ICEA S-94-649-2004
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ICEA S-94-649-2004 standard for power cables...
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STANDARD FOR CONCENTRIC NEUTRAL CABLES
Approved by AMERICAN NATIONAL STANDARDS INSTITUTE
0 2 0 0 4 by
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S TA N D A R D F O R
Standard
Approved by Insulated Cable Engineers Association, Inc.: August 31, 2004 Accepted by IEEEíICC2-A 14: September 9,2004 Accepted by AEIC: Cable Engineering Committee: September 13, 2004 Approved by ANSI: September 20,2005
including translation into other languages, reserved under the Universal Copyright and the international and Pan American Copyright Conventions.
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NOTICE AND DISCLAIMER The information in this publication was considered technically sound by the consensus of persons not necessarily mean that there is unanimous agreement among every person participating in the development of this document. The Insulated Cable Engineers Association, Inc. (ICEA) standards and guideline publications, of which the document contained herein is one, are developed through a voluntary consensus standards development process. This process brings together persons who have an interest in the topic covered by this publication. While ICEA administers the process and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or verify the accuracy or completeness of any ICEA disclaims liability for personal injury, property, or other damages of any nature whatsoever, whether application, or reliance on this document. ICEA disclaims and makes no guaranty or warranty, expressed or implied, as to the accuracy or completeness of any information published herein, and disclaims and makes no warranty that the information in this document will fulfill any of your particular purposes or needs. ICEA does not undertake to guarantee the performance of any individual manufacturer or seller's products or services by virtue of this standard or guide. other services for or on behalf of any person or entity, nor is ICEA undertaking to perform any duty owed by reasonable care in any given circumstances. Information and other standards on the topic covered by this publication may be available from other sources, which the user may wish to consult for additional views or information not covered by this publication. document. ICEA does not certify, test, or inspect products, designs, or installations for safety or health purposes. Any certification or other statement of compliance with any health or safety-related information in statement.
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DATE: 10/14/04
FOREWORD
developed by the Insulated Cable Engineers Association Inc. (ICEA). for his particular need. Existence of an ICEA standard does not in any respect preclude the manufacture or conformity with this Standard. be provided. Suggestions for improvements gained in the use of this Standard will be welcomed by the Association.
and Electronics Engineers, Insulated Conductors Committee, Subcommittee A, Discussion Group A-1 4 for following:
F. Kuchta, Chairman
D. Fox B. Temple
P. Cinquemani N. Ware
S. Campbell R. Fleming
A. Pack B. Vaughn
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ICEA S-94-649-2004
DATE: 10/14/04
1.2 GENERAL INFORMATION ...................................................................................................................1 1.3 INFORMATION TO BE SUPPLIED BY PURCHASER ........................................................................ 1 2 2
5 2.1.1 Copper Conductors ................................................................................................................... 2.1.2 5 2.2 OPTIONAL SEALANT FOR STRANDED CONDUCTORS ................................................................. 2.3 CONDUCTOR SIZE UNITS ................................................................................................................... 6 6 6 2.4.1 2.4.2
13 3.2 EXTRUDED SHIELD THICKNESS ..................................................................................................... 13 3.2.1 3.3 PROTRUSIONS AND CONVOLUTIONS ...........................................................................................13 3.4 VOIDS ................................................................................................................................................... 14 3.6.1 3.6.2 Extruded Nonconducting Material (For EPR Insulation Only) ................................................ 3.6.3 Semiconducting Tape ............................................................................................................. 14
Part 4 INSULATION........................................................................................................................................ 4.2.1 4.2.1.1 4.2.1.2 4.2.1.3
14
15 16 16 16
For Delta Systems Where One Phase May Be Grounded For Periods Over One Hour ..........................................................................................................
16 16
16
4.3.1 4.3.2 Electrical Requirements .......................................................................................................... 17 Partial-DischargeExtinction Level for Discharge-Free Designs Only ...................... 17 4.3.2.1 4.3.2.2 Voltage Tests 4.3.2.3 18
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DATE: 10/14/04 4.3.3.1 4.3.3.2 4.3.4
Part 5.1 5.2 5.3 5.4
19
EXTRUDED INSULATION SHIELD ....................................................................................................22 THICKNESS AND INDENT REQUIREMENTS .................................................................................. 22 PROTRUSIONS ................................................................................................................................... 23 INSULATION SHIELD REQUIREMENTS .......................................................................................... 23 23 5.4.1 Insulation Shield for DISCHARGE-FREE Cable Designs Only ............................................. Removability .............................................................................................................. 23 5.4.1.1 Voids .......................................................................................................................... 5.4.1.2 23 5.4.1.3 Electrical Requirements ............................................................................................ 24 5.4.1.4 Wafer Boil Test ........................................................................................................... 24 5.4.1.5 24 5.4.2 Insulation Shield for DISCHARGE-RESISTANTCable Designs Only .................................. .. .............................................................................................................. 24 Removability 5.4.2.1 5.4.2.2 Electrical Requirements ............................................................................................ 24 5.4.2.3 Wafer Boil Test .......................................................................................................... 24 5.4.2.4
Part 25 6.1 25 6.2 25 6.3 LAY LENGTH ....................................................................................................................................... 6.4 CONCENTRIC WIRES ......................................................................................................................... 25 6.4.1 Minimum Sizes ........................................................................................................................ 25 6.4.2 Contrahelical Wire ................................................................................................................... 25 6.4.3 Diameter and Area .................................................................................................................. 25 6.5 FLAT STRAPS ..................................................................................................................................... 26 OPTIONAL WATER BLOCKING COMPONENTS FOR METALLIC SHIELD ................................. 6.6
26
28 Pari JACKETS ............................................................................................................................................. 28 7.1 7.1.1 Low and Linear Low Density Polyethylene, Black (LDPULLDPE) ........................................ 28 29 7.1.2 Medium Density Polyethylene, Black (MDPE) ........................................................................ High Density Polyethylene, Black (HDPE) .............................................................................. 30 7.1.3 31 7.1.4 Semiconducting Jacket Type II ............................................................................................... 32 7.1.5 7.1.6 Polyvinyl Chloride (PVC) ......................................................................................................... 33 7.1.7 Chlorinated Polyethylene (CPE) ............................................................................................. 34 7.1.8 Thermoplastic Elastomer (TPE) ............................................................................................. 35 7.1.9 Polypropylene, Black (PP) ...................................................................................................... 36 JACKET TYPES ................................................................................................................................... 37 7.2 7.2.1 Extruded-To-FillJacket ........................................................................................................... 37 7.2.2 Overlaying Jacket .................................................................................................................... 37 JACKET IRREGULARITY INSPECTION ........................................................................................... 37 7.3 7.3.1 Nonconducting Jackets ........................................................................................................... 37 7.3.2 Semiconducting Jackets ......................................................................................................... 37
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DATE: 10/14/04 8.2.1 Jacketed Cable ....................................................................................................................... 39 39 8.2.2 Unjacketed Cable .................................................................................................................... 39 8.2.3 8.2.4
Part 9.1 TESTING .............................................................................................................................................. 41 9.2 9.3 CONDUCTOR TEST METHODS ........................................................................................................ 41 9.3.1 41 9.3.2 Cross-Sectional Area Determination ...................................................................................... 41 9.3.3 9.4 9.4.2 Measurement of Thickness .................................................................................................... 41 9.4.2.1 9.4.2.2 42 9.4.3 9.4.4 Size of Specimens .................................................................................................................. 42 9.4.5 9.4.6 43 9.4.7 Calculation of Area of Test Specimens .................................................................................. 43 9.4.8 Test Temperature ...................................................................................................... 43 9.4.8.1 Type of Testing Machine ........................................................................................... 44 9.4.8.2 Tensile Strength Test ................................................................................................ 44 9.4.8.3 Elongation Test .......................................................................................................... 44 9.4.8.4 9.4.9 Aging Tests ............................................................................................................................. 44 Aging Test Specimens .............................................................................................. 44 9.4.9.1 Air Oven Test ............................................................................................................. 45 9.4.9.2 45 9.4.9.3 45 9.4.1 1 Solvent Extraction ................................................................................................................... 45 45 9.4.12.1 9.4.1 3 Amber, Agglomerate, Gel, Contaminant, Protrusion, Indent, Convolutions and Void Test ................................................................................................................................. 46
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ICEA 5-94-649-2004
DATE: 10/14/04 49 49
9.6
9.7.1 Heat Shock .............................................................................................................................. 49 9.7.2 50 9.7.3 50 9.8 VOLUME RESISTIVITY .................................................................................................... 50 9.8.1 Conductor Shield (Stress Control) .......................................................................................... 9.8.2 Insulation Shield ...................................................................................................................... 50 9.8.3 Test Equipment ....................................................................................................................... 51 9.8.4.1 9.8.4.2 9.8.4.3 51 9.8.5 Semiconducting Jacket Radial Resistivity Test ...................................................................... 9.8.5.1 52 Test Equipment Setup ............................................................................................... 52 9.8.5.2 Calculation ................................................................................................................. 53 9.8.5.3 9.9 ADHESION (Insulation Shield Removability) TEST ........................................................................ 54 9.10 SHRINKBACK TEST PROCEDURE ............................................................................................. 54 9.10.1 Sample Preparation ................................................................................................................ 54 54 9.1 0.2 54 9.11 54 AC VOLTAGE TEST ....................................................................................................................... 55
9.1
55 9.1 .2 AC Voltage Test ...................................................................................................................... PARTIAL-DISCHARGETEST PROCEDURE ............................................................................... 55
DIELECTRIC STRENGTH OF EXTRUDED NONCONDUCTING POLYMERIC STRESS CONTROL LAYERS ................................................................................ 55 55 9.1 5.1 Water Under the Jacket .......................................................................................................... 55 9.1 5.2 Water in the Conductor ...........................................................................................................56 9.1 5.3 Water Expulsion Procedure.................................................................................................... 56 9.1 5.4 Presence of Water Test .......................................................................................................... 56 9.16 PRODUCTION TEST SAMPLING PLANS .................................................................................... 57 Part 10 10.0
GENERAL
-
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ICEA S-94-649-2004
DATE: 10/14/04
Load Cycle ................................................................................................................. 10.1 5 4 65 65 10.1.6 Accelerated Water Treeing Test (AWTT) Procedure ............................................................ General ...................................................................................................................... 65 10.1.6.1 Quantity of Cable To Be Aged ................................................................................... 65 10.1.6.2 10.1.6.3 Conduit Fixture .......................................................................................................... 65 10.1.6.4 10.1.6.5 10.1.6.6 10.1.6.7 10.1.6.8 10.1.6.9 1 0.1.6.1
66 Water ......................................................................................................................... 66 Ambient Temperature ............................................................................................... 66 Test Procedure .......................................................................................................... 66 Water pH ................................................................................................................... 68 68 69
10.1.8 Qualification Test Physical Measurements ............................................................................ 10.2.1
Scope ......................................................................................................................................
10.2.2.1 10.2.2.2 10.2.2.3 10.2.2.4
Fixture ........................................................................................................................ Load Cycling ..............................................................................................................
70
70 70 70 70
71 JACKET MATERIAL QUALIFICATION TESTS ............................................................................ 72 10.3.1 Polyethylene And Polypropylene Jackets ............................................................................... 72 10.3.1.1 73 10.3.1.1.2 Test Procedure ................................................................................................... 73 Absorption Coefficient Test ....................................................................................... 73 10.3.1.2 10.3.2 SemiconductingJackets ......................................................................................................... 73 10.3.2.1 73 10.3.3 Polyvinyl Chloride and Chlorinated Polyethylene Jackets ...................................................... 73 10.3.3.1 73 10.3.3.1.1 Test Samples...................................................................................................... 73 10.3.3.1.2 Test Procedure ................................................................................................... 73 73 10.3.4 Extruded Red Stripe For Jackets ............................................................................................ 10.3.4.1 73 10.3.4.1.1 Test Samples
10.3
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ICEA S-94-649-2004
DATE: 10/14/04
10.5.6.1 Test Environment ...................................................................................................... 77 10.5.6.2 10.5.6.3 10.5.7 Dissipation Factor CharacterizationTest ................................................................................ 78 10.5.7.1 Thermal Conditioning ................................................................................................ 78 10.5.7.2 Dissipation Factor Testing ......................................................................................... 78 10.5.7.3 Part 11 APPENDICES ................................................................................................................................. 79 NEMA. ICEA. IEEE. ASTM AND ANSI STANDARDS (Normative) ....................... 79 APPENDIX A Al 79 A2 IEEE AND ANSI STANDARDS .............................................................................................. 79 A3 A4 79 EMERGENCY OVERLOADS (Normative) ............................................................. 82 APPENDIX APPENDIX C SHIELDING (Informative) ........................................................................................ 88 APPENDIX D DEFINITION OF SHIELDING................................................................................................. 88 Dl FUNCTIONS OF SHIELDING ................................................................................................ 88 D2 USE OF INSULATION SHIELDING ....................................................................................... 88 D3 D4 D5 89 SPLICES AND TERMINATIONS ........................................................................................... 89 D6 HANDLING AND INSTALLATION PARAMETERS (Informative) ......................... 90 90 El 90 E2 DRUM DIAMETERS OF REELS ............................................................................................ 90 E3 MAXIMUM TENSION AND SIDEWALL BEARING PRESSURES ....................................... 90 E4 90 E5 During Installation ...................................................................................................... 90 E5.1 E5.2 90 In Service ................................................................................................................... E5.3 90 OPTIONAL FACTORY DC TEST (Informative) ..................................................... 92 APPENDIX F REDUCED NEUTRAL DESIGNS (Informative) ..................................................... 93 APPENDIX G ADDITIONAL CONDUCTOR INFORMATION (Informative) ................................. 97 APPENDIX H ETHYLENE ALKENE COPOLYMER (EAM) (Informative) ................................. 100 APPENDIX REVISED AWTT CONDUIT FIXTURES (Informative) ......................................... 101 APPENDIX
-
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ICEA 5-94-649-2004
DATE: 10/14/04
Table 2-3 (Metric)
of Solid and Concentric Lay Stranded Conductor ................................................... Nominal Diametersfor Copper and Aluminum Conductors ................................. 10 Table 2-4 Table 2-4 (Metric) Nominal Diametersfor Copper and Aluminum Conductors ................................. 11 Factors for Determining Nominal Resistance of Stranded Conductors Table 2-5 Per 1000 Feet at 25 OC ................................................................................................ 12 Extruded Conductor Shield Thickness .................................................................... 13 Table 3-1 Extruded Conductor Shield Requirements ............................................................. 14 Table 3-2 Conductor Maximum Temperatures ........................................................................15 Table -1 Table 4-2 Dielectric Constant and Dissipation Factor ............................................................ 18 Table 4-3 Shrinkback Test Requirements Cables Having Sealed Strand Table 4-4 Conductors and/or a Tape Over the Conductor ..................................................... 19 Shrinkback Test Requirements All Cables Not Covered by Table 4-4 ................. 19 Table 4-5 Cable BIL Values ......................................................................................................... 20 Table 4-6 Conductor Sizes. Insulation Thicknesses and Test Voltages .............................. 20 Table 4-7 Conductor Sizes. Insulation Thicknesses and Test Voltages .............................. 21 Table 4-7 (Metric) Insulation Shield Thickness Cables With Wire Neutral ......................................... 22 Table 5-1 Extruded Insulation Shield Requirements Discharge-Free Designs ................... 23 Table 5-2 Table 5-3 Concentric Neutral Wire Size ....................................................................................26 Table 6-1 Full Neutral Concentric Copper Conductor ............................................................ 26 Table 6-2 One-third Neutral Concentric Copper Conductor .................................................. 27 Table 6-3 Table 7-1 Medium Density Polyethylene, Black (MDPE) ......................................................... 29 Table 7-2 Table 7-3 31 Table 7-4 Semiconducting Jacket Type II ................................................................................. 32 Table 7-5 Table 7-6 Chlorinated Polyethylene (CPE) ............................................................................... 34 Table 7-7 Thermoplastic Elastomer (TPE) ................................................................................ 35 Table 7-8 Polypropylene, Black (PP) ......................................................................................... 36 Table 7-9 Extruded-To-Fill Jacket Thickness and Test Voltage ............................................ Table 7-10 37 Table 8-1 Table 9-1 Table 9-2
40
Test Specimens for Physical and Aging Tests ....................................................... Insulation Shield Hot Creep Requirements ............................................................. 46
42
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DATE: 10114/04 Table F-1 Table Table G-2 Table G-3 Table G-4 Table G-5 Table G-6 Table H-1 Table H-2 Table H-3
DC Test Voltages ........................................................................................................ 92 One-sixth Neutral Concentric Conductor for Copper Center Conductor ............ 93 One-twelfth Neutral Concentric Conductor for Copper Center Conductor ........ 94 One-eighth Neutral Concentric Conductor for Aluminum Center Conductor ....95 One-twelfth Neutral Concentric Conductor for Aluminum Center Conductor ... 95 Solid Aluminum and Copper Conductors ............................................................... 97 98 Concentric Stranded Class C and D Aluminum and Copper Conductors ..........99
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DATE: 10/14/04
1.1 SCOPE
Part 1 GENERAL
crosslinked polyethylene and ethylene propylene rubber insulated single conductor or multiplexed concentric
1.2GENERAL INFORMATION "DISCHARGE-FREE" and the other as "DISCHARGE-RESISTANT", as well as allowing for selection of those individual components (such as conductors, insulation type and thickness, concentric neutral sizes, optional jackets, etc.) as required for specific installation and service conditions.
Each of these parts designates the materials, material characteristics, dimensions, and tests applicable
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DATE: 10/14/04 h. Description of installation. 2. Direct burial in ground. 3. Descriptions other than the foregoing. I.
Installation conditions.
conduits. 4. Method of bonding and grou ding of metallic neutral. 5. Wet or dry location. 6. Thermal resistivity (rho) of soil, concrete and/or thermal backfill. 1.3.2
Quantities and Description of Cable
a. Total number of feet, including test lengths, and lengths if specific lengths are required. b. etc.. C. Rated circuit voltage, phase-to-phase. d. e. complete description should be given. f. Type of insulation. g. Thickness of insulation in mils. h. Size of neutral. Type of jacket.
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Cable Core:
The portion of a cable which includes the conductor, the conductor shield, the insulation and the insulation shield.
Cable Core Extruder Run:
A continuous run of cable core with one conductor size, one conductor shield compound, one insulation compound and thickness, and one insulation shield compound.
requirements of this Standard. Contaminant: Dielectric Constant:
Discharge-Free Cable Design:
Any solid or liquid material which is not an intended ingredient. material as a dielectric to the capacitance of the same electrode configuration with a vacuum (or air for most practical purposes) as the dielectric. A cable designed to eliminate electrical discharge in the insulation at normal operating voltage.
Discharge-Resistant A cable design capable of withstanding electrical discharge. Cable Design: Dissipation 'Factor:
The cotangent of the dielectric phase angle of a dielectric material or the
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DATE: 10/14/04
Maximum Conductor Temperatures: Normal Operating:
The highest conductor temperature permissible for any part of the cable line under normal operating current load.
Emergency Overload:
The highest conductor temperature permissible for any part of the cable line during emergency overload of specified time, magnitude, and frequency of application.
Short Circuit:
The highest conductor temperature permissible for any part of the cable line during a circuit fault of specified time and magnitude.
Partial Discharge Level:
The maximum continuous or repetitious apparent charge transfer, measured in picocoulombs, occurring at the test voltage.
pc:
picocoulombs
Room Temperature (RT): Shipping Length:
A completed length of cable which has passed all test requirements. It may or customer.
Shipping Reel:
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D AT E : 10/14/04
ICEA S-94-649-2004
Part CONDUCTOR 2.0 GENERAL Conductors shall meet the requirements of the appropriate ASTM standards referenced in this Standard except that resistance will determine cross-sectional area as noted in 2.4 and diameters will be in accordance with 2.5. Compliance with cross-sectional area is not required. Requirements of a referenced ASTM standard shall be determined in accordance with the procedure or method designated in the referenced ASTM standard unless otherwise specified in this Standard. The following technical information on typical conductors may be found in Appendix H:
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DATE: 10/14/04
2.2OPTIONAL SEALANT FOR STRANDED CONDUCTORS
penetration may be incorporated in the interstices of the stranded conductor. Compatibility with the conductor shield shall be determined in accordance with ICEA Publication T-32-645. Longitudinal water
2.3CONDUCTOR SIZE UNITS equivalents for small sizes shall be found in Table 2-4. The metric equivalents for all sizes are found in Table 2-4 (Metric).
2.4CONDUCTOR DC RESISTANCE PER UNIT LENGTH
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2.5 CONDUCTOR DIAMETER The conductor diameter shall be measured in accordance with 9.3.3. The diameter shall not differ from -
Table 2-1 Weight Increment Factors' ~~
r
~~
Conductor TypdSize
Weight Factor (K)
Solid All Sizes
1
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ICEA 5-94-649-2004
Table 2-3 Nominal Direct Current Resistance in Ohms Per 1000 Feet at 25 OC of Solid and Concentric L y Strand d Conductor
I Conductor Si ze
DATE: 10/14/04
I
Solid Aluminum
Copper
Aluminum
I
Class B,C,D
-
8
1
Concentric Lay Stranded'
Uncoated Class B,C,D
Coated Class
Class C
Class
~
0.424
0.652 0.519 0.41 1 0.325 0.258
0.678 0.538 0.427 0.338 0.269
0.678 0.538 0.427 0.339 0.269
0.680 0.538 0.427 0.339 0.269
0.334
0.205
0.21 3
0.213
0.213
0.640 0.508 0.403 0.31 9 0.253
0.659 0.522 0.414 0.329 0.261
1 .O7 0.851
5 4
1 .O5 0.833 0.661 0.524 0.415
3
0.329
0.201
0.207
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ICEA S-94-649-2004
DATE: 10/14/04
Concentric Lay Stranded'
Solid ConductorSize
AWG
Or Kcmil
Aluminum
mm2
Aluminum
Copper
Coated
5 4
8.37 10.6 13.3 16.8 21.1
3.44 2.73 2.17 1.72 1.36
0.830
2.16 1.71 1.36 1 .O8 0.856
3
26.7
1 .O8
0.659
0.679
8 7
t
Uncoated
Copper Coated
Class B,C,D
Class
Class
0.846
2.22 1.76 1.40 1.11 0.882
2.22 1.76 1.40 1.11 0.882
2.23 1.76 1.40 1.11 0.882
0.672
0.699
0.699
0.699
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DATE: 10/14/04 Table 2-4
I
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ICEA S-94-649-2004 Table 2-4 (Metric) Nominal Diameters for Copper and Aluminum Conductors
DATE: 10/14/04
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DATE: 10/14/04
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ICEA S-94-649-2004
3.1
DATE: 10/14/04
Part 3 CONDUCTOR SHIELD (STRESS CONTROL LAYER)
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DATE: 10114/04 conductor shields with reduced thickness, protrusions and convolutions into the conductor shield shall not
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DATE: 10/14/04
ICEA S-94-649-2004
9.7.2 Heat Distortion
9.7.3 Cold Bend shall have a diameter in accordance with the following table:
Table 9-4
Inches
mm
0-0.800
0-20.32
0.801 and larger
Outside Diameter of Cable
20.32 and larger
8 10
1
9.8.1 Conductor Shield (Stress Control) shall be applied to the conductor shield spaced at least 2 inches (50.8 mrn) apart.
p=
IOOL
Where:
9.8.2 Insulation Shield apart.
The volume resistivity shall be calculated as follows:
-
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DATE: 10/14/04
ICEA S-94-649-2004
P=
100L
Where: -
9.8.3 Test Equipment
A.
9.8.4 Test Procedure 9.8.4.1 Two-electrode Method
9.8.4.2 Four-electrode Method The four-electrode method may be used as a referee method. Conductor shield: The samples shall be cut in half longitudinally and the conductor removed. Four silverpotential electrode. shall be placed at least
inch (25.4 mm) beyond each potential electrode.
9.8.4.3 Measurement The resistance of the conducting component between the electrodes shall be determined at the specified temperature.
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ICEA S-94-649-2004
DATE: 10/14/04
direction. The apparent resistivity of the jacket is calculated from the electrical measurement and geometry of the cable.
9.8.5.1 Sample Preparation
separated approximately 1/8 inch (3.2 mm) from the measuring electrode.
Electrode Semi-
G 2.0"
Concentric Neutral Electrode
E2
Figure 9-3 Sample Preparation for Radial Resistivity Measurement Legend:
The sample shall be tested in air at room temperature.
9.8.5.2 Test Equipment Setup voltmeters, an ammeter, an adjustable resistor and an adjustable voltage dc or 60 Hz ac power supply. The measuring circuit is connected as shown in Figure 9-4. This is done to prevent surface current from affecting the measurement. As it is adjusted, the measured
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DATE: 10/14/04
ICEA S-94-649-2004
G
G
E2
-
Reiu Ammeter n
Guard
Figure 9-4 Circuit for Radial Resistivity Measurement of Semi-Conducting Jackets
9.8.5.3 Calculation
cable sample, calculate the apparent resistivity as follows:
P, ):n I(
Where:
diametrically opposite from each other.
vo It
Meters
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DATE: 10/14/04
Adhesion test shall be performed in accordance with. ICEA T-27-58VNEMA WC-53 (Adhesion).
9.10 SHRINKBACK TEST PROCEDURE
Five samples, each 1.5 feet (0.45 m) are required for the test. A length of the specimen cable 17.5 feet
end pieces from the original cable length are to be discarded. 9.1 0.2
-
Test Procedure
performed three times, if required. At the end of each cooling period, the samples shall be measured for shrinkback using a micrometer, or preferably an optical measuring device. The selected measuring device shall have a minimum resolution of
maximum.
The measured values shall be in accordance with Tables 4-5 or 4-6 of Part 4. Only consider the worst sample of the five using the total shrinkback of both ends.
9.1
RETESTS ON SAMPLES Except for physical and aging properties and thickness tests Except for Amber, Agglomerate, Gel, Contaminant, Protrusion, Indent, Except for Internal Irregularity Test
See 9.4.1 6
See 9.4.13.3 See 9.4.1 4.3
they represent shall be considered as meeting the requirements of this Standard.
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DATE: 10114/04 considered as meeting the requirements of this Standard. Failure of any sample shall not preclude resampling and retesting the length of cable from which the original sample was taken.
9.12 AC VOLTAGE TEST 9.12.1 General between the conductor and the metallic shield with the metallic shield grounded. The rate of increase from the initially applied voltage to the specified test voltage shall be approximately uniform and shall be not more
This test shall be made with an alternating potential from a transformer and generator of ample capacity and shall have a wave shape approximating a sine wave as closely as possible. The initially applied ac test voltage shall be not greater than the rated ac voltage of the cable under test.
9.13 PARTIAL-DISCHARGE TEST PROCEDURE Partial-discharge test shall be performed in accordance with ICEA Publication T-24-380. The manufacturer shall wait a minimum of 7 days after the insulation extrusion process before the tests are
discharge test.
CONTROL LAYERS Determination of dielectric constant and dielectric strength shall be peiformed in accordance with ICEA
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on each end. The strands shall be individually separated and visually examined. If water is present, the
9.15.3 Water Expulsion Procedure of Water Test. As soon as possible after the procedure, both ends of the cable shall be sealed to prevent the ingress of water during shipment and storage.
To verify the presence of water in the conductor, the following steps shall be taken.
Each length of cable to be tested shall be sealed at one end over the insulation shield using a rubber cap filled with anhydrous calcium sulphate granules. The rubber cap shall be fitted with a valve. The valve on the rubber cap shall then be opened sufficiently to hear a flow of gas.
This procedure shall be repeated after placing new granules in the cap.
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DATE: 10/14/04
STANDARD
TEST
MINIMUM
REFERENCE
REFERENCE
FREQUENCY
dc Resistance
Part
9.3.1 and ICEAT-27-581
100%
Diameter
Part 2
ICEA T-27-581
Plan A
Temper
Part
ASTM
Manufacturer certification that required values are met
ElongationAfter Aging
Part 3
9.4.15
Plan
Volume Resistivity
Part 3
9.8.1
Plan
Thickness
Part 3
9.4.2
Plan
Voids, Protrusions and Irregularities
Part 3
9.4.1 3
Plan A
Wafer Boil
Part 3
9.4.1 2
Plan
Spark Test (Non-conducting Layer Only)
Part
K E A T-27-581
100%
~~~
~
_
_
_
_
_
_
_
_
_
_
~
9.4.8 and 9.4.9
~
Hot Creep
Part 4
Voids and Contaminants
Part4
9.4.13
Internal Irregularity Test (XLPE/TRXLPE Only) Part 4
9.4.14
Diameter
Appendix C
9.6
Shrinkback Test (XLPW RXLPE Only)
Part
9.10
II
Plan C
II
1
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Table 9-5
TEST
STANDARD REFERENCE
TEST METHOD REFERENCE
MINIMUM FREQUENCY
Dimensional Measurements
Part 6
9.5
Plan E
Unaged and Aged Tensile and Elongation
Part 7
9.4.8 and 9.4.9
Plan H
Thickness
Part 7
9.4.2
Plan E
Heat Distortion
Part 7
ICEA 1-27-581
Plan H
Heat Shock
Part 7
9.7.1
Plan H
Cold Bend
Part 7
ICEA T-27-581
Plan
Oil Immersion
Part 7
9.4.9.3
Plan H
Radial Resistivity
Part 7
9.8.3
Plan
ac Withstand Test
Part
9.12
Plan
Partial Discharge Test
Part 4
ICEA T-24-380
Plan
Jacket Spark Test
Part 7
100% ~
~~
Other Tests Part
Water in Conductor
Plan
9.15 I
I
Water Under Jacket
Part
Conductor Water Penetration Test, if applicable
Part
ICEA T-31-610
Part 6
ICEA T-34-664
9.15
~
~
~~
Plan
II
Plan C I
Plan
II
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ICEA S-94-649-2004
DATE: 10/14/04
Plan D
Plan E -
Table 9-6 Plan E
II
Per Extruder Run each shipping length 2 10% of shipping lengths
20 and greater
next higher integer value)
Plan Table -7 Plan Jacket Extruder Run Length-feet (meters) ~
less than 250 (127) 250 (127) and larger 250 (127) and larger 250
Samples
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DATE: 10/14/04
QUALIFICATION TESTS 10.0
GENERAL
Qualification tests included in this Standard are intended to demonstrate the capability of materials to be used in high quality cable with the desired performance characteristics. It is intended that the product furnished under this Standard shall consistently comply with all of the qualification test requirements. The tests are divided into five categories. A) Core Qualification i) Core Material Qualification Requirements ¡i) Manufacturing Qualification Requirements C) Jacket Material Qualification
D) CV Extrusion Qualification E) Other Qualification Tests
certified copy of the qualification test report that represents the cable being purchased. If a conductor shield/insulation combination, insulation shield or a completed cable design was qualified qualification tests, or thermomechanical qualification test, as applicable, in this standard.
Additional
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ICEA S-94-649-2004
DATE: 10/14/04
The results of all tests shall be provided in the qualification report.
10.1.1.2 Insulation/lnsulation Shield Qualification 120 days of testing (Tests 1-5). This test can be performed once and all cable manufacturers can use the
CS/I qualification test. The results of all tests shall be provided in the qualification report. shield without performing a separate insulation shield qualification test.
10.1.2 Manufacturing Qualification Requirements Once a set of cable core interfaces meet the Material Qualification Requirements, each cable Manufacturing Qualification Tests as outlined below. The Conductor Shield/lnsulation and Insulation/lnsulation Shield manufacturing qualification requirement may be met by conducting the appropriate tests on a single cable or on two different cables. The appropriate test must be repeated
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ICEA S-94-649-2004
DATE: 10/14/04
FLOW CHART FOR CORE QUALIFICATION TESTS
I Test Number High Voltage Time Test
I
21 Samples
I -
Electrical Measurements Para. 10.1.7 Sample 7
-
Para. 10.1.3
I
Physical Measurements
Hot Impulse Test
Test Number
Para. 10.1.4 Para. 10.1.4
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ICEA S-94-649-2004
DATE: 10/14/04
10.1.3 High Voltage Time Test (HVTT) Procedure A high voltage time test shall be made on samples of cable as shown in the Flow Chart (Test Numbers (3.9 kV/mm), based on the nominal insulation wall thickness of the sample, shall be applied under the will be reported for this test. Insulation Thickness at Failure
Measured insulation thickness immediately adjacent to the failure site.
AC Breakdown Step
The voltage step, calculated in V/mil (kV/mm) and based on the nominal insulation thickness of the sample, at which the sample failed.
AC Withstand Step
The highest voltage step, calculated in V/mil (kV/mm) and based on the nominal insulation thickness of the sample, that was maintained for an entire 5-minute period without the sample failing.
If a sample fails while the voltage is being increased from one step to the next, then both the ac added within the qualification report to clarify that the failure occurred during the voltage transition between steps. The minimum qualification ac withstand values are listed in Table 10-1.
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ICEA S-94-649-2004
DATE: 10/14/04
held for 30 seconds. It shall then be increased in 40 V/mil (1.6 kV/mm) steps and held for 30 seconds at each step, continuing to the step at which the terminal failure occurred. The voltage shall be held for until breakdown occurs. It must be documented in the test report that a termination failure occurred along with the active length of cable that was tested after re-termination.
10.1.4 Hot Impulse Test Procedure To establish impulse performance characteristics, a hot impulse test shall be made in accordance with
horizontally mounted, 3-inch nominal diameter polyethylene or PVC conduit that is 6-feet (1.8m) in length. The conduit ends shall be closed to prevent air circulation into or out of the conduit. For hot impulse tests, the temperature of the conductor shall be equal to the rated emergency overload temperature of the cable +0/-5”C. The temperature shall be achieved by circulating current in the conductor with no current in the metallic shield. Ten impulses of positive polarity with a magnitude equal to the BIL shown in Table 4-6 shall be applied,
impulses of negative polarity applied at each step and continuing to cable breakdown outside the terminals. qualification test report. If a failure occurs outside of the active length of the sample, the value obtained shall be reported as a failure outside the active length. Samples must meet the minimum impulse withstand requirements provided in paragraph 4.3.2.3 of this standard.
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ICEA S-94-649-2004
DATE: 10/14/04
10.1 5 4 Load Cycle during which the current is on for the first 8 hours and off for the remaining 16 hours. The conductor voltage is applied during the load cycle. Temperatures shall be established before the test is performed by test sample.
10.1.6 Accelerated Water Treeing Test (AWTT) Procedure 10.1.6.1 General .placed in a 3-inch nominal diameter polyethylene or PVC conduit and with both the conductor interstices and
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ICEA S-94-649-2004
DATE: 10/14/04
10.1.6.4.1 Structures Above Conduit Fixtures Structures, such as platforms, walkways, etc., may be installed above the conduit fixtures if temperature profiles demonstrate that the structures do not affect the required temperatures of the cable.
10.1.6.4.2 Conduit Fixture Dimensions Conduit fixtures shall be constructed such that individual cable samples are produced that meet the within five years of the date of this standard.
10.1.6.5 Water maintained within .4 inches from the top of the conduits at all times throughout the test. Tap water shall also be maintained within the interstices of the conductors at all times throughout the test. Before each test -
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DATE: 10/14/04
in-water insulation shield temperature requirement, it may be necessary to use a thin blanket of thermal profile for the outermost conduits (conduits not bounded on both sides by other conduits containing similarly energized cables). If insulation is required, it must remain in place throughout the aging period conductor in air and water and the insulation shield in water shall be reported graphically in the qualification test report. The 24-hour load cycle temperature profile for the insulation shield in water determined by the dummy load cycle shall be followed during the cable aging load cycle. If a laboratory has more than one bank of conduit fixtures, temperature profiles must be established for each bank of fixtures. Temperature profiles must also be established for the outermost conduit fixtures (conduits not bounded on both sides by other conduits containing similarly energized cables) in a multiple
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ICEA S-94-649-2004
DATE: 10/14/04
180-Dav Samples These samples must experience a cumulative total time of 180 days at the proper aging voltage. They must also experience 129 days with thermal load cycles at the required time and temperature values. The objective is to have repeating, seven-day load cycle periods consisting of 5 consecutive days with
shall be no periods with more than eight consecutive days with thermal load cycles and no periods with more than four consecutive days with no thermal load cycles. cycle must be repeated. There will be an exception to this for up to five load cycles that do not achieve this requirement, the total voltage aging time may exceed 180 days. When this occurs, report the total
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DATE: 10/14/04
ICEA S-94-649-2004 Table 10-1 Minimum ac Withstand Values I
~~
Type Crosslinked Polyethylene
After 120 Days After 180 Days After 360 Days of AWTT Aging of AWTT Aging of AWTT Aging
Prior To Cyclic Aging
After Cyclic Aging
620 (24.4)
620 (24.4)
300 (1 1.8)
660 (26.0)
660 (26.0)
Tree Retardant 620 (24.4) Crosslinked Polyethylene
Not Required
580 (22.8)
Not Required 380 (15.0)
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ICEA S-94-649-2004
DATE: 10/14/04
10.1.8 Qualification Test Physical Measurements To
u
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ICEA S-94-649-2004
DATE: 10/14/04
10.2.2.3 Electrical Measurements Initially and after 14 test cycles partial discharge (unless otherwise specified) and dissipation factor measurements shall be made with the cable conductor at room temperature and at the emergency overload
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insulations:
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ICEA S-94-649-2004 10.3.1.1.1 Test Specimen
DATE 10/14/04
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DATE: 1 0/14/04 10.3.4.1.1 Test Samples Five samples shall be prepared from material intended for extrusion.
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