7)

I

1o01-3000 1 (506.8-1520)

2001 -5000

5001 -8000

8001-1 5000

85 (2.16) 1 120 (3.05) 1 110 (2.79) 145 (3.68) I 35 1 45 1 I 35 ! 45 I

135 (3.43) 135 (3.43) 170 (4.32)

110 (2.79) 145 (3.68) 135 (3.43) 170 (4.32)

165 (4.19) 205 (5.21) 165 (4.19) 205 (5.21) 45 55

165 (4.19) 205 (5.21) 210 (5.33) 250 (6.35) 70

80

I I i 70 1 210 (5.33) 250 (6.35) 210 (5.33) 250 (6.35)

5001-25000 1-3000 (42.4-1 520)

I 245(6.22) 1 290(7.37) 1 305 (7.75) 1 350 (8.89) 1 100

25001 -28000 . 125 y (42.4-1 1-3000 520)

265 (6.73) I 310 (7.87) 330 (8.38) 375 (9.53) 1 105 I I

89

28001-35000 330 (8.38) 375 (9.53) 1 400 (10.; 450 (1 1.4) 125 155 I (53.51 520)

4'0-3000 35001-46000 1 (107.2-1520)

425 (10.8) 485 (12.3) 550 (14.0) 610 (15.5) 165 1 215


ICEA S-94-649-2000 DATE: 07/24/00

APPENDIX G REDUCED NEUTRAL DESIGNS

These are suggested reduced neutrals, consuit the cable manufacturer for availability and suitability of neutrals.

Table G-1

Concentric Copper Conductor Minimum Number of Wires

Insulated Copper Conductor

Size, AWG or kcmil

... ... ... I 250 /I 17

I l l ... 23 I 15 1 ... 1 ...

21 1 13 ... I ... ~~~

...

1 ... ...

600 I I 25 I 16 10

650 27 17 I 11

... I 31 1 20 1 12 1 10 I ,

... ... 16 I 13 26 1

... ... 32 20 16

... ... ... 24 20

... ... 1 ... I 28

... ... ...

Table G-2

Concentric Copper Conductor Minimum Number of Wires Insulated Copper 11 Condudor

II Size’AWGorkcmil II 16AWG I 14AWG I 12AWG I 10AWG II

II 500 II 25 I 16 I . 10 I ...

...

600 29 19 12

650 32 20 I 13

... I 23 15 ... I I

II 1 O00 ...

... ... 1 24 I 15

... ... 29 i a -

II 1750 II ... I ... I 34 I 21 II II 2000 II ‘.‘ I ...


ICEA S-94-649-2000

Table G-3

Insulated Copper ¡mum Number of Wires

Table G-4 One-sixth Neutral Concentric Conductor for Aluminum Center Conductor ¡i

Concentric Copper Conductor Minimum Number of Wires

91

DATE: 07/24/00


ICEA S-94-649-2000

750

1 O00

1250

DATE: 07/24/00

23 I 14 ... ... i

... 24 15 10 l I

30 19 12 ... I

Table G-5 ûneeishth Neutral Concentric Conductor for Aluminum Center Condu

Concentric Copper Conductor Aluminum Minimum Number of Wires

... ... ...

10 ... I ...

... l6oOl 18 i 12 i l ... I

2000 ... ... 24 15

Table G-6

Insulated Aluminum


ICEA S-94-649-2000

Tables G-1 througn G-5 were calculated by the following equation:

Where:

CMA = Conductor Size in circular mils %IACS = Copper - 100

Aluminum - 61 Neutral = Neutral Size (Le., 1, 113, 116, etc.) Wire Size Nominal diameter of one neutral wire in mils N, = Number of wires in neutral

=

DATE: 07/24/00

. I-

Fractional wire portion was rounded as f6llows:

< 0.1 - Round down 2 0.1 - Round up

Example 1, consider a 750 kcmil Aluminum conductor and a 1/6 neutral with a 12 AWG wire.

(750,000 x 1/6 x 61)

100 x 80.8’ N wires =

N~~~~~ = I I . 679

This would be rounded to 12 wires.

Exampie 2, consider a 750 kcmil CoppB conductor and a 1/6 neutral with a 1 O AWG wire.

- (750,000 x 1/6 x i 00) ’ N w r e s -

100 x I 01.9’

= 12.038

This would be rounded to 12 wires.

.93 COPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling ServicesCOPYRIGHT Insulated Cable Engineers Association, IncLicensed by Information Handling Services

ICEA S-94-649-2000 DATE: 07124100

APPENDIX H ADDITIONAL CONDUCTOR INFORMATION

Table H-1 Solid Aluminum and Comer Conductors

Approximate Weight Conductor

Sue, Aluminum Copper

g/m Pounds per 1000

glm Feet AWG or kcmil Pounds per 1000

Feet

16

15

14

13

12

1 1

10

9

8

7

6 5 4

3

2

1

1 IO

210

310

4JO

250

300

350

400

450

...

...

...

... 6.01

7.57

9.56

12.04

15.20

19.16

24.15

30.45

38.41

48.43

61 .O7

77.03

97.15

122.5

154.4

194.7

230.1

276.1

322.1

368.2

414.4

...

...

...

...

8.94

11.3

14.22

17.92

22.62

28.52

35.94

45.32

57.17

72.08

90.89

114.6

144.6

182.3

229.8

289.8

342.4

410.9

479.4

547.9

616.3

500 460.2 648.8

7.81

9.87

12.4

15.7

19.8

24.9

31.43

39.62

49.98

63.03

79.44

100.2

126.3

159.3

200.9

253.3

319.5

402.8

507.8

640.5

... b

...

...

...

...

...

11.6

14.7

18.5

23.4

29.4

37.1

46.77

58.95

74.38

93.80

118.2

149.0

188.0

237.1

298.9

377.0

475.5

599.5

755.8

953.2

...

...

...

...

...

...


ICEA S-94-649-2000 DATE: 07124100

Table H-2 Concentric Stranded Class B Aluminum and Copper Conductors

Approximate Weight

Aluminum C Q P W Approximate Diameter of

Each Strand

mils mm

Conductor Number of Size, AWG of Strands

g/m Pounds per

a/m 1000 Feet kcmil Pounds per

1000 Feet

8 7 6 5 4 3 2 1

1 IO 20 310 410 250 300 350 400 450 500 550 WO 650 700 750 800 900 1 O00 1100 1200 1250 1300 1400 1500 1600 1700 1750 1800 1900 2000

--

4 37

7 7 7 7 7 7 7

19 19 19 19 19 37 37 37 37 37 37 61 61 61 61 61 61 61 61 91 91 91 91 91 91 127 127 127 127 127

48.6 54.5 61.2 68.8 77.2 86.7 97.4 66.4 74.5 83.7 94.0

105.5 82.2 90.0 97.3

104.0 110.3 116.2 95.0 99.2

103.2 107.1 110.9 114.5 121.5 128.0 109.9

117.2 119.5 124.0 128.4 112.2 115.7 117.4 119.1 122.3

114.8

1.23

125.5

1.39 1.56 1.75

.1.% 2.20 2.47 1.69 1.89 2.13 2.39 2.68 2.09 2.29 2.47 2.64 2.80 2.95 2.41 2.52 2.62 2.72 2.82 2.91 3.09 3.25 2.79 2.92 2.98 3.04 3.15 3.26 2.85 2.94 2.98 3.02 3.1 1 3.19

15.5 19.5 24.6 31.1 39.2 49.4 62.3 78.6 99.1 125 157 199 235 282 329 376 422 469 517 563 61 O 657 704 751 845 939

1032 1126 1173 1220 1313 1408 1501 1596 1643 1691 1783 1877

23.1 29.1 36.7 46.2 58.3 73.5 92.7 117 147 1 86 234 296 349 419 489 559 629 699 768 838 908 978

1050 1120 1260 1400 1540 1680 1750 1820 1960

' 2100 2240 2370 2440 2510 2650 2790

51.0 64.2 80.9 102 129 162 205 259 326 41 1 51 8 653 772 925

1 O80 1236 1390 1542 1700 1850 2006 21 60 2316 2469 2780 2086 3394 3703 3859 4012 4320 4632 4936 5249 5403 5562 5865

75.9 95.7 121 152 192 242 305 385 485 61 1 77 1 972

1150 1380 1610 1840 2070 2300 2530 2760 2990 3220 3450 3680 4140 4590 5050 5510 5740 5970 6430 6890 7350 7810 8040 8270 8730

6176 91 90


IC EA S -94-649-20 O0 DATE: 01/24/00

Table H-3 Concentric Stranded Class C and D Aluminum and Copper Conductors

Class c Class D

Conductor Approximate Diameter of Each Approximate Diameter of Each Strand Number of Strand

mils mm mils mm

Size, AWG or Number of

kcmil Strands Sbands

8 7 6 5 4 3 2 1

1 /o a0 310 410 250 300 350 400 450 500 550 600 650 700 750 800 900 1 O00 1100 1200 1250 1300 1400 1500 1600 1700 1750 1800 1900 2000

19 19 19 19 19 19 19 37 37 37 37 37 61 61 61 61 61 61 91 91 91 91 91 91 91 91 127 127 127 127 127 127 169 169 169 169 169 169

29.5 33.1 37.2 41.7 46.9 52.6 59.1 47.6 53.4 60.0 67.3 75.6 64.0 70.1 75.7 81 .o 85.9 90.5 77.7 81.2 84.5 87.7 90.8 93.8 99.4 104.8 93.1 97.2 99.2 101.2 105.0 108.7 97.3 100.3 1 01.8 103.2 106.0 108.8

0.749 0.841 0.945 1 .O6 1.19 1.34 1.50 1.21 1.36 1.52 1.71 1.92 1.63 1.78 1.92 2.06 2.18 2.30 1.97 2.06 2.15 2.23 2.31 2.38 2.53 2.66 2.36 2.47 2.52 2.57 2.67 2.76 2.47 2.55 2.59 2.62 2.69 2.76

37 37 37 37 37 37 37 61 61 61 61 61 91 91 91 91 91 91 127 127 127 127 127 127 127 127 169 169 169 169 169 169 217 21 7 217 21 7 21 7

21.1 23.7 26.6 29.9 33.6 37.7 42.4 37.0 41.6 46.7 52.4 58.9 52.4 27.4 62.0 66.3 70.3 74.1 65.8 68.7 71.5 74.2 76.8 79.4 84.2 88.7 80.7 84.3 86.0 87.7 91 .o 94.2 85.9 88.5 89.8 91.1 93.6

0.536 0.602 0.676 0.759 0.853 0.958 1 .O8

0.940 1 .O6 1.19 1.33 1.50 1.33 1.46 1.57 1.68 1.79 1.88 1.67 1.74 1.82 1.88 1.95 2.02 2.14 2.25 2.05 2.14 2.18 2.23 2.31 2.39 2.18 2.25 2.28 2.31 2.38

~~ 217 96.0 2.44 The weights of Class C and Class 0 conauctors are the same as for the equivalent Class B conductor (see Taole H-2). NOTE:


ICEA 5-94-649-2000 DATE: 07/24/00

APPENDIX I ETHYLENE ALKENE COPOLYMER (EAM)

The purpose of this discussion is to familiarize the reader with the chemical designation, EAM. Cable manufacturers may desire to supply a filled or unfilled EAM compound where specifications require a thermoset material such as XLPE, TRXLPE or EPR.

Ethylene alkene copolymer (EAM) is the ASTM nomenclature (E-Ethylene, A-Alkene and M-repeating CH2 unit of the saturated polymer backbone) for copoiymers consisting of ethylene and an alkene comonomer. The chemical nomenclature ‘alkene’, which includes ethylene, is defined by the Intemational Union of Pure and Applied Chemistry (IUPAC) in its publication Nomenclature of Organic Chemistry as follows:

“Alkenes are hydrocarbons with a carbon-carbon double bond. Specific alkenes are named as a derivative of the parent alkane, which is the saturated form, ¡.e.. no carbon-carbon double or triple bonds. Alkanes are named according to the number of carbon atoms in the chain. The first four members of the alkane series (methane, ethane, propane, and butane) came into common use before any attempt was made to systematize nomenclature. Those with 5 and greater carbon atoms are derived from Greek numbers (Penta, hexa, etc.).”

Continuing technological developments in the manufacture of polymers for wire and cable applications have resulted in the ability to polymerize (chemically join) ethylene with other monomers such as butene, hexene and octene rather than the conventional propylene. Polymers can be manufactured in various ways, as can any copolymer of ethylene and an alkene. These variations include the type of poiymerization catalysffco-catalyst, process conditions, molecular weight, ethylene/comonomer ratio, and ethylene (or comonomer) distribution. The resultant polymers may provide improvements while complying with applicable requirements in ICEA standarcs.

As the industry progresses towards performance based standards, it is appropriate to consider a more general material classification such as EAM, rather than create a series of ethylene based polymeric designations. sucn as EO (Ethylene Octene), EH (Ethylene Hexene) or EB (Ethylene Butene).

97


ICEA S-94-649-2000

Documents

Transcript of ICEA S-94-649-2000