CS9+Draft+G+June 2006ID615VER26

Specification for Extruded Insulation Power Cables
AEIC CS9-06 1
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Edition and their Accessories Rated aboe !6 "# throu$h %!& "#ac
SPECI'ICA(I)* ')R
E+(R,-E- I*S,.A(I)* P)/ER CA0.ES
A*- (1EIR ACCESS)RIES
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First Edition
(Draft G, June 4, 2006)
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Association of Edison Illuminating Comanies
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Co/rig"t 2006 */ t"e Association of Edison Illuminating Comanies
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AEIC CS9-06 1
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AEIC CS9-06 1
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AEIC CS9-06 1
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2
AEIC CS9-06 1
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')R/AR-
This specifcation was prepared by the AEIC Cable Engineering Committee Task Group 10-2:
Specifcation for Extruded Insulation Power Cables and their Accessories Rated above 46 kV
through 345 kVac. At the time it was approved, the task group had the following membership:
W. A. Banker
L. W. Bobb
R. Ghafurian
J. M. Hans
R. A. HartleinH
H. R. Jones
T. M. Kopchick
G. A. MacPhail - Chair
R. I. Mosier
T. Nishioka Vice Chair
E. T. Robeson
G. B. Shattuck
M. R. Smith
J. C. Spence
J. G. Valdes
D. M. Wedam
At the time the specifcation was approved, the AEIC Cable Engineering Committee had the
following membership:
W. A. Banker
L. W. Bobb
J. Carter
J. Cote
J. C. Erickson
P. L. Fontaine
C. L. Fletcher
M. Furtick
R. Ghafurian
J. M. Hans
R. L. Harp Vice Chair/Secretary
R. A. HartleinH
H. L. Hayes
S. V. HeyerH
H. R. Jones
T. M. Kopchick
G. A. MacPhail
D. T. Metzinger - Chair
R. I. Mosier
T. Nishioka
T. J. Pekarek
E. T. Robeson
G. B. Shattuck
M. J. Smalley
M. R. Smith
G. J. Stano
J. C. Spence
J. G. Valdes
M. L. Walker
D. M. Wedam
H Technical Advisor
The AEIC Cable Engineering Committee thanks the Insulated Cable Engineers Association
(ICEA) for the valuable contributions they have made to this specifcation. Reviews were done
through the Utility Power cable Standards Technical Advisor Committee (UPCSTAC), composed
2i
AEIC CS9-06 1
st
of cable engineers representing cable manufacturers (ICEA) and power utilities (AEIC Cable
Engineering Committee).
2ii
SPECIFICATION FOR
EXTRUDED INSULATION POWER CABLES
AND THEIR ACCESSORIES
RATED ABOVE 46 kV THROUGH 345 kVac
-ISC.AI6ER
The Cable Engineering Committee of the Association of Edison Illuminating Companies has
prepared this specifcation.
Use of this specifcation is voluntary. The existence of the specifcation is not intended in any
respect to preclude the manufacture or use of products not conforming to the specifcation.
In preparation of this specifcation, AEIC makes no warranty or representation in connection with
its use. Persons electing to use it should independently evaluate their specifc needs and
requirements before doing so. Users are also cautioned that there may be requirements issued
by government and other regulatory organizations, which are not addressed by this
specifcation. Because this specifcation is subject to review and revision, those who use it are
cautioned to obtain the latest version. A listing of the latest AEIC documents is available on the
website (htpp://www.aeic.org).
PRE'ACE
The electric utility industry requires transmission power cable systems to provide safe, cost
efective and reliable long-term service. Other organizations have prepared valuable standards
documents. This user specifcation provides additional methods to help ensure that power cable
systems, including cables, joints, terminations and sheath bonding systems, will meet the
purchasing, quality assurance and performance needs of the electric utility industry.
0AC72R),*-
AEIC CS9 describes the requirements for design and supply of single core extruded insulation
power cable systems, including their accessories, for rated ac voltages above 46 kV to 345 kV. It
applies to cable systems with ethylene propylene rubber (EPR) insulation above 46 kV to 138
kV, and to cable systems with cross-linked polyethylene (XLPE) insulation over the complete
voltage range above 46 kV to 345 kV.
AEIC CS9 has evolved from AEIC CS7, which was frst issued in 1982. It described power
cables with only cross-linked polyethylene insulation and was written as a supplement to
Insulated Cable Engineers Association standard ICEA S-66-524 "Cross-Linked Thermosetting
Polyethylene Insulated Wire and Cable for the Transmission and Distribution of Electrical
Energy". Since S-66-524 only applied to the 5 to 46 kV range, CS7 was developed to cover
rated voltages from 69 to 138 kV, and to introduce special electric utility industry needs for the
increased reliability requirements of high capacity underground transmission systems. Later
CS9-06
Page 1
AEIC and their Accessories Rated !6 "# throu$h %!& "#ac
revisions of CS7 were issued in 1987 and 1993, the latter providing methods for determining
insulation thickness based on maximum electrical stress at the conductor shield, in addition to
traditional fxed insulation thickness for the various voltage classes. AEIC CS7 was re-afrmed
in 1998.
In 2000 ICEA withdrew ICEA S-66-524 and replaced it with several new application standards.
This included development of a new Standard S-108-720 Standard for Extruded Insulation
Power Cables Rated above 46 kV to 345 kV, incorporating much of the content of CS7-93, and
including ethylene propylene rubber insulation to 138 kV and XLPE to 345 kV. S-108-720 was
frst issued in July, 2004. The AEIC Cable Engineering Committee considered whether a
separate user specifcation would still be needed following ICEAs development of a new high
voltage cable standard.
This frst edition of AEIC CS9 confrms AEICs belief in the importance of purchasing complete
integrated cable systems, including their accessories, for extruded insulations at transmission
voltages. This is especially true for the high voltage (HV) and extra high voltage (EHV) levels,
where cable transmission capacity can approach 1000 MVA at 345 kV, reliability is extremely
important, and operating experience with long EHV extruded insulation cable systems is
relatively limited.
15 2E*ERA.
151 SC)PE
This specifcation describes the requirements for design and supply of single core extruded
insulation power cable systems, including their accessories, for rated ac voltages above 46 kV to
345 kV. It applies to cable systems with ethylene propylene rubber (EPR) insulation above 46 kV
to 138 kV, and to cable systems with cross-linked polyethylene (XLPE) insulation over the
complete voltage range above 46 kV to 345 kV.
Optional Qualifcation tests are described for complete cable systems (cables and accessories)
rated above 46 kV to 150 kV. For cable systems above 150 kV the tests on complete cable
systems are mandatory.
Pre-Qualifcation long term aging tests are described for complete cable systems rated above
150 kV. The purpose is to demonstrate reliable performance of the complete cable system,
throughout the design life.
Accessories are limited to cable joints, terminations and link box connecting systems for bonding
and grounding of metallic shield/sheath circuits. They do not include structural support systems
for cables, terminations, joints, etc., nor do they include the grounding grids in manholes, joint
bays, tunnels, terminal structures or power stations.
CS9-06 Pa$e 8
For the purposes of this specifcation, the manufacturer is the primary designer and supplier of
the complete cable system described herein, even though some components may be sub-
contracted to others.
In the event of conficts between this specifcation and other reference standards, this
specifcation shall take precedence. In the event of conficts between and among the reference
standards, the most stringent requirements shall apply.
Compliance with this specifcation in no way relieves the manufacturer of responsibility for
design and manufacturing details for performance of the complete cable system.
158 2E*ERA. I*')R6A(I)*
Measurement units are generally expressed using the Imperial system, as is traditional for AEIC.
SI unit equivalents are also provided, usually in brackets.
15% I*')R6A(I)* () 0E PR)#I-E- 09 P,RC1ASER
15%51 Purchaser:s Specification
The scope of CS9 assumes that the purchaser will include it as part of a custom project
specifcation (purchasers specifcation), describing particular requirements for the design and
supply of cable and accessories for the intended application. It should include at least:
A Purchasers Technical Information File, as described in 1.3.2 below
A description of the required Manufacturers Technical Declaration File, as described in
1.4.1 below
A description of Information to be Submitted After Award of Contract, similar to that
described as a guide in Appendix 10
A description of the specifc required components and quantities
A description of cable system installation responsibilities, as applicable
A description of civil work installation responsibilities, as applicable
A description of components and work to be provided by others, as applicable
A description of responsibilities for overall design of the complete installed cable system
A description of special commercial requirements which could override or add to those
contained within this specifcation, such as 1.3.3 Warranty, delivery schedules, delivery
location, etc.
15%58 Purchaser:s (echnical Infor;ation 'ile
When requesting proposals from cable manufacturers, the purchaser shall provide the
information tabulated in ICEA S-108-720 Information to be Supplied by Purchaser. This should
CS9-06 Pa$e %
be supplemented with select information taken from Appendix 8 Purchasers Technical
Information File, as well as any other relevant additional information necessary to completely
describe the intended application.
15%5% /arrant<
The manufacturer shall warrant that the supplied cable system meets or exceeds all the
requirements of this specifcation and is free from defects in design, material, and workmanship.
The manufacturer shall also warrant that the cable system has been tested in accordance with
these specifcations and that the results of the tests are compliant.
The warranty duration shall be no less than one year from the date of cable energization, unless
stated otherwise by the purchasers specifcation.
15%5! )peratin$ #olta$e
The cable system shall be designed for a maximum phase-to-phase operating voltage, which
may exceed the rated voltage by 5 percent during continuous operation. The cable system shall
be designed for an emergency phase-to-phase operating voltage, which could exceed the rated
voltage by 10 percent, for durations not more than 15 minutes for each occurrence.
15%5! 'ault -ut<
Fault duties can signifcantly afect the design of all fault current carrying components, such as
the main conductor, metallic shields, sheaths, link boxes, bonding cables, terminations, joints,
and all their respective electrical insulations.
Cable and accessory designs shall make provision for thermal-mechanical efects due to rapid
increases in temperature of the conductor and other cable and accessory components, which
can lead to very high axial forces. They shall also make provision for electro-dynamic efects
which can apply high transverse forces as a result of the interaction of the current of each cable
with the magnetic feld produced by adjacent cables.
Informative Note: Purchasers should do sufcient system studies to determine realistic ultimate
values for fault current and duration, in advance of seeking proposals from manufacturers.
Investigations of fault current duration should consider the time to successful operation of
secondary relays and circuit breakers, in the event that the primary protection system
malfunctions. Fault duties should also consider the possibility and efects of multiple reclosing
operations by circuit breakers.
15! I*')R6A(I)* () 0E PR)#I-E- 09 6A*,'AC(,RER /I(1 PR)P)SA.
15!51 6anufacturer:s (echnical -eclaration 'ile
CS9-06 Pa$e !
The manufacturer shall submit a Manufacturers Technical Declaration File with its proposal,
summarizing the information described in ICEA S-108-720 Information to be Supplied by
Manufacturer, supplemented with select information taken from the Appendix 9 Manufacturers
Technical Declaration File guide, as deemed necessary by the purchaser and described in the
purchasers specifcation.
15!58 Alternatie Proposals
Manufacturers are encouraged to submit alternative proposals for cable systems they consider
superior to those specifed herein, clearly stating the advantages in terms of cost, reliability,
longevity, installation methods, etc. The alternative proposal shall meet or exceed all the
technical requirements of this specifcation and contain the recommended changes or additions
to it, together with the reasons and appropriate supporting data.
Notwithstanding the foregoing, a conforming proposal shall be submitted as a basis for
comparing the alternative, before the alternative proposal will be considered by the purchaser.
15& -E'I*I(I)*S A*- S960).S
15&51 2eneral
The following defnitions apply to this specifcation. Those not included shall be as described in
IEEE 100 The Authoritative Dictionary of IEEE Standards Terms.
Accessory: Cable joints, terminations and link box connecting systems for
bonding and grounding of metallic shield/sheath circuits.
Active Length: Length of cable covered by insulation shield and metallic shield.
Agglomerate: A discernible area of compound constituents in ethylene propylene
based insulation, which is generally opaque and can be broken
apart.
Amber: A localized area in cross-linked polyethylene insulation which is
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 fow patterns, which are normally associated with
the extrusion process.
AWG: American Wire Gauge
CS9-06 Pa$e &
BIL: Basic Impulse Insulation Level.
Bonding Cable: The insulated conductor forming the connection between the
sheath of the cable, joint or termination base, and a link in the link
box.
Cable Core: The portion of a cable, which includes the conductor, the
conductor shield, the insulation and the extruded insulation shield.
Cable Core Extruder Run: A continuous extrusion of cable core, comprised of conductor,
conductor shield, insulation and insulation shield, with one
beginning and one end, using uniform extrusion processes and
materials throughout.
Cable System: Cable with installed accessories.
Certifed Test Report: A report containing the results of production tests or qualifcation
tests which declares that the cable shipped to a customer meets
the applicable requirements of this standard.
Contaminant: Any solid or liquid material, which is not an intended ingredient.
Dielectric Constant: The ratio of the capacitance of a given confguration of electrodes
with the material as a dielectric to the capacitance of the same
electrode confguration with a vacuum (or air for most practical
purposes) as the dielectric.
Discharge-Free Cable Design:
A cable designed to eliminate electrical discharge in the insulation
system at normal operating voltage.
Discharge-Resistant Cable Design:
A cable design capable of withstanding electrical discharge in the
insulation system at normal operating voltage.
Dissipation Factor: The cotangent of the dielectric phase angle of a dielectric material
or the tangent of the dielectric loss angle. It is often called tan .
Dry Location: A location not normally subject to dampness or wetness.
EPR Insulation Compound: A mixture of ethylene propylene base resin and selected
ingredients.
CS9-06 Pa$e 6
Gel: A discernible region of compound constituents in ethylene
propylene based insulation, which is gelatinous, not readily
removable from the insulation, and generally translucent.
G
max
: Voltage stress at the conductor shield/insulation interface (internal
stress) at nominal phase-to-ground operating voltage, V
g.
G
min
: Voltage stress at the insulation/insulation shield interface (external
stress) at nominal phase to ground operating voltage, V
g.
High Dielectric Constant Compound:
An extruded compound used for the conductor shield, which has a
dielectric constant typically between 8 and 200.
Insulated Sheath System: A cable system in which the metallic shield/sheath, joint casings
and termination bases are individually insulated throughout their
length, except where any necessary grounding or inter-
shield/sheath connections are made
Jacket Extruder Run: A cable with a jacket, which was applied in one continuous run,
having one jacket compound and one jacket thickness.
kcmil: Thousands of circular mils.
Link Box: A box through which bonding and/or grounding connections are
made through removable links and which may also contain sheath
voltage limiters.
Lot (Component): The quantity of components requiring one test.
Lot (Material): A quantity of material used in cable or accessory construction
which is produced at the same location under the same
manufacturing conditions during the same time period.
Master Length: A continuous length of cable collected on a reel at the end of an
extrusion line.
Maximum Conductor Temperatures:
CS9-06 Pa$e =
Normal Operating: The highest conductor temperature permissible
for any part of the component under normal operating load
current.
Emergency Overload: The highest conductor temperature
permissible for any part of the component during emergency
overload of specifed time, magnitude, and frequency of
application.
Short Circuit: The highest conductor temperature permissible for
any part of the component during a circuit fault of specifed time
and magnitude.
Nominal Value: The value by which a quantity is designated and often used in
tables (taking into account specifed tolerances).
Partial Discharge Level: The maximum continuous or repetitious apparent charge transfer,
measured in picoCoulombs, occurring at the test voltage.
pC: picocoulombs
Rated Voltage: Nominal phase-to-phase operating voltage.
Room Temperature (RT): 20 C -5/+10 C air temperature.
Sheath Sectionalizing Joint:A joint in which the internal shield, metallic shield/sheath and
casing are electrically interrupted from each side of the joint. The
interruption in the casing of the joint is done by means of a sheath
sectionalizing insulator.
Sheath Voltage Limiter: A device connected to a sheath or to the sheaths of specially
bonded cables intended to limit sheath over-voltages during
system transients.
Shipping Length: A completed length of cable, which has passed all test
requirements. It may or may not be cut into shorter lengths before
it is supplied to the end use customer.
Shipping Reel: A completed reel of cable shipped to the end use customer.
V: Nominal phase-to-phase operating voltage (rated voltage)
V
g
: Nominal phase-to-ground operating voltage
CS9-06 Pa$e >
V
m
: Maximum continuous phase-to-phase operating voltage (V+5%)
V
t
: Phase-to-ground test voltage
Vented Water Tree: A water tree, which originates at the conductor shield or insulation
shield.
Void: Any cavity in a compound, either within or at the interface with
another extruded layer.
Wet Location: Installations underground or in concrete slabs or masonry in direct
contact with the earth; in locations subject to saturation with water
or other liquids and in unprotected locations exposed to weather.
XLPE Insulation Compound:Cross-linked polyethylene insulation.
15&58 -efinition of (ests
The following additional defnitions clarify the various testing terms used herein and in
documents referred to in this specifcation.
Production Tests: Tests made on each manufactured component (length of cable or
accessory), or samples thereof, to confrm compliance of the
fnished product with this specifcation and other standards
referenced herein. They also verify that the delivered products
have at least the same quality as those having passed the
Qualifcation and Pre-qualifcation Tests. Production Tests are
sometimes variously referred to in other documents as factory
tests, routine tests and acceptance tests.
Qualifcation Tests: Tests made before supplying on a general commercial basis, a
type of cable, accessory or cable system (cable and accessories)
covered by this specifcation and referenced standards, in order to
demonstrate satisfactory performance characteristics for the
intended application. Once successfully completed, these tests
need not be repeated, unless changes are made in the cable or
accessory materials, or design, or manufacturing process, or
manufacturing plant, which might change the performance
characteristics. Qualifcation Tests are sometimes variously
referred to in other documents as prototype tests, type tests and
design tests.
CS9-06 Pa$e 9
Pre-qualifcation Tests: Tests made before supplying on a general commercial basis, a
type of cable system covered by this specifcation and referenced
standards, in order to demonstrate satisfactory long-term
performance of the complete cable system. The pre-qualifcation
test need only be carried out once, unless there is a substantial
change in the cable system with respect to materials, or design, or
manufacturing process, or manufacturing plant, which might
adversely afect the performance of the cable system.
De2eloment ;ests3 ;ests comleted */ t"e manufacturer during de2eloment of t"e
ca*le s/stem *efore re.Cualification tests1 ;"e recise nature
and e)tent of de2eloment 0orB and anal/ses s"all *e at t"e
discretion of t"e manufacturer, *ut ma/ include t"e follo0ing3
An e2aluation of t"e materials and rocesses emlo/ed,
including le2els of 2oids, contaminants, rotrusions, etc1
6oltage.time endurance testing and 5ei*ull anal/sis of test
results, including determination of In>, t"e long term aging
e)onent
Development of compatible accessories, including factory tests
to assess aging efects related to electrical stress,
temperature, interface pressure, environmental conditions, etc.
6erification tests on full siAe ca*le s/stems,
Correlation of development test results with service reliability
requirements
156 RE'ERE*CES
The following standards and references form a part of this specifcation. The most recent
editions apply.
ASTM 1693 Tests for Environmental Stress Cracking of Ethylene Plastics
Electra No. 128 Article: Guide to the protection of specially bonded cable systems against
sheath over-voltages, January 1992
Electra No. 141 Article: Guidelines for Tests on High Voltage Cables with Extruded
Insulation and Laminated Protective Coverings, April 1992
Electra No. 151 Article: Earthing of GIS An Application Guide, December 1993
ICEA S-94-649 Standard for Concentric Neutral Cables Rated 5 through 46 kV
ICEA S-105-692 600 Volt Single Layer Thermoset Insulated Utility Underground
Distribution Cables
ICEA S-108-720 Standard for Extruded Insulation Power Cables Rated above 46 kV
through 345 kV
ICEA T-24-380 Guide for Partial Discharge Test Procedure
ICEA T-27-581 Standard Test Methods for Extruded Dielectric Power, Control,
Instrumentation & Portable Cables for Test
CS9-06 Pa$e 10
ICEA T-31-610 Guide for Conducting a Longitudinal Water Penetration Resistance Test
for Sealed Conductors
ICEA T-32-645 Guide for Establishing Compatibility of Sealed Conductor Filler
Compounds with Conductor Stress Control Materials
IEC 60228 Conductors of insulated cables
IEC 60229 Tests on cable oversheaths which have a special protective function
IEC 60287 Calculation of the continuous current rating of cables (100% load factor)
IEC 60853-2 Calculation of the cyclic and emergency current rating of cables
IEC 60529 Degrees of protection provided by enclosures (IP Code)
IEC 60840 Power cables with extruded insulation and their accessories for rated
voltages above 30 kV up to 150 kV Test methods and requirements
IEC 60859 Cable connections for gas-insulated metal-enclosed switchgear for rated
voltages of 72.5 kV and above
IEC 60855 Electrical test methods for power cables
IEC 62067 Power cables with extruded insulation and their accessories for rated
voltages above 150 kV up to 500 kV Test methods and requirements
IEEE 48 Standard Test Procedures and Requirements for Alternating Current
Cable Terminations 2.5 kV through 765 kV
IEEE C62.11 Standard for Metal-Oxide Surge Arresters for AC Power Circuits (> 1 kV)
IEEE 100 The Authoritative Dictionary of IEEE Standards Terms
IEEE 404 Standard for Extruded and Laminated Dielectric Shielded Cable Joints
Rated 2,500 500,000 V
IEEE 693 Recommended Practice for Seismic Design of Substations
ISO 9001 Quality Systems Model for quality assurance in design, development,
production, installation and servicing
NEMA WC26 Binational Wire and Cable Packaging
NEMA 250 Enclosures for Electrical Equipment
Other standards are in turn referenced from within the above documents.
15= -R9 I*S,.A(I)*
Cable systems having cable insulation with nominal internal and external ac electrical stresses
greater than 100 V/mil (4.0 kV/mm) and 50 V/mil (2.0 kV/mm) respectively, shall be supplied with
a metallic moisture barrier to maintain dry insulation. Higher ac stresses may be applied to wet
design cable systems, if agreed to between the purchaser and manufacturer.
15> -ESI2* .I'E A*- RE.IA0I.I(9
Cable systems meeting the requirements of this specifcation are expected to have a minimum
design life of 40 years. The manufacturer shall supply test data and calculations supporting
these design and reliability requirements, if required by the purchasers specifcation (reference
CS9-06 Pa$e 11
Appendix 8, Item 25). The documentation shall include the electrical, thermal and mechanical
performance characteristics of the cable core, laminated metallic moisture barriers (if present),
solid metallic sheath, jacket and accessories.
Manufacturers shall take into account the Aging Factors, Design Life and Reliability
Considerations for Extruded Insulation Cables and Accessories in Appendix 2, to ensure that
the cable and accessory system performs reliably for the expected design life and intended
application. The design life shall also take into account the maximum operating temperature
considerations described in Appendix 4 and 1.9 below.
159 6A+I6,6 )PERA(I*2 (E6PERA(,RES A*- -,RA(I)*S
The design and construction of the cable and accessories shall be such that they perform
reliably together as a complete system, at conductor temperatures not exceeding those shown in
Table1.9-1.
Table1.9-1 Maximum Conductor Temperatures (C)
Type of Operation XLPE
EPR
(to 138 kV max)
Normal Operation 90 90
Emergency Operation
(46 150 kV)
105 105*
Emergency Operation
(>150 345 kV)
105 Not applicable
Short Circuit Operation 250 250
*Emergency operation at conductor temperatures up to 130 C may be used if mutually
agreed between purchaser and manufacturer and verifed by qualifcation and pre-
qualifcation tests.
The temperatures identifed for Emergency Operation apply for no more than 72 hours duration
on average per year during the design life of the cable system, without exceeding 216 hours in
any 12 month period. Users are referred to Appendix 4 for a description of the basis of these
emergency temperature/time requirements and an explanation of verifcation tests.
If emergency operation (for cables rated >150 to 345 kV) to 105 C or higher is desired, the pre-
qualifcation tests in IEC 62067 shall include 90 additional load cycles to the maximum
emergency operation temperature, as described in Appendix 4. In addition, the qualifcation
tests (type tests) in IEC 62067 and IEC 60840 shall be performed at the maximum emergency
operation temperature, as described in Appendix 4.
CS9-06 Pa$e 18
The temperatures identifed as for Normal Operation apply to operating load cycles typical of
electric utility systems (approximately 0.80 daily load factor for transmission lines; approximately
1.0 daily load factor for generating stations). Cable system designs shall assume that the
normal maximum operation temperatures can be applied continuously throughout the cable
systems design life, with corresponding load factors.
Designs for operation at the Table 1.9-1 maximum temperatures shall take into consideration
actual feld-proven performance and design limits of transmission cable and accessories, as
relevant to the intended application. This shall include consideration of at least the factors
described in ICEA S-108-720 Appendix B, as well as the following:
the efects of high operating temperatures on radial expansion of XLPE insulation
possible degradation of stress relief cone interface pressure due to mechanical stress
relaxation, over the cable system design life
the temperature gradient across the cable core and the corresponding jacket temperature
limits, which could be excessive for some installation conditions
possible loss of adhesion at the overlap of laminated moisture barriers and loss of bond
adhesion to the underside of the jacket
high axial thrust forces that can be transmitted to joints and terminations, especially for large
conductors
possible permanent distortion of the insulation due to high sidewall forces at bends, resulting
in a local reduction of insulation and jacket thickness
possible permanent distortion of the insulation due to radial expansion at clamps and
anchors, for some sheath/shield constructions
cyclic fatigue resistance of metal moisture barriers and corresponding value of the limiting
cyclic strain (see Appendix 2 references 17 42, and especially 20, 32, 35 and 37)
efective axial stifness (longitudinal rigidity) of the cable (see Appendix 2 references 17
43) and the design of duct/pipe clearance, layouts in tunnels, manholes and approaching
terminations
efective bending stifness (fexural rigidity) of the cable (see Appendix 2 references 17 - 43)
and the design of duct/pipe clearance, layouts in tunnels, manholes and approaching
terminations
The Table 1.9-1 maximum operating temperatures apply to the hottest portion of the cable
system at any time. They may be used in current rating calculations when adequate information
is known about the overall thermal characteristics of the cable system environment, to ensure
that these temperatures shall not be exceeded. In the absence of this information, the
maximum temperatures used in current rating calculations shall be reduced by 10 C, or in
accordance with available data.
1510 C,RRE*( RA(I*2 A*- CA0.E (E6PERA(,RE CA.C,.A(I)*S
CS9-06 Pa$e 1%
Current ratings and cable temperatures shall be calculated in accordance with IEC 60287, or as
described in The Calculation of Temperature Rise and Load Capability of Cable Systems, J.H.
Neher, M.H. McGrath, AIEE Transactions on Power Apparatus and Systems, vol. 76, October
1957. Daily load factor efects shall be calculated in accordance with the latter reference or IEC
60853-2.
For conductors with large cross-sections, values for the skin efect factor (k
s
) and proximity efect
factor (k
p
) shall be in accordance with the recommendations of CIGRE Technical Brochure 272
Large Cross-sections and Composite Screen Designs, WG B1.03, June 2005, unless
otherwise agreed to between purchaser and manufacturer and verifed by measurement of ac
resistance during qualifcation tests.
Emergency current ratings and cable temperatures shall be calculated in accordance with IEC
60853-2.
85 CA0.ES
Cables shall comply with ICEA S-108-720 and as described herein.
An Insulation System Quality Assurance Plan shall be submitted with the Manufacturers
Technical Declaration File (reference Appendix 9, Item 24), if required by the purchasers
specifcation. The plan shall describe procedures to ensure that the cleanliness and smoothness
requirements of extruded insulation and semi-conducting shield materials are met throughout
the supply chain from compound supplier to the manufacturers extruders.
851 C)*-,C()RS
85151 2eneral
The conductor material shall be copper or aluminum with circular cross-section.. If the area and
construction is not described by the purchasers specifcation, the manufacturer shall provide a
conductor with material, cross-sectional area and construction sufcient to meet the required
normal current carrying capacity, emergency current carrying capacity and short circuit fault
duty, without exceeding the temperature limits described in Table 1.9-1, in accordance with the
installation conditions and other information in the purchasers specifcation.
85158 Sealant for Stranded Conductors
If specifed by the purchaser, a sealant designed as an impediment to longitudinal water
penetration shall be used to fll all the interstices of stranded conductors. Compatibility with the
conductor shield shall be determined in accordance with ICEA T-32-645. Longitudinal water
penetration resistance shall be determined in accordance with ICEA T-31-610 and shall meet a
minimum pressure requirement of 5 psig (35 kPa).
CS9-06 Pa$e 1!
8515% Preferred Conductor Si?es
ICEA S-108-720 Tables 2-2 and 2-3 describe 31 possible conductor sizes ranging from 250
kcmil (127 mm
2
) to 4000 kcmil (2027 mm
2
), in copper and aluminum. Fewer standard sizes for
HV and EHV cable can result in lower tooling costs for manufacturers, smaller spare cable
inventories for purchasers and greater opportunities for sharing of spare cables between users.
Cables supplied under this specifcation shall therefore be limited to the conductor sizes shown
in Table 2.1-1, unless described otherwise in the purchasers specifcation, or proposed as an
alternative by the manufacturer.
Table 2.1-1 Standard Imperial Conductor Sizes (kcmil) and Nearest IEC 60228 SI Sizes
(mm
2
)
69 kV 115 kV 138 kV 161 kV 230 kV 345 kV
kcmil mm
2
kcmil mm
2
kcmil mm
2
kcmil mm
2
kcmil mm
2
kcmil mm
2
500 240
750 400 750 400 750 400 750 400
1000 500 1000 500 1000 500 1000 500 1000 500 1000 500
1250 630 1250 630 1250 630 1250 630 1250 630 1250 630
1500 800 1500 800 1500 800 1500 800 1500 800 1500 800
1750 800 1750 800 1750 800 1750 800 1750 800 1750 800
2000 1000 2000 1000 2000 1000 2000 1000 2000 1000 2000 1000
2500 1200 2500 1200 2500 1200 2500 1200 2500 1200 2500 1200
3000 1600 3000 1600 3000 1600 3000 1600 3000 1600 3000 1600
3500 1600 3500 1600 3500 1600 3500 1600 3500 1600 3500 1600
4000 2000 4000 2000 4000 2000 4000 2000 4000 2000 4000 2000
5000 2500 5000 2500
ICEA S-108-720 Tables 2-2 and 2-3 describe soft metric sizes, which are mathematically
correct conversions from Imperial to SI (1.000 kcmil = 0.507 mm
2
). The metric sizes shown in
the above Table 2.1-1 are hard conversions, complying with the closest standard sizes in IEC
60228 Conductors of insulated cables.
8515! Conductor Characteristics
The conductor characteristics, including dc resistances for the IEC 60228 SI conductor sizes,
shall comply with ICEA S-108-720.
858 C)*-,C()R S1IE.-
85851 2eneral
CS9-06 Pa$e 1&
The conductor shield shall provide a uniform, continuous, smooth, concentric, thermosetting,
semi-conducting, voltage stress control layer between the outer surface of the conductor and the
inner surface of the insulation. It shall be in direct contact with the conductor and adhere well to
the inner surface of the insulation under all operating conditions.
85858 6aterial
The conductor shield material shall be as per ICEA S-108-720 except for XLPE insulations with
ac electrical stress at the conductor shield greater than 200 V/mil (8.0 kV/mm), the conductor
shield shall be formulated using acetylene black. The manufacturer shall verify with the
compound supplier that the sulfur and ash content is less than 0.005 % and 0.01 % respectively.
8585% Extruded Shield (hic"ness
The nominal thickness of the extruded conductor shield shall be as per ICEA S-108-720.
8585! #oids@ Protrusion and Irre$ularit< .i;its
The maximum allowable void, protrusion and irregularity limits for XLPE insulation cables shall
be as per ICEA S-108-720, except as modifed in Table 2.2-1 for cables with nominal internal ac
stresses greater than 200 V/mil (8.0 kV/mm).
Voids are assumed to occur at the interface between the extruded conductor shield and the
insulation.
Protrusion and irregularity heights from the conductor shield into the insulation and from the
insulation into the conductor shield are one half the maximum allowable contaminant diameter,
which is less than described in ICEA S-108-720 for insulation internal stresses greater than 250
V/mil (10.0 kV/mm). (Refer to Appendix 1 for a description of the basis for these values.)
Table 2.2-1 Extruded Conductor Shield/Insulation Interface; Void, Protrusion and
Irregularity Limits vs Nominal Internal ac Stress (dimensions rounded to nearest 0.5 mil)
CS9-06 Pa$e 16
Nominal Internal ac Stress
at V
g
V/mil (kV/mm)
100
(4.0)
125
(5.0)
150
(6.0)
175
(7.0)
200
(8.0)
225
(9.0)
250
(10.0)
275
(11.0)
300
(12.0)
325
(13.0)
350
(14.0)
Maximum Void
Dimension
mils (m)
2.0
(50)
1
2.0
(50)
1
2.0
(50)
1
2.0
(50)
1
2.0
(50)
1
2.0
(50)
2
1.5
(38)
2
1.5
(38)
2
1.5
(38)
2
1.0
(25)
2
1.0
(25)
2
Maximum Protrusion and
Irregularity Height
mils (m)
3.0
(75)
1
3.0
(75)
1
3.0
(75)
1
3.0
(75)
1
3.0
(75)
1
3.0
(75)
1
3.0
(75)
1
3.0
(75)
2
2.5
(63)
2
2.0
(50)
2
2.0
(50)
2
1
refect current practices and ICEA S-108-720 limits.
2
less than ICEA S-108-720 limits.
For EPR-insulated cable the void, protrusion and irregularity limits shall be as per Table 2.2-1,
but with nominal internal ac stress no greater than 200 V/mil (8.0 kV/mm).
8585& Ph<sical ReAuire;ents
The physical requirements of the conductor shield shall comply with ICEA S-108-720.
85856 Electrical ReAuire;ents
The electrical requirements of the conductor shield shall comply with ICEA S-108-720.
85% I*S,.A(I)*
The insulation shall be capable of withstanding all electrical stresses that will be distributed
across it when the cable is energized and fully loaded to the maximum emergency operating
temperature. It shall also withstand the mechanical and thermal forces that occur during
installation and operation.
85%51 6aterial
The insulation compound shall be either unflled cross-linkable polyethylene (XLPE) or ethylene
propylene rubber (EPR). The insulation material shall comply with ICEA S-108-720 and as
described herein.
The insulating compound shall be specifcally formulated for high voltage and extra high voltage
cables, not containing any contaminants with their greatest dimension larger than as described
in Table 2.3-2.
CS9-06 Pa$e 1=
XLPE insulation shall be extruded together with the extruded conductor shield and extruded
insulation shield, in one common triple head extruder. The three layers shall be cross-linked in a
dry curing process.
XLPE insulation material shall be inspected for contaminants using a continuous sampling plan.
The plan must sample a minimum of 2 percent of the insulation material volume. Materialnot
inspected by the compound supplier must be inspected at the 2 percent rate by the cable
manufacturer. The material analysis shall be reported for engineering information and as a
minimum, provide a statistical analysis of the size and number of contaminants found per weight
of insulation inspected.
85%58 Insulation (hic"ness
For wet design cables without a metallic moisture barrier, insulation thickness shall be based
on the traditional values described in ICEA S-108-720, Appendix F.
For dry design cables, the insulation thickness shall be designed based on electrical stress, as
described in ICEA S-108-720 as well as the following, unless proposed otherwise by the
manufacturer or purchaser and supported by tests:
ac stresses at the conductor shield (internal stress) and over the insulation (external stress),
as calculated in 2.3.4, shall not exceed the limits described in Table 2.3-1 at the rated phase-
to-ground operating voltage V
g
,
the ac and impulse stresses at the inner starting point of stress relief cones in accessories,
shall not exceed the limits defned by the manufacturer,
consideration of the Generic nominal thicknesses described in Appendix 5, which are
intended to satisfy the nominal internal and external stress limit criteria over the standard
conductor size range and provide a degree of standardization.
Table 2.3-1 Rated Voltage, Conductor Size Range, Insulation Eccentricity Limits, Nominal
Internal ac Stress Limits and Nominal External ac Stress Limits
Rated
Voltage
kV
Conductor
Size
kcmil
Conductor
Size
mm
2
Maximum
Insulation
Eccentricity
%
Nominal
Internal ac
Stress Limit
V/mil (kV/mm)
Nominal
External ac
Stress Limit
V/mil (kV/mm)
69 wet 500-4000 240-2000 12 100 (4.0) 50 (2.0)
69 dry 500-4000 240-2000 12 150 (6.0) 75 (3.0)
115 750-4000 400-2000 12 200 (8.0) 100 (4.0)
138 750-4000 400-2000 12 200 (8.0) 100 (4.0)
161 750-4000 400-2000 10 225 (9.0) 100 (4.0)
230 1000-5000 500-2500 10 275 (11.0) 125 (5.0)
345 1000-5000 500-2500 10 350 (14.0) 150 (6.0)
CS9-06 Pa$e 1>
Notwithstanding the Table 2.3-1 values, for cables used with taped joints, the nominal internal
and external ac stresses shall be limited to 150 V/mil (6.0 kV/mm) and 75 V/mil (3.0 kV/mm)
respectively.
Insulation eccentricity shall not exceed the values in Table 2.3-1, as described in ICEA S-108-
720.
85%5% Insulation ReAuire;ents
The insulation requirements shall comply with ICEA S-108-720 and as described herein.
The void, contaminant and amber limits for XLPE-insulated cables shall be as per Table 2.3-2
(see Appendix 1 for derivation). The applicable limits shall be based on the actual calculated
internal stress for the proposed cable system, which will vary with specifc conductor size and
insulation thickness for each rated voltage level.
Table 2.3-2 Void, Contaminant and Amber Limits versus Nominal Internal ac Stress for
XLPE Insulation Cable
3
(dimensions rounded to nearest 0.5 mil)
Nominal
Internal ac
Stress at V
g
V/mil (kV/mm)
100
(4.0)
125
(5.0)
150
(6.0)
175
(7.0)
200
(8.0)
225
(9.0)
250
(10.0)
275
(11.0)
300
(12.0)
325
(13.0)
350
(14.0)
Maximum Void
Diameter
mils (m)
2.0
(50)
1
2.0
(50)
1
2.0
(50)
1
2.0
(50)
1
2.0
(50)
1
2.0
(50)
2
1.5
(38)
2
1.5
(38)
2
1.5
(38)
2
1.0
(25)
2
1.0
(25)
2
Maximum
Contaminant
Dimension
mils (m)
5.0
(125)
1
5.0
(125)
1
5.0
(125)
1
5.0
(125)
1
5.0
(125)
1
5.0
(125)
1
5.0
(125)
1
5.0
(125)
1
5.0
(125)
1
4.0
(100)
2
4.0
(100)
2
Maximum
Amber
Dimension
mils (m)
10.0
(250)
1
10.0
(250)
1
10.0
(250)
1
10.0
(250)
1
10.0
(250)
1
10.0
(250)
1
10.0
(250)
1
10.0
(250)
1
10.0
(250)
1
8.0
(200)
2
8.0
(200)
2
1
refect current practices and ICEA S-108-720-2004 limits.
2
3
minimum point stresses could be higher. See 2.3.4.
85%5! Calculation of Insulation Electric Stress
CS9-06 Pa$e 19
For cables with a semi-conducting conductor shield, the nominal ac electric stress at any point
in the insulation shall be calculated using the following formula:
rs
ri
r
Vg
Gr
ln
Where:
Gr = nominal ac voltage stress at radius r (kV/mm)
V
g
= nominal phase to ground voltage (kV)
r
i
= nominal radius over the insulation (mm)
r
s
= nominal radius over the conductor shield (mm)
r = radius of a point of interest in the insulation (mm)
The nominal internal ac stress (G
max
) occurs at the interface between the conductor shield and
the insulation, when r = r
s
.
The nominal external ac stress (
Gmin
) occurs at the outside of the insulation, when r = r
i.
The average stress =
rs ri
Vg
For EPR cables with a non-conducting conductor shield, the nominal ac electric stress at any
point in the insulation shall be calculated using the following formula:
( )
,
_
,
_
,
_
Ki
rp
ri
kp
rc
rp
Ki r
Vg
Gr
ln ln
Where:
G
r
= nominal ac voltage stress at radius r (kV/mm)
V
g
= nominal phase to ground voltage (kV)
r
c
= nominal radius over the conductor (mm)
r
i
= nominal radius over the insulation (mm)
r
p
= nominal radius over the conductor shield (mm)
r = radius of a point of interest in the insulation (mm)
K
i
= dielectric constant of the insulation
K
p
= dielectric constant of the non-conducting insulation shield
The nominal internal ac stress (G
max
) occurs at the interface between the conductor shield and
the insulation, when r = r
s
.
CS9-06 Pa$e 80
The nominal external ac stress (G
min
) occurs at the outside of the insulation, when r = r
i
.
The average stress =
rs ri
Vg
Similar methods shall be used to determine the nominal impulse stresses, by substituting BIL for
V
g
.
Informative Note: Users are reminded that ICEA S-108-720 allows a 5% continuous and
10% ffteen-minute over-voltage above the rated phase-to-ground voltage (V
g
). In
addition, ICEA S-108-720 allows a minimum point insulation thickness 10% less than
nominal values. Conductor radii can also vary from nominal values. These efects can
lead to a lower value of r
i
and possibly higher actual stresses in cable and accessories
compared to those calculated above.
85!5 E+(R,-E- I*S,.A(I)* S1IE.-
85!51 2eneral
The extruded insulation shield shall provide a uniform, continuous, smooth, concentric,
thermosetting, semi-conducting, voltage stress control layer over the surface of the insulation. It
shall be in direct contact with and adhere well to the insulation under all operating conditions. It
shall be designed to conduct the insulation charging and leakage current to the overlying
bedding layer and metallic shield or sheath. It shall exhibit long-term chemical stability and
compatibility with adjacent cable components and its allowable operating temperature shall be
at least as high as the insulation.
85!58 6aterial
The extruded insulation shield material shall be as per ICEA S-108-720.
85!5% (hic"ness ReAuire;ents
The nominal thickness of the extruded insulation shield shall be as per ICEA S-108-720.
85!5! #oids@ Protrusions and Irre$ularit< .i;its
The maximum allowable void, protrusion and irregularity limits shall be as described in ICEA S-
108-720, repeated below.
Maximum void diameter 2.0 mils (50 m)
Maximum protrusion height 5.0 mils (125 m )
CS9-06 Pa$e 81
Maximum irregularity height 5.0 mils (125 m )
85& 6E(A..IC S1IE.-4S1EA(1
85&51 2eneral
The metallic shield/sheath shall comply with ICEA S-108-720 and as described herein. It shall
make continuous or frequent (for corrugations) electrical contact with the underlying semi-
conducting layers to provide a concentric conducting path for insulation charging and leakage
current, as well as neutral current, phase unbalance current, fault current, and surge current.
85&58 0eddin$ and .on$itudinal /ater 0loc"in$
For XLPE insulations, a continuous semi-conducting bedding layer shall be applied under the
metallic shield/sheath to protect the insulation from deformation due to thermal radial expansion
of the core and lateral pressure at bends at maximum normal and emergency operating
temperatures. The manufacturer shall design the cable such that the bedding layer functions to
limit the maximum deformation of the insulation to 5% of its thickness. Deviations shall be
based on agreement between the purchaser and manufacturer, considering specifc cable
constructions.
If not also provided by the bedding layer, for XLPE cables an additional layer of continuous
semi-conducting water swelling tapes or powder shall also be applied, to prevent longitudinal
water penetration.
The bedding and water blocking layers shall be semi-conducting and meet the requirements of
ICEA S-108-720 and as described herein.
The semi-conducting bedding layer and semi-conducting water blocking layer, if used, shall be
designed to efectively conduct the insulation charging and leakage current from the underlying
semi-conducting insulation shield to the overlying metallic shield/sheath.
85&5% Shields
If a metallic shield is proposed, it shall comply with ICEA S-108-720.
85&5! Sheaths
If a continuous metallic sheath is proposed (as opposed to a metallic shield system), it shall
comply with ICEA S-108-720. Sheaths shall provide the same electrical function as shields,
except they shall also ensure a radial moisture barrier to the underlying layers.
CS9-06 Pa$e 88
If required by the purchasers specifcation, the manufacturer shall state the limiting 2alue of
s"eat" c/clic strain for 40./ear life (J) (reference Appendix 8, Item 12 e)), to verify that cyclic
fatigue testing has been performed for the specifc cable construction, and that it is adequate for
the intended application. Additional information is provided in Appendix 2.
85&5& Radial 6oisture 0arrier
XLPE-insulated cables shall incorporate a metallic, radial moisture barrier, unless a wet design
cable is specifcally requested by the purchaser, and insulation electric stress limits are reduced
in compliance with 1.7 and 2.3.2. Radial moisture barriers can be a continuous metal sheath, as
described above, or a longitudinally applied metal foil layer bonded to the inside of the jacket.
Longitudinally applied metal foil moisture barriers shall meet the requirements of ICEA S-108-
720. When applied, they shall be in addition to an underlying shield, which is required to ensure
a satisfactory concentric conducting path for insulation charging and leakage current, as well as
neutral current, phase unbalance current, fault current, and surge current.
856 BAC7E(
85651 2eneral
The jacket shall comply with ICEA S-108-720 and as described herein.
Supplemental anti-corrosion protection shall be provided for aluminum sheaths, which are not
bonded to the inside of the jacket, by applying a continuous coating of waterproof compound
over the sheath immediately prior to extruding the jacket.
Users shall consider polyethylene jackets for cold-weather installation applications.
Jackets for wet design XLPE cables shall be polyethylene.
85658 Bac"et (hic"ness
The jacket thickness shall comply with ICEA S-108-720, or as modifed in the purchasers
specifcation for the intended application (reference Appendix 6 Jacket Thickness
Considerations).
8565% Se;i-conductin$ Coatin$
Unless specifcally excluded by the purchaser, a continuous graphite coating or extruded semi-
conducting layer shall be applied over the jacket to form an electrode for Production Tests, dc
testing during installation, and for periodic maintenance testing after commissioning.
85= PR)-,C(I)* (ES(S )* CA0.E
CS9-06 Pa$e 8%
85=51 2eneral
The production tests shall comply with ICEA S-108-720, except as described herein.
85=58 Su;;ar< of ICEA S-10>-=80 Production (ests and 'reAuenc<
ICEA S-108-720 Production Tests and performance frequency are summarized in Tables 2.7-1
and 2.7-2 with specifc variations from ICEA performance frequency noted.
Table 2.7-1, Electrical Tests on Main Insulation
Rated
Voltage,
V
kV
Phase-to-
Ground
Voltage,
V
g
kV
BIL
(for
reference)
kV crest
G
max
Maximum
Allowable
Internal ac
Stress
volts/mil
(kV/mm)
ac Test Voltage Withstand
and Test Time
kV
Partial Discharge Test-
Voltages V
t
Corresponding to V
t
/V
g
Ratio (see 3. below)
kV
2.0 V
g
1.0 hr.
2.5 V
g
0.5 hr.
3.0 V
g
0.25 hr.
V
t/
V
g
1.0
V
t
/V
g
1.5
V
t
/V
g
2.0
69 40 350 150 (6.0) 80 100 120 40 60 80
115 70 550 200 (8.0) 135 160 200 65 100 135
138 80 650 200 (8.0) 160 200 240 80 120 160
161 92 750 225 (9.0) 185 230 280 95 140 185
230 132 1050 275 (11.0) 265 330 N/A 135 200 265
345 200 1300 350 (14.0) 400 N/A N/A 200 300 400
1.ac and PD tests done on each shipping length and 49-61 Hz, after cable completion, including
degassing.
2.G
max
during ac test shall be < 27-30 kV/mm; lower V
g
and increase test time to compensate, but
regardless, test voltage must be >1.5 V
g
and duration < 10 hours.
3.There shall be no detectable discharge within the cable with a measurement sensitivity of 5 pC or
less.
4.Assumes cables are used on an efectively grounded system.
Table 2.7-2 Summary of ICEA S-108-720 and Supplementary Production Tests and
Frequency (* identifes variations from ICEA S-0108-720)
Test
Test Method
Reference
Test Frequency
Conductor
dc Resistance 9.3.1 1 test per each shipping length*
CS9-06 Pa$e 8!
ICEA T-27-581
Diameter ICEA T-27-581 1 sample from each end of each shipping
length*
Temper ASTM Manufacturer certifcation that values are met
Non-Metallic Conductor Shield
Elongation After Aging 9.4.14 Each lot of material used for extrusion onto
the cable
Volume Resistivity 9.8.1 Each lot of material used for extrusion onto
the cable
Note: This test is performed (in combination
with insulation shield volume resistivity) on a
sample of cable
Thickness 9.4.2 1 sample from each end of each shipping
length*
Voids, Protrusions & Irregularities 9.4.13 1 sample from each end of each shipping
length*
Wafer Boil 9.4.13 3 samples from each extruder run; near two
ends & middle
Spark Test (non-conducting layer) ICEA T-27-581 100%
Insulation
Unaged & Aged Tensile & Elongation 9.4.8
9.4.9
1 test per 50,000 ft (15 km) or at least 1 per
extruder run
Hot Creep 9.4.10 and ICEA
T-28-562
3 samples from each extruder run; near two
ends & middle
Voids & Contaminants 9.4.13 1 sample from each end of each shipping
length*
Samples shall be prepared using a lathe, or
Owner-approved equivalent, to minimize
contamination of the surface of the samples
Diameter 9.6 1 sample from each end of each shipping
length*
Shrinkback (XLPE only) 9.9 For rated voltages 150 kV, 1 sample from
each 50,000 ft (15 km) or at least 1 per
extrusion run
For rated voltages > 150 kV, 1 sample from
each end of each extrusion run
Thickness & Eccentricity 9.4.2 1 sample from each end of each shipping
length*
Non-Metallic Insulation Shield
Elongation After Aging 9.4.14.3 Each lot used for extrusion onto the cable
Volume Resistivity 9.8.2 Each lot used for extrusion onto the cable
Note: This test is performed (in combination
with insulation shield volume resistivity) on a
sample of cable
CS9-06 Pa$e 8&
length*
Voids & Protrusions 9.4.13 1 sample from each end of each shipping
length*
Wafer Boil 9.4.12 3 samples from each extrusionr run; near two
ends & middle
Diameter 9.6 1 sample from each end of each shipping
length*
Metallic Shields
Dimensional Measurements 9.5 1 sample from each end of each shipping
length*
Jackets
Unaged & Aged Tensile & Elongation 9.4.8
9.4.9
1 test per 50,000 ft (15 km) or at least 1 per
jacket extruder run
length*
Other Tests Applicable to Jacket
Heat Distortion 9.7.2
ICEA T-27-581
Each lot used for extrusion onto the cable
Heat Shock 9.7.1 Each lot used for extrusion onto the cable
Cold bend ICEA T-27-581 0 samples for <1,000 ft (0.3 km); 1 sample
for 1,000 25,000 ft (0.8 8.0 km); 1
sample for each additional 25,000 ft (8 km)
of jacket extruder run
Oil Immersion (for PVC jackets) 9.4.9.3 Each lot used for extrusion onto the cable
Volume Resistivity 9.8.2 1 test per 50,000 ft (15 km) or at least 1 per
jacket extruder run
Electrical Tests
Ac Withstand 9.11 1 test per shipping length
Partial Discharge ICEA T-24-380 1 test per shipping length
Metallic Shield/Sheath Resistance 1 test per shipping length or master length*
Capacitance 1 test per shipping length or master length*
Jacket Spark ICEA T-27-581 1 test per master length, continuous
Jacket Withstand 7.4.2 1 test per shipping length*
Other Tests
Moisture in Conductor 9.14 1 test per shipping length
Moisture Under Jacket 9.14 1 test per shipping length
85=5% )ther Additions and 6odifications to ICEA S-10>-=80 Production (ests
Other additions and modifcations to ICEA S-108-720 Production Tests shall be as follows:
2.7.3.1 Method for dc Resistance Determination (ICEA S-108-720 clause 9.3.1, ICEA T-27-581
clause 2.1)
CS9-06 Pa$e 86
Clause 9.3.1 shall also include the following requirements:
The complete shipping length reel shall be placed in the test room, which shall be kept at a
reasonably constant temperature for at least 24 hours before the test. The temperature of the
cable (measured by placing a thermocouple one layer below the outer wrap) at the time of the
test shall be within 3 C compared with the testing room temperature.
The manufacturer shall report the following:
length of cable on the reel at the time of conductor dc resistance measurement
measured temperature of the cable and the test room, as well as the method of
measurement
measured conductor dc resistance, for each reel of cable
conductor dc resistance corrected to 25 C
2.7.3.2 Clarifcation and Extension of Shrinkback Test (ICEA S-108-720 clauses 9.9 and 9.15;
Table 4-8)
The clause 9.9 Shrinkback Test Procedure shall be modifed to include a high temperature
heating-cooling cycle, to determine dimensional stability. The test shall be done following any of
the frst three heating-cooling cycles which meets the acceptance limits of ICEA S-108-720
Table 4-8.
The additional heating-cooling cycle shall be to 105 C +/- 2 C for a period of 20 hours and then
cooled to room temperature.
The protrusion acceptance limit, at either end, shall be 175 mils (4.37 mm) for conductor shields
extruded directly over the conductor and 240 mils (6.00 mm) for conductor shields extruded over
semi-conducting tape shields.
2.7.3.3 Amber, Agglomerate, gel, Contaminant, Protrusion, Irrregularity and Void Tests (ICEA S-
108-720 clauses 9.4.13 and 9.15)
If either of the two samples from any shipping length fails, the shipping length shall be rejected.
2.7.3.4 Longitudinal Water Penetration
A longitudinal water penetration test shall be performed for sealed conductor cables, according
to the procedures in ICEA T-31-610. Tests shall be done on a sample of completed cable.
CS9-06 Pa$e 8=
2.7.3.5 Segmented Conductor Eccentricity
The eccentricity of cabled segmental conductors shall be determined from measurement of both
maximum callipered and circumference tape diameters taken at fve locations spaced
approximately 1 foot (30 cm) apart along the conductor. The average of fve maximum
callipered diameters shall not exceed the average of the fve circumference tape diameters by
more than two percent (2%). At any one location, the maximum callipered diameter shall not
exceed the circumference tape diameter by more than three percent (3%).
85=5! Conditions Appl<in$ to (ests
The cable and accessories shall not be shipped (except when agreed to by the purchaser)
unless all required tests have been completed and results of testing show compliance with all
requirements of this specifcation.
All production tests prescribed by this specifcation shall be made at the expense of the
manufacturer. The manufacturer shall provide all samples.
The purchaser may elect to witness tests and to make inspection of the cable during the process
of manufacture, except for those processes of a confdential nature. Refer to procedures and
requirements of 9.0 Quality Assurance, 9.2 Manufacturing and Test Plan.
Where tests are required for engineering information, the results of these tests shall not be
cause for rejection.
85=5& Certified (est Reports
If required by the purchasers specifcation, the manufacturer shall furnish the purchaser with
certifed copies of all production and qualifcation test reports required by this specifcation.
Qualifcation test reports shall clearly describe the insulation and semi-conducting shield
compounds used to manufacture the cable made for the tests, including a copy of the suppliers
technical data sheets for each compound. The location, type and identifcation number of the
extrusion line used to make the cable core, shall also be clearly identifed.
The manufacturer shall furnish certifed copies of actual test values from those tests required for
engineering information.
85> C,A.I'ICA(I)* (ES(S )* CA0.E
The qualifcation tests shall comply with ICEA S-108-720 and as otherwise described herein.
859 CA0.E I-E*(I'ICA(I)*
CS9-06 Pa$e 8>
The cable identifcation shall comply with ICEA S-108-720 and as described herein.
The outer surface of each cable shall be durably marked throughout its length with the
manufacturers name, type of insulation, insulation thickness, conductor material and size,
sequential length indication, rated voltage and year of manufacture. Additional information may
be required by government and regulatory authorities.
85951 Se;i-conductin$ .a<er 6ar"in$
Polymeric insulation shielding and semi-conducting jackets shall be conspicuously identifed as
semi-conducting. The preceding identifcation shall be repeated along the cable at regular
intervals with unmarked surfaces not exceeding six inches (15 cm).
85958 6ethod of 6ar"in$
Marking on the semi-conducting shielding shall be by surface printing only. Durable marking on
an outer jacket may be accomplished by indenting or embossing to a depth not greater than 15
percent of its thickness, or by surface printing.
8595% Production Records
For all cables, the manufacturer shall maintain records to permit the identifcation of stock reel
lengths and shipping reel lengths, insulated adjacent to any particular stock or shipping reel
length. The records shall be maintained for a period of not less than fve years from the shipping
date, unless a longer period is requested by the purchaser, at the time of inquiry.
8595! Conductor Strand Identification
When center strand identifcation is requested by a purchaser, the center strand of each
conductor shall be indented with the manufacturer's name and the year of manufacture at
regular intervals with un-indented surfaces not exceeding 12 inches (30 cm). Additional
information, such as a specifc purchaser's identifcation shall be provided with the mutual
agreement between the purchaser and manufacturer.
8595& Production SeAuence *u;bers
The manufacturer shall establish sequential insulation extruder run numbers on a yearly basis.
On each insulation extruder run, production sequence numbers shall be established which will
permit identifcation of the insulation extrusion sequence (i.e., the lower number is to be
assigned to cables on the reel which left the insulation extruder frst). The extruder run and
production sequence number shall become part of the records to be maintained by the
CS9-06 Pa$e 89
manufacturer for a period of not less than fve years from shipping date, unless a longer period
is requested by the purchaser at the time of inquiry.
%50 (ER6I*A(I)*S
%51 2E*ERA.
The cable system manufacturer shall provide terminations in accordance with the purchasers
custom project specifcation, suitable for terminating the cable described herein.
Terminations for use in air shall comply with IEEE 48. Terminations in gas insulated switchgear
(GIS) shall comply with IEC 60859, IEC 60840 and IEC 62067. Consideration shall also be
given to GIS grounding designs, as described in Electra No. 151 article Earthing of GIS An
application guide.

If required by the purchasers specifcation, the cable system manufacturer shall provide a copy
of representative qualifcation test reports for the proposed terminations with the proposal, or
include such testing with the proposal.
Each termination shall be packaged as a self-sufcient kit. It shall contain packing lists,
instructions and all permanent and consumable materials, as required for installation by
qualifed Journeymen Cablemen, under the Supervision of a manufacturers representative.
Aerial connector lugs shall be provided for each air termination. The connectors shall have
NEMA four hole spacing and be capable of carrying the emergency operating current for 40 C
ambient air temperature, with sun and no wind.
%58 (ER6I*A(I)* 6),*(I*2 I*S,.A(I)*
Termination mounting assemblies shall be provided with electrical insulating systems to allow
temporary isolation of the shield/sheath circuit from ground for periodic maintenance testing of
the jacket with a dc test voltage. They shall also allow permanent isolation of the shield/sheath
circuit from ground, to implement special bonding systems, such as single point bonding, as
described in Electra No. 128 article Guide to the protection of specially bonded cable systems
to sheath over-voltages. The termination isolation systems shall withstand the same electrical
requirements as the external anti-corrosion serving for joint casings (see Table 4.2-1 Each part
to Ground, below).
%5% PR)-,C(I)* (ES(S )* (ER6I*A(I)*S
Production tests shall be done in accordance with the requirements of IEEE 48 or IEC 60859 for
installation in GIS, as applicable. In addition, the following tests shall be done on each of the
termination pre-molded or prefabricated stress relief cones and the housing:
CS9-06 Pa$e %0
1.Partial Discharge Measurements The test shall be carried out in accordance with
ICEA T-24-380 or IEC 60885-2. The sensitivity of the partial discharge (PD)
measurements shall be 5 pC or better. The stress cone shall be installed on a length
of XLPE cable or a simulated accessory test mandrel, subject to agreement between
purchaser and manufacturer. The test voltage shall be raised gradually to and held
at 1.75 x V
g
for 10 seconds, and then slowly reduced to 1.5 x V
g
. The magnitude of
the PD at 1.5 x V
g
shall not exceed 5 pC.
2.Dimensional Checks The dimensions of the stress cone shall be measured and
checked against the tolerances established by the manufacturer. Checks shall
commence no earlier than the start of cable production.
3.Visual Inspection The bore of each stress cone shall be inspected with a fber
scope or other suitable instrument to determine that there are no irregularities on the
surface of the bore. Each termination housing shall be visually inspected for the
presence of any defects prior to shipping.
%5! C,A.I'ICA(I)* (ES(S )* (ER6I*A(I)*S
Qualifcation tests shall be done in accordance with IEEE 48 and IEC 60859 for installation in
GIS, as applicable, and as described herein.
Informative Note: Users are reminded that the IEEE 48 heating cycle voltage tests are
more severe than for IEC 60840 and 62067.
Terminations shall meet the qualifcation test requirements of IEEE 693 Recommended Practice
for Seismic Design of Substations, for Moderate Site, unless specifcally excluded or more
onerous requirements are identifed by the purchaser. IEEE 693 requires qualifcation by time-
history shaker table tests for voltage classifcations 242 kV and static pull tests or time-history
shaker table tests for voltage classifcations < 242 kV. The tests are done prior to the IEEE 48
qualifcation tests.
Static pull tests consist of pulling perpendicular to the top of the termination with a load twice the
operating weight of the termination. The load shall be applied for a minimum of 2 s. There shall
be no damage or cracks in any part, including the insulating housing, and no fuid leakage
before and after the static pull test.
Shaker table tests are described in IEEE 693.
%5!51 Cualification (est for (er;ination 6ountin$ Insulators
CS9-06 Pa$e %1
With the termination support structure connected to ground, 25 kVdc shall be maintained for one
minute across the termination mounting insulation, using the termination base plate for the
positive high voltage connection.
Having successfully withstood the application of dc voltage, the test assembly shall be submitted
to an impulse test. With the termination support structure grounded, ten positive, followed by
ten negative impulses shall be applied across the termination mounting insulation, using the
base plate for the high voltage connection. The magnitude of the impulses shall be in
accordance with Table 4.2-1 Each part to Ground.
Termination mounting insulators shall meet the requirements of IEEE 693, by being incorporated
into the termination assembly for the static pull tests or the time-history shaker table tests
described in 3.4.1.
!50 B)I*(S
!51 2E*ERA.
The manufacturer shall provide joints in accordance with the purchasers custom project
specifcation, suitable for jointing the cable supplied to the purchaser.
Joints shall comply with IEEE 404 and as described herein.
If required by the purchasers specifcation, manufacturers shall provide a copy of representative
qualifcation test reports for the proposed joints, with the proposal, or include such testing with
the proposal.
Each joint shall be packaged as a self-sufcient kit. It shall contain packing lists, instructions
and all permanent and consumable materials, as required for installation by qualifed
Journeymen Cablemen, under the supervision of a manufacturers representative.
!58 S1EA(1 SEC(I)*A.IDI*2 I*S,.A()RS A*- B)I*( CASI*2 I*S,.A(I)*
Unless specifcally excluded by the purchaser, joints shall be provided with a sheath
sectionalizing insulator with internal shield interrupt. The insulation of the two shall be
coordinated so that sectionalizing insulator voltage withstand is less than the internal shield
interrupt. Both shall withstand the ac and transient over-voltages imposed on them during all
operating conditions, as described in the purchasers specifcation.
Joints supplied for use with dry insulation cables with a metallic moisture barrier, shall be
provided with a metallic casing enclosure to facilitate a continuous hermetic seal between the
two ends of the cable sheath.
CS9-06 Pa$e %8
Joint casings shall be provided with an external anti-corrosion serving (jacket), to isolate the
metallic shield/sheath circuit from ground. It shall withstand the ac and transient over-voltages
induced onto it during all normal and abnormal operating conditions.
The sheath sectionalizing insulator and joint casing anti-corrosion covering designs shall ensure
long term ability to meet the above requirements and impulse withstand levels for 33 feet (10 m)
bonding leads, as described in Table 4.2-1 below. The table is derived from IEC 60840, IEC
62067 and the Electra No. 128 article Guide to the protection of specially bonded cable systems
to sheath over-voltages. It is also compatible with IEC 60229.
Table 4.2-1: Metallic Shield/Sheath Insulating Covering Impulse Withstand Voltage versus
BIL
Rated BIL for Main Insulation
kV
Impulse Test Level (1.2 x 50 sec)
Between Parts Each Part to Ground
Bonding
Cable Length
10
( 3m)
kV
Bonding
Cable Length
10 30
(3m 10m)
kV
Bonding
Cable Length
10
( 3m)
kV
Bonding
Cable Length
10 30
(3m 10m)
kV
250 to 325 60 60 30 30
550 to 750 60 75 30 37.5
1050 60 95 30 47.5
1175 to 1425 75 125 37.5 62.5
Notwithstanding the conservative assumption for testing based on 33 foot (10 m) bonding cable
length, connections shall be as short as possible to minimize surge voltage drop, especially
when exposed to high frequency transient over-voltages near GIS disconnects and breakers, or
near outdoor cable terminals exposed to lightning strikes.
The sheath sectionalizing insulators in joints shall withstand the Table 4.2-1 values Between
Parts. All other components, except link box insulation, shall withstand half these values.
The designs shall consider lifetime degradation due to repeated feld voltage application,
moisture degradation, thermal degradation and a factor of safety.
Informative Note: The recommended approach is to design the insulating coverings for metallic
shield/sheath circuit components to withstand at least the Table 4.2-1 values throughout their
design life, but to also provide additional protection against transient over-voltages by applying
sheath voltage limiters (SVLs) with lower protective levels. (Reference Appendix 3)
!5% PR)-,C(I)* (ES(S )* B)I*(S
CS9-06 Pa$e %%
Production tests shall be done in accordance with the requirements of IEEE 404. In addition,
the following tests shall be done on each of the joint pre-molded or prefabricated stress relief
cones:
1.Partial Discharge Measurements The test shall be carried out in accordance with
ICEA T-24-380 or IEC 60885-2. The sensitivity of the partial discharge (PD)
measurements shall be 5 pC or better. The stress cone shall be installed on a length
of XLPE cable or a simulated accessory test mandrel, subject to agreement between
purchaser and manufacturer. The test voltage shall be raised gradually to and held
at 1.75 x V
g
for 10 seconds, and then slowly reduced to 1.5 x V
g
. The magnitude of
the PD at 1.5 x V
g
shall not exceed 5 pC.
2.Dimensional Checks The dimensions of the stress cones shall be measured and
checked against the tolerances established by the manufacturer. Checks shall
commence no earlier than the start of cable production.
3.Visual Inspection The bore of each stress cone shall be inspected with a fber
scope or other suitable instrument to determine that there are no irregularities on the
surface of the bore.
!5! C,A.I'ICA(I)* (ES(S )* B)I*(S
Qualifcation tests shall meet the requirements of IEEE 404 and as described herein. Users are
reminded that the IEEE 404 heating cycle voltage tests are more severe than for IEC 60840 and
62067.
IEC 60840 and 62067 impulse voltage tests for joints embodying sheath sectionalizing
insulation and insulating coverings are more severe than IEEE 404-2000 for main insulation BIL
greater than 1050 kV. Therefore, for cables with main insulation BIL greater than 1050 kV, the
external insulation of sheath sectionalizing joints shall meet the test requirements described in
Table 4.2-1. The joint casing insulation shall also be proven to withstand at least 25 kVdc for
one minute, applied between the joint casing and the external electrode of the submerged joint.
&50 S1EA(1 0)*-I*242R),*-I*2 S9S(E6S
&51 2E*ERA.
Sheath Bonding/Grounding systems shall provide the sheath circuit interconnection and
insulation protection systems described in Electra No. 128 article Guide to the protection of
specially bonded cable systems to sheath over-voltages. The systems shall consist of bonding
cables, link boxes and sheath voltage surge arresters, as required for an insulated sheath
power cable system, as defned in the Electra No. 128 article.
CS9-06 Pa$e %!
Over-voltage protection shall be used for GIS terminations to limit transient over-voltages
between the cable sheath and the GIS enclosure, as described in IEC 60859 and Electra No.
151 Article: Earthing of GIS An Application Guide.
If specifed by the purchaser, the manufacturer shall provide drawings of the sheath
bonding/grounding system and calculations of expected sheath voltages and currents, done in
accordance with the Electra No. 128 article (reference Appendix 10 Information to be Submitted
After Award of Contract).
Ratings described below assume use on an efectively grounded system.
&5151 0ondin$ Cables
Single conductor bonding cables shall meet the requirements of ICEA S-105-692, except that
the minimum average insulation thickness shall be 130 mils (3.3 mm).
Bonding cable connections to link boxes shall be as short as possible, but no greater than 33
feet (10 m) in total length to a ground point. They shall be single conductor construction,
provided the frequency of transient over-voltages is less than 25 kHz and the bonding cables
from adjacent phase connections are touching each other. For transient frequencies greater
than 25 kHz, the manufacturer shall provide concentric bonding cables, as agreed to with the
purchaser. Concentric bonding cables shall meet the requirements of ICEA S-94-649 except
that:
the minimum average central insulation thickness shall be 180 mils (4.6 mm)
the minimum average external insulation (jacket) thickness shall be 130 mils (3.3 mm)
conductor and insulation shields shall be eliminated
the central concentric and conductors shall be identical in area and material (full neutral)
All conductors shall be designed to withstand the rated fault current and duration, as well as the
sheath currents corresponding to emergency loading. The insulation shall withstand the same
impulses as the main cable jacket and joint casing insulation, as described in Table 4.2-1.
Bonding cables used as a parallel earth continuity conductor (reference Electra No 128 article,
Fig. 4) shall be identical to those described in the foregoing, except that their conductors only
need to be designed to withstand the rated fault current and duration.
&5158 .in" 0oxes
Link boxes shall be designed for central water-tight interconnection of sheath cross-bonding,
single point bonding and grounding systems.
CS9-06 Pa$e %&
Link boxes shall incorporate removable links, to easily isolate sections of sheath circuit for
maintenance dc testing of cable jackets, joint sectionalizing insulators, termination mounting
insulators, etc. The links shall also be designed to easily re-confgure the bonding connection
system to solidly bonded.
At cross-bonding locations, or single point bonding open point locations, link boxes shall also
incorporate sheath voltage limiters (SVLs) to protect the sheath circuits insulation from transient
over-voltages.
Link box conducting components shall be designed to withstand the rated fault current and
duration.
The insulation between the links in all link boxes, including those without SVLs, shall be capable
of withstanding the following voltages, with an additional 25% margin to allow for variability in
service:
i) The dc voltage used for qualifcation tests (25 kV + 25% for one minute), initial
commissioning tests (24 kV maximum +25% for one minute) and maintenance testing of
the sheath insulation circuit (5 kV dc maximum for 1 minute)
ii) The highest power frequency voltage arising between sheaths during an external system
fault + 25%
iii) A 1.2/50 microsecond impulse voltage with a maximum value equal to the protective
level as defned in the referenced Electra No. 128 article, paragraphs 5.1.4 and 5.2.3, +
25%, noting that if the SVLs are connected in star, the protective level must be doubled
to allow for the fact that two SVLs are connected in series between each pair of sheaths.
Water-tightness of the link box enclosures shall meet the requirements of IEC 60529, with the
specifc IP Code classifcation as agreed to between the manufacturer and purchaser,
depending on location of the installation (in manholes periodically submerged, in dry manholes
or tunnels, above ground outdoors, above ground indoors, etc.). Alternatively, they shall meet
the requirements of NEMA 250, based on agreement between the purchaser and manufacturer.
(Users are reminded that NEMA 250 Appendix A contains an equivalency conversion from
NEMA to IEC classifcations.)
&515% Sheath #olta$e .i;iters
Sheath voltage limiters (SVLs) shall meet the requirements of IEEE C62.11 Standard for Metal-
Oxide Surge Arresters for AC Power Circuits (> 1 kV).
The metal oxide component of the SVLs shall be encased in a waterproof material to prevent
absorption of moisture.
CS9-06 Pa$e %6
The SVLs shall be capable of withstanding continuously the sheath standing voltage applied to
them during full load or emergency overload.
The SVLs shall be capable of withstanding the highest power frequency voltage applied to them
during system faults, for the maximum fault current duration specifed by the purchaser.
The residual voltage protective level of each SVL shall be less than the impulse withstand levels
of the sheath insulating circuit, taking into account surge voltage drop in bonding cable leads
and SVL connection methods.
&58 PR)-,C(I)* (ES(S )* S1EA(1 0)*-I*242R),*-I*2 S9S(E6S
Production tests on single conductor bonding cables shall meet the requirements of ICEA S-
105-692.
Production tests on SVLs shall meet the requirements of IEEE C62.11.
Production tests on link box water-tightness shall meet the requirements of IEC 60529 or NEMA
250. They shall also demonstrate the ability to withstand a dc test voltage of 25 kV +25% for
one minute, between the conducting components and ground.
&5% C,A.I'ICA(I)* (ES(S )* S1EA(1 0)*-I*242R),*-I*2 S9S(E6S
Qualifcation tests on single conductor bonding cables shall meet the requirements of ICEA S-
105-692 and as described herein. They shall also demonstrate the ability to withstand the
impulse test voltages described in Table 4.2-1.
Qualifcation tests on SVLs shall meet the requirements of IEEE C62.11.
Qualifcation tests on link box water-tightness shall meet the requirements of IEC 60529 or
NEMA 250.
In addition, link boxes shall withstand a water immersion test followed by an impulse voltage test
carried out on one assembly, as described in the Electra No. 75 article: Recommendations for
tests on anti-corrosion coverings of self contained pressure cables and accessories and
equipment for specially bonded circuits. The test voltages shall be in accordance with section
5.1.2 above.
650 C,A.I'ICA(I)* (ES(S )* C)6P.E(E CA0.E S9S(E6
For rated voltages >46 kV to 150 kV, if required by the purchasers specifcation, the
manufacturer shall demonstrate satisfactory performance of a complete system comprised of
cable and at least one of each type of accessory to be provided. Demonstration shall consist of
CS9-06 Pa$e %=
meeting the requirements of IEC 62067 Section 12. Type tests on cable systems, with the
Voltage Test done at 2.5 x Uo (V
g
) for 30 minutes (as described in IEC 60840).
For rated voltages > 150 kV to 345 kV, the manufacturer shall demonstrate satisfactory
performance of a complete system comprised of cable and at least one of each type of
accessory to be provided. Demonstration shall consist of meeting the requirements of IEC
62067 Section 12. Type tests on cable systems.
651 RA*2E )' APPR)#A.
IEC 62067 Section 12.2 describes the Range of type approval and the validity of type, or
qualifcation, tests done on other similar cables and accessories, with respect to the purchasers
intended application. The same provisions shall apply equally to this specifcation, except for the
specifc additions shown in brackets and underlined below.
When the type tests have been successfully performed on one cable system of specifc cross-
section, rated voltage and construction, the type approval shall be accepted as valid for cable
systems within the scope of this standard with other cross-sections, rated voltages and
constructions if the following conditions are met:
a)the voltage group is not higher than that of the tested cable system;
NOTE In this context, cable systems of the same rated voltage group are those of rated voltages
having a common value of U
m
[V
m
], highest voltage for equipment, and the same test voltage values.
b)the conductor cross-section is not larger than that of the tested cable;
c)the cable and the accessories have the same or a similar construction as that of the tested
cable system;
NOTE Cable and accessories of similar construction are those of the same type and manufacturing
process of insulation and semi-conducting screens. Repetition of the electrical type tests is not
necessary on account of the diferences in the conductor type or material or of the protective layers
applied over the screened cores or over the main insulation part of the accessory, unless these are
likely to have a signifcant efect on the results of the test. In some instances, it may be appropriate to
repeat one or more of the type tests (e.g. bending test, heating cycle test and/or compatibility test).
d)calculated maximum electrical stresses on the conductor and insulation screens, in the main
insulation part(s) of the accessory and in boundaries [or interfaces] are equal to or lower
than for the tested accessory.
NOTE If the voltage group is the same, if the cable conductor cross-section is smaller and if the
insulation thickness is not less than that of the tested cable, calculated maximum stress on the
conductor may be 10% higher than that of the tested cable.
e) [material compositions, manufacturing processes, manufacturing plants, and equipment
used for making the cable and accessories subjected to the tests, have not signifcantly
changed].
CS9-06 Pa$e %>
The type tests on cable components (see IEC 62067 clause 12.5) need not be carried out on
samples from cables of diferent voltage ratings and/or conductor cross-sectional areas unless
diferent materials are used to produce them. However, repetition of the aging tests on pieces of
complete cable to check compatibility of materials (see IEC 62067 clause 12.5.4), may be
required if the combination of materials applied over the screened core is diferent from that of
the cable on which the type tests have been previously carried out.
A type test certifcate signed by the representative of a competent witnessing body, or a
[notarized] report by the manufacturer giving the test results and signed by the appropriate
qualifed ofcer, or a test certifcate issued by an independent test laboratory, shall be
acceptable as evidence of type testing.
=50 PRE-C,A.I'ICA(I)* (ES(S )* C)6P.E(E CA0.E S9S(E6
For applications with a rated voltage greater than 150 kV, the manufacturer shall demonstrate
satisfactory, long-term performance of a complete system, comprised of cable and at least one
of each type of accessory to be provided. Demonstration shall consist of meeting the 365 day
test requirements of IEC 62067 Section 13. Pre-qualifcation test of the cable system, with
modifcations to demonstrate performance at emergency conductor temperatures, as described
in section 1.9 preceding. Alternative long term tests may be accepted, as agreed to between the
purchaser and manufacturer, and provided they are applicable to the specifc installation
conditions.
The above tests shall also be done for applications with a rated voltage above 46 kV to 150 kV,
with stresses greater than 200 V/mil (8.0 kV/mm) at the cable conductor shield, or greater than
100 V/mil (4.0 kV/mm) over the cable insulation, subject to agreement between the purchaser
and the manufacturer.
=51 RA*2E )' APPR)#A.
IEC 62067 Section 13.1 describes the Range of pre-qualifcation test approval and the validity
of tests done on other similar cables and accessories, with respect to the purchasers intended
application. The same provisions shall apply equally to this specifcation, except for the specifc
additions shown in brackets and underlined below.
When a pre-qualifcation test has been successfully performed on a cable system, it qualifes the
manufacturer as a supplier of [similarly constructed] cable systems with the same or lower
voltage ratings, as long as the calculated electrical stresses at the insulation screen are equal to
or lower than for the system tested [and material compositions, manufacturing processes,
manufacturing plants, and equipment used for the cable system subjected to the tests, have not
signifcantly changed].
CS9-06 Pa$e %9
A pre-qualifcation test certifcate signed by the representative of a competent [independent]
witnessing body, or a [notarized] report by the manufacturer giving the test results and signed by
the appropriate qualifed ofcer, or a test certifcate issued by an independent test laboratory
shall be acceptable as evidence of pre-qualifcation testing.

>50 E.EC(RICA. (ES(S A'(ER I*S(A..A(I)*
Installation of cable systems is not included in this specifcation and therefore Electrical Tests
After Installation do not form a direct part of it. However, testing of the completed cable system
after installation shall be subject to mutual agreement between the purchaser and manufacturer
prior to testing. For information purposes, general recommendations are described in Appendix
7 and in ICEA S-108-720.
950 C,A.I(9 ASS,RA*CE
951 C,A.I(9 S9S(E6 REC,IRE6E*(S
The manufacturer shall have a current quality assurance program and manual in place, for each
factory engaged in the work. It shall conform to ISO 9001 or equivalent, as acceptable to the
purchaser and registered by an accredited agency.
If required by the purchasers specifcation, the manufacturer shall submit a copy of their quality
assurance plans with their proposal (reference Appendix 9 Manufacturers Technical Declaration
File).
958 6A*,'AC(,RI*2 I*SPEC(I)* A*- (ES( P.A*
If required by the purchasers specifcation, within two weeks after a contract is awarded, the
manufacturer shall submit to the purchaser for acceptance, a fnal Inspection and Test Plan,
conforming to the requirements of ISO 9001 or equivalent (reference Appendix 10 Information to
be Submitted after Award of Contract). The Inspection and Test Plan shall be detailed and shall
include at least the following categories: Material or Parameter to be controlled; Method of
Inspection/Tests and Equipment Used; Frequency of the Inspection/Test; Reference Documents
Governing the QA Activity; QA Record Form; agreed Review/Witness/Hold points, etc.
The Inspection and Test Plan shall contain details of quality assurance activities to be performed
for all materials, manufacturing and handling processes. Inspection and test review/witness/hold
points shall be jointly established between the manufacturer and purchaser. If sub-contractors
are employed, the Inspection and Test Plan shall indicate the portion of the work that will be
undertaken by them, including their inspection and testing.
95% 'AC()R9 I*SPEC(I)*
CS9-06 Pa$e !0
The manufacturer shall carry out such inspections and tests, in accordance with the accepted
Inspection and Test Plan to verify the conformity of each part of the work in accordance with
this specifcation. At least 7 working days written notice, prior to each established witness/hold
point, shall be given to the purchaser to allow for arrangements to be made for his attendance.
95! I*SPEC(I)* A*- A,-I( 09 (1E P,RC1ASER
Any quality assurance inspection carried out by the purchaser shall in no way relieve the
manufacturer of full responsibility for the quality, character or performance of the completed
work.
95& ACCESS () C,A.I(9 ASS,RA*CE A*- (ES( -)C,6E*(S
When requested, the manufacturer shall provide timely access to, and copies of, the following
documents: shop travelers, detailed shop inspection procedures, certifcations, qualifcations,
inspection and test results, production records, process control charts, calibration certifcation
records and other quality assurance documents, compiled during the work.
956 *)*-C)*')R6A*CE REP)R(S
The manufacturer shall provide non-conformance reports (NCRs) to the purchaser, for review
and acceptance, in accordance with ISO 9001 paragraph 4.13, or equivalent, for all major
factory non-conformances to this specifcation. The requirement for NCRs includes work by
sub-contractors. All NCRs shall include the manufacturers proposed disposition and/or
corrective action. The manufacturer shall establish criteria for submission of NCRs to the
purchaser, including the defnition of major and minor non-conformances, with submission of the
Inspection and Test Plan. Unless otherwise agreed to between purchaser and manufacturer,
NCRs shall be submitted within 24 hours of the manufacturers discovery of the non-
conformance.
The above requirement is limited to only products which the manufacturer plans to supply to the
purchaser.
95= 'I*A. C,A.I(9 ASS,RA*CE REP)R(
If specifed by the purchaser, the manufacturer shall submit three certifed copies of the fnal
quality assurance reports, to the purchaser, certifying the compliance of the work to this
specifcation, including all assembly and test data required in the Inspection and Test Plan,
within one week of completion of fnal inspection and testing. The fnal quality assurance report
shall be a bound collection of relevant quality assurance documents as listed below, compiled
during the manufacture of the work.
CS9-06 Pa$e !1
Unless limited by the purchasers specifcation, the fnal quality assurance report shall include at
least:
Sub-contractor inspection reports
Receiving inspection reports
Mill test certifcates
Cable insulation quality reports
Material qualifcation reports
Component dimensional inspection data reports
Instrument and Gauge calibration certifcates and records
Component test reports
Accepted non-conformance reports
Certifed Test Reports in accordance with the specifcation
1050 S1IPPI*2
1051 CA0.E REE.S
105151 Cable Reel Pac"in$@ Sealin$@ and Shippin$
The cables shall be placed on reels so that they are protected from damage during shipment.
Each end of the cable shall be frmly and properly secured to the reel. Care shall be taken to
ensure that the cable is tightly wrapped to prevent movement during transportation.
There shall be no water in the completed cable when the reel is shipped.
Each length of cable listed on the purchaser's order or detail list shall be shipped on a separate
reel unless specifcally agreed to between the purchaser and manufacturer.
The reels shall be lagged or covered with suitable material to provide physical protection for the
cables during transit and during ordinary storage and handling operations.
105158 Reel -i;ensions
The minimum drum diameters for shipping reels shall be determined by the manufacturer. Reel
construction and dimensions shall comply with NEMA WC 26.
If the cable has a metallic sheath, the minimum drum diameter of the reels shall be in
accordance with the following Table 10.1-1, or as otherwise agreed to between the purchaser
and manufacturer.
Table 10.1-1 Minimum Drum Diameter for Various Metallic Sheath Types
CS9-06 Pa$e !8
Sheath Type
Insulation Thickness
mils (mm)
Ratio of Outside Diameter of Reel
Drum to Cable Outside Diameter
Lead < 500 (12.7) 14
Lead 500 to 800 (12.7 to 20.3) 18
Lead > 800 (20.3) 22
Aluminum (smooth
tubular)
30
Aluminum (smooth
tubular, bonded to
jacket)
18
Corrugated Metallic
(copper or aluminum)
< 800 mils (20.3 mm) 18
Corrugated Metallic
(copper or aluminum)
> 800 mils (20.3 mm) 22
The inner or drum end of the cable, when allowed to project through the fange of the reel, shall
be protected to avoid damage to the cable or seal.
10515% 6ar"in$ on Reels
Each reel shall be marked with a durable label securely attached to the outside of a fange. The
label shall plainly state all the identifcation information described in section 2.9, as well as the
following:
manufacturers name and address
purchaser's order and contract number
destination
shipping length of cable on reel
reel identifcation number
conductor size
type of cable
thickness and type of insulation
voltage rating
gross, tare and net weight
Each reel shall be marked with an arrow on the fange indicating the direction the reel is to be
turned to unwind the cable.
Each reel shall be identifed with a number permanently attached to the outside of a reel fange.
CS9-06 Pa$e !%
Shipping reels shall be free of any information not pertaining to the order.
10515! Cable End 'ittin$s
Cables with a metallic moisture barrier shall have their ends hermetically sealed from moisture
entry with durable and efective metallic end caps. Special consideration shall be given to
efectively sealing cables with longitudinally applied metal foil moisture barriers.
A pulling eye, approved by the purchaser, shall be attached at the outside end of each shipping
length. The pulling eye shall be suitable for pulling the cable through wet or dry ducts or pipes,
trenches, or tunnels.. The tensile strength requirements shall be at least the same as the main
cable conductor, or as otherwise agreed to between the purchaser and manufacturer.
Cable caps and pulling eyes shall be designed and applied to allow performing a dc jacket
integrity test without having to remove them and their hermetic seals.
1058 C)*(AI*ERS@ 0)+ES A*- PA..E(S
105851 6ar"in$ of Containers@ 0oxes and Pallets
All containers, boxes and pallets shall be identifed with an aluminum tag securely attached.
The following information shall be stamped in raised or indented letters on the tag:
manufacturers name and address
purchaser's order and contract number
destination
general contents
quantity in container
container identifying number
105858 Pac"a$in$ and Shippin$
(a) General
All items shall be packaged and loaded for shipment in a manner to protect them from damage,
moisture and corrosion in transit, handling, outdoor storage and transportation to the site.
Burlap and other absorbent material shall not be used for packing of any material shipped.
The manufacturer shall be responsible for and correct any and all damage and shortages
incurred during loading and transit to the delivery point.
(b) Packaging
CS9-06 Pa$e !!
Joints and terminations shall be shipped in wooden boxes, with one complete accessory kit per
box. Other materials that might otherwise be lost shall be boxed or wired in bundles.
(c) Shipping
Material shall be shipped in a manner to facilitate of-loading, handling and erection on site.
Where required for proper handling and erection, lifting lugs and special lifting devices shall be
provided. In such cases, slinging diagrams shall be included with the shipping reports
described herein. All parts shall be prepared for shipment so that handling slings may be
attached readily while the parts are on the rail car, truck or ship. Where equipment is boxed,
and it is unsafe to attach slings to the box, provision shall be made to attach the slings to the
equipment, and the slings shall project through the box or crate so that attachment can be made
readily.
The manufacturer shall be responsible for tracing and expediting all shipments and for obtaining
all required clearances.
10585% Pac"in$ .ists
Packing lists shall be included with each shipment and submitted with the shipping reports.
Packing lists shall show the following information:
description of the contents of each box
calculated net weight and actual gross weight of each package unit
overall dimensions of each individual package
identifcation number of each package in the shipment
10585! Shippin$ Adice
(a) Shipping Notice
The manufacturer shall, on the date of material shipment, send the purchaser the following
information by e-mail or fax:
contract number and purchase order number
items and quantities shipped.
carrier.
bill of lading numbers.
delivery point.
anticipated date of arrival.
CS9-06 Pa$e !&
(b) Shipping Reports
A copy of the complete shipping reports shall be sent to the purchaser by e-mail, fax or courier
service, within 24 hours after each shipment is made. The shipping reports shall include:
packing lists
bills of lading
carrier
shipping date
delivery point
estimated time of arrival at the delivery point
details of any special requirements regarding the methods of handling and storing the items
shipped
The manufacturer shall give the purchaser not less than two working days notice of the actual
arrival times of all shipments at the delivery point.
CS9-06 Pa$e !6
1150 APPE*-ICES
CS9-06 Pa$e !=
APPE*-I+ 1 E 0ASIS ')R #)I-@ C)*(A6I*A*( A*- PR)(R,SI)* .I6I(S
FI*')R6A(I#EG
The CS7-2005 limits for permissible size of contaminants, voids and protrusions for XLPE
insulation and extruded shields, are based mainly on Appendix 1 references 1., 2. and 3.
1. Voids
The maximum permissible void size is based on the condition that partial discharges would not
occur under normal rated voltage and would extinguish even if they might occur under ac over-
voltages. Void location is assumed to be at the extruded conductor shield surface.
The following equation is developed in the Appendix 1 references:
65 . 2
) / ln(
23 . 1
550
2
1 2 1

r r r
Va
a
(1)
Where:
2a = diameter of void considered to be harmful (mm)
Va = discharge inception voltage
= cable maximum ac voltage / 3 x 1! (kV) (assuming that the ratio of inception voltage to extinction
voltage is 1!)
= V
g
x 11 x 1! (kV) (assuming a 1"# over$voltage for 1% minutes)
r
!
= outer radius of insulation (mm)
r
1
= inner radius of insulation (mm)
The above equation can also be expressed in terms of G
max
, the nominal ac voltage stress at
the conductor shield/insulation interface at nominal phase-to-ground operating voltage, V
g
:
65 . 2 2 . 1 1 . 1 max 23 . 1
550
2

G
a
(2)
) / ln(
max
1 2 1
r r r
Vg
G
(3)
The maximum permissible void size can then be expressed in terms of various values of G
max
:
G
max
(kV/mm)
4 5 6 7 8 9 10 11 12 13 14
CS9-06 Pa$e !>
MaximumV
oid diam. 2
a
mils (m)
2.0
(51)
1
2.0
(51)
1
2.0
(51)
1
2.0
(51)
1
2.0
(51)
1
1.9
(49)
2
1.7
(43)
2
1.5
(38)
2
1.4
(35)
2
1.3
(32)
2
1.1
(29)
2
1
reduced from calculated value to refect current practices and ICEA S-108-720-2004 limits.
2
2. Contaminants and Protrusions
Contaminants in the insulation form a local high electric feld in their vicinities, which may cause
electrical treeing. The maximum permissible contaminant size is determined when local felds
approach the electrical tree inception stress. Electrical tree generation from contaminants and
protrusions is generally considered to follow a voltage-time relationship and is also temperature
dependent, according to the following equation (ref. 1.):
Kf Ka Kt G Gc 1 . 1 max
(4)
Where:
Gc = electrical tree inception stress for metallic contaminants (assumed 3"" kV/mm at !" &)
Gmax = the nominal voltage stress at the conductor shield/insulation interface at nominal phase$to$ground
operating voltage
Kt = temperature coefficient (ratio of the electrical tree inception stress at !" & to that at '" & = 1!)
Ka = deterioration coefficient( the life conversion coefficient based on a value of n obtained from
voltage$time test data for model cables) the ratio bet*een voltage raising steps of t* minutes in tree
initiation tests and the design life to
n
t* to Ka / (%)
n = 1% (except for taped +oints) *here n=1!)
to = ," x 3-% x !,x-" (minutes) (assuming a ," .ear life)
t* = 1% (minutes)
Kf = electric stress concentrating coefficient at the tip of a metallic defect
'

,
_
+

1 1
1
ln
2
1 1
1
2
Kf
(6)
Where:

1
1
1
ln
2
1

,
_
(7)
2
1
1
1
'
,
_
a
/
(8)
CS9-06 Pa$e !9
2a = major axis of ellipsoidal contaminant (m)
R = radius of point end used for tree initiation stress tests (assumed 10 m)
By solving equation (4) with various values of G
max
and contaminant diameters (2a), one can
determine the appropriate values to assure not exceeding the electric tree inception stress of
300 kV/mm. G
max
is of course dependent on the phase-to-ground voltage, conductor radius and
insulation thickness, for the particular application.
The limit for amber size in the insulation is twice the contaminant diameter (4a).
The limit for height of protrusions (either into the shield or into the insulation) is one half the
contaminant diameter (a).
The maximum permissible contaminant, amber and protrusion sizes can then be expressed in
terms of various values of G
max
:
G
max
(kV/mm) 4 5 6 7 8 9 10 11 12 13 14
Maximum
Contaminant diam.
2 a
mils (m)
5.0
(127)
1
5.0
(127)
1
5.0
(127)
1
5.0
(127)
1
5.0
(127)
1
5.0
(127)
1
5.0
(127)
1
5.0
(127)
1
5.0
(127)
1
4.0
(110)
2
4.0
(100)
2
Maximum Amber
diam. 4 a
mils (m)
10.0
(254)
1
10.0
(254)
1
10.0
(254)
1
10.0
(254)
1
10.0
(254)
1
10.0
(254)
1
10.0
(254)
1
10.0
(254)
1
10.0
(254)
1
8.0
(220)
2
8.0
(200)
2
Maximum
Protrusion height
at conductor shield
a
mils (m)
3.0
(76)
3
3.0
(76)
3
3.0
(76)
3
3.0
(76)
3
3.0
(76)
3
3.0
(76)
3
3.0
(76)
3
3.0
(76)
3
2.5
(63)
2
2.0
(55)
2
2.0
(50)
2
1
reduced from calculated value to refect current practices and ICEA S-108-720-2004 limits.
2
3
one half of the ICEA S-108-720 contaminant diameter, as per JEC-3408, if lower than ICEA
limits.
Maximum protrusion height at the insulation shield is 0.6 times the value at the conductor shield,
to refect ICEA S-108 practice and in consideration of the approximate typical ratio between
internal and external ac stresses.
ICEA S-108-720 has an additional requirement that the insulation not contain more than 0.6
contaminants per cm
3
between 51 and 127 m in diameter.
CS9-06 Pa$e &0
Users are reminded that the formulas described above provide only a general idea of electric
stresses, based on a number of assumptions. For example, elliptical, parabolic or hyperbolic
models could be used to simulate protrusions, with diferences in results. The elliptical model
selected above does not consider very sharp tips of protrusions, as they may exist in real life,
and which would result in signifcantly higher stresses than those calculated using the formulas.
The values translated to Tables 2.2-1 and 2.3-2 of the specifcation have therefore been rounded
to the closest 0.5 mil (13 m).
More recent work using fnite element analysis has concluded that for maximum background
felds in the range of 15kV/mm, as seen near the conductor shield of some high stress
transmission class cables, a worst case conducting contaminant particle length in the range of
4.0 mils (100 m) is likely to be required to cause failure for the worst-case local polymer
morphology in the range of the maximum operating temperature
4
. This confrms the validity of
the above approach.
Appendix 1 References:
1.Standard of the Japanese Electrotechnical Committee, JEC-3408 High Voltage
Tests on Cross-linked Polyethylene Insulated Cables and their Accessories for Rated
Voltages from 11 kV to 275 kV, 1997.
2.M. Fukawa, T. Kawai, Y. Okano, S. Sakuma, S. Asai, M. Kanaoka, H. Yamanouchi,
Development of 500 kV XLPE Cables and Accessories for Long Distance
Underground Transmission Line Part III: Electrical Properties of 500 kV Cables,
IEEE Transactions on Power Delivery, Vol. 11, No. 2, April 1996.
3.K. Kaminaga, T. Harada, M. Ono, T. Kojima, Y. Sekii, M. Marumo, Research and
Development of 500 kV XLPE Cables, Conference Record of 1986 IEEE
International Symposium on Electrical Insulation, Washington, DC, June 9-11, 1986.
4.S. Boggs, Z. Zheng, Defect Tolerance of Solid Dielectric Transmission Class Cable,
IEEE Electrical Insulation Magazine, Vol. 21, No. 1, January/February 2005.
CS9-06 Pa$e &1
APPE*-I+ 8 EA2I*2 'AC()RS@ -ESI2* .I'E A*- RE.IA0I.I(9 C)*SI-ERA(I)*S ')R
E+(R,-E- I*S,.A(I)* CA0.ES A*- ACCESS)RIES FI*')R6A(I#EG
The ELECTRA No. 140 article Consideration of Ageing Factors in Extruded Insulation Cables
and Accessories describes the main factors to be considered when designing and evaluating
extruded insulation cables and accessories with respect to ability to meet design life (see
Reference 1.). The following Table A2-1 is extracted from it, and provides a valuable reminder
for every new application.
Table A2-1 Factors to be Considered in Aging of Extruded Insulation Cable Systems
Cables H
accessor<
insulation
Se;i-
conductin$
shields
Se;i-
conductin$
contact
la<ers
Swellin$
tapes or
powders
6etallic
wires4
tapes
0onded
;etal
barriers
6etallic
sheaths
Bac"ets
PHYSICAL
#1 Cr/stallinit/ c"anges x
21 C"anges in molecular
0eig"t distri*ution
x
+1 8ec"anical locBed.in stress
c"anges and s"rinBage
x x x x x
41 Deformation under
temerature and e)ternall/
alied mec"anical stress
x x x x x
,1 ;"ermal e)ansion effects
(radial)
x x x x x x
61 ;"ermal E)ansion effects
(longitudinal)
x x x x x
?1 8a)imum 0orBing K
o2erload temeratures
x x x
$1 7oss of ad"esion x x x
-1 Fatigue due to c/clic
*ending
x x x
#01&resence of fugiti2e
comonents
x x x x x
##17oss of gaseous or liCuid
insulant
x
#21Damaged insulation and
fault/ Jointing
x x x x x x x x
#+1Contamination x x
#418oisture re.distri*ution (not
from e)ternal rene0a*le
sources)
x x x x
#,15ater tree acti2it/ x
CHEMICAL
#61')idation x x
#?1Comati*ilit/ (diffusion of
comonents)
x x x x x
#$1Corrosion x x x x x
PHYSICO-CHEMICAL
#-1%emi.conducting s"ield
resisti2it/ c"anges
x x x
201%urface resisti2it/ c"anges
(loss of electrical contact)
x x x x x
ELECTRICAL
2#17o0.le2el artial disc"arge
acti2it/
x
221Electrical stress (ac and
imulse)
x x
2+1Dissiation factor x x
CS9-06 Pa$e &8
241%ta*ilit/ of electrical
connections
x x x x
2,1(iological effects x x
Part 1.8 of the specifcation requires the manufacturer to supply data and calculations
supporting a minimum 40 year cable system design life, if required by the purchasers
specifcation. References 2 16 provide some examples of work done by others to verify similar
requirements, mainly from an electrical performance perspective.
Part 1.8 also requires the manufacturer to supply supporting data and calculations verifying the
thermal-mechanical performance of the cable system, if required by the purchasers
specifcation. References 17 43 provide examples of work done by others to verify similar
requirements. Some of these references also overlap with the electrical performance references
described in the preceding paragraph.
Part 2.5.4 requires the manufacturer to state the limiting 2alue of s"eat" c/clic strain for 40./ear
life (J) (reference Appendix 8, Item 12 e)), to verify that cyclic fatigue testing has been
performed for the specifc cable construction, and that it is adequate for the intended application,
and if required by the purchasers specifcation. If necessary, tests shall be done in general
accordance with methods described in References 20, 32, 35 and 37.

Aging Factors:
1. CIGRE Working Group 21-09, Consideration of Aging in Extruded Insulation Cables
and Accessories, ELECTRA No. 140, pages 57-75, February 1992.
Electrical Design Life and Reliability
2. Metra, Ochini, Portinari, High Voltage Cables with Extruded Insulation, Staistical
Controls and Reliability Evaluation, IEEE Transactions on Power Apparatus and
Systems, vol. PAS-94, no. 3, May/June 1975.
3. Bossi, Farnetti, Portanari, Criteria for the Qualifcation of Extruded Insulation
Cables, paper 21-10, CIGRE 1976.
4. Kaminaga, Harada, Ono, Kojima, Sekii, Marumo, Research and Development of 500
kV XLPE Cables, Conference Record of 1986 IEEE International Symposium on
Electrical Insulation, Washington, DC, June 9-11, 1986.
,1 'ls"ausen, &esc"Be, %c"rot", IDe2eloment of E=6 @7&E Ca*les3 Dimensioning
and ;est &"iloso"/>, aer 2#.#0?, CIG4E #--01
CS9-06 Pa$e &%
6. Dorison, Sin, Argaut, Becker, Dejean, High Voltage Cross-Linked Polyethylene
Insulated Cables in the French National Grid Experience in the Field Potential
Utilization at Higher Voltages, paper 21-107, CIGRE 1994.
7. Peschke, Schroth, Olshausen, Extension of XLPE cables to 500 kV based on
progress in technology, paper A.1.2, Jicable 1995.
8. Fukawa, Kawai, Okano, Sakuma, Asai, Kanaoka, Yamanouchi Development of 500
kV XLPE Cables and Accessories for Long Distance Underground Transmission Line
Part III: Electrical Properties of 500 kV Cables, IEEE Transactions on Power Delivery,
Vol. 11, No. 2, April 1996.
9. Dorison, Bourgeat, Maugain, Argaut, Dejean, Mirebeau, Optimizing 400 kV
Underground Links with Cross-Linked Polyethylene Insulated Cables for Bulk
Transmission, paper 21-105, CIGRE 1998
10. Attwood, Dickinson, Gregory, Hampton, Swoma, Development of High Stress HV
and EHV XLPE Cable Systems, paper 21-108, CIGRE 1998.
11. Demaria, Gregory, Hampton, Mainwaring, The design of power cables to operate at
high electrical stress, paper A.2.1, Jicable 1999.
Tanaka, T., Tanaka A., Shibata, Hirotsu, The efect of temperature on dielectric
characteristics of XLPE, Jicable 99.
12. Bolza, Parmigiani, Donazzi, Bisleri, Prequalifcation Test Experience on EHV Cable
Systems, paper 21-104, CIGRE 2002.
13. Bjorlow-Larsen, Del Brenna, Kaumans, Meier, Kirchner, Argaut, Large Projects of
EHV Underground Cable Systems, paper A.2.5, Jicable 2003.
14. Toya, Kobashi, Okuyama, Sakuma, Katakai, Sato, Higher Stress Designed XLPE
Cable in Japan, paper B1-111, CIGRE 2004
15. Cho, et al, Koo, Development of High Stress XLPE Cable System, paper B1-105,
CIGRE 2004.
16. Weissenberg, Rengel, Scherer, EHV Cable Systems up to 400 kV More than 10
years of Experience, paper B1-102, CIGRE 2004.
Thermal-Mechanical Design Life and Reliability:
#?1 E&4I, L8ec"anical Effects on E)truded Dielectric Ca*les and Joints in :nderground
;ransmission %/stems in !ort" AmericaM, E&4I 4eort #00#$4-, 8arc" 20041
#$1 CIG4E ;asB Force (#.#0, L;"ermal 4atings of =6 AccessoriesM, E7EC;4A !o1
2#2, Fe*ruar/ 20041
#-1 <amada, !aBaga0a, 9ataBai, 9is"i, !aBanis"i, 8urata, LDe2eloment of =eat.
resistant @7&E Ca*le and AccessoriesM, IC&AD8, 200+1
201 :meda, 8atsura, 5atana*e, %aBaguc"i, '"imo, LDe2eloment of 2?, B6 @7&E
Ca*le 0it" Aluminum 7aminated ;ae and 4adial 8oisture (arrierM, aer A1#1,, Jica*le
>0+1
2#1 CIG4E Joint ;asB Force 2#D#,, LInterfaces in accessories for e)truded =6 and E=6
ca*lesM, E7EC;4A !o1 20+, CIG4E ;ec"nical (roc"ure 2#0, August 20021
221 CIG4E 5orBing Grou 2#1#?, LConstruction, la/ing and installation tec"niCues for
e)truded and self contained fluid filled ca*le s/stemsM, CIG4E ;ec"nical (roc"ure #-4,
'cto*er 200#1
CS9-06 Pa$e &!
2+1 ;arno0sBi, Iordanescu, A0ad, 4o/er, L;"ermomec"anical 8odelling of +4, B6
@7&E Ca*les in DuctM, aer A41#, Jica*le >--1
241 (rincourt, Dorison, L;"ermomec"anical (e"a2iour of 400 B6 %/nt"etic Ca*lesM,
aer A412, Jica*le >--1
2,1 G1&1 6an der 5iNB, E1 &ultrum, =1;1F1 Geene, LDe2eloment and Eualification of a
!e0 400 B6 @7&E Ca*le %/stem 0it" Integrated %ensors for DiagnosticsM, aer 2#.
#0+, CIG4E #--$1
261 =ead, CrocBett, ;a/lor, 5ilson, L;"ermo.mec"anical C"aracteristics of @7&E =6
Ca*le InsulationM, Conference on Dielectric 8aterials, 8easurements and Alications>,
IEE, #-$$1
CIG4E 5orBing Grou 2#10#, L7a/ing and Installation of =ig" 6oltage E)truded Ca*le
%/stems, 7iterature E2aluation Data ComarisonM, E7EC;4A !o1 #,6 Article, 'cto*er,
#--41
2?1 %c"oonaBBer, 5illems, L;"ermomec"anical (e"a2iour of =6 and E=6 Ca*les 0it"
Coer ConductorsM, aer A141+, Jica*le >-#1
2$1 Is"ii, I0ata, Inoue, LDesign 8et"od and Anal/sis for ;"ermo.mec"anical (e"a2iour
of 2?, B6 @7&E Ca*lesM, aer A141,, Jica*le >-#1
2-1 9oma*a, Iida, Is"ii, 9asu/a, ;anaBa, 9ido, ;ana*e, FuNisa0a, L;"ermomec"anical
(e"a2iour of 7arge Conductor 2?, B6 @7&E Ca*leM, FuruBa0a 4e2ie0 !o1 -, #--#1
+01 7eufBens, 5illems, LDe2eloments ;o0ards a 4elia*le 'erating E=6 E)truded
Ca*le %/stemM, aer 2#.#0$, CIG4E #--01
+#1 !agasaBi, <os"ida,Ai"ara, FuNiBi, 9ato, !aBaga0a, L&"iloso"/ of Design and
E)erience on =ig" 6oltage @7&E Ca*les and Accessories in JaanM, aer 2#.0#,
CIG4E #-$$1
+21 Anelli, DonaAAi, 7a0son, L;"e Fatigue 7ife of 7ead Allo/ E as a %"eat"ing 8aterial
for %u*marine &o0er Ca*lesM, IEEE ;ransactions on &o0er Deli2er/, 6ol1 +, !o1 #,
Januar/ #-$$1
++1 5atana*e, <agisa0a, =i/ama, !is"inoma, L;"ermo.mec"anical *e"a2ior of 2?, B6
@7&E ca*le in tunnelM, Jica*le >$?1
+41 %"inNi <os"iBa0a, LInstallation 8et"od for ?? B6 @7&E Ca*lesM, %umitomo Electrical
4e2ie0 !o1 22, Januar/ #-$+1
+,1 9ris"nasam/, LFatigue 4esistance of 7arge %iAe =elicall/ Corrugated Aluminum
%"eat"ed Ca*leM, IEEE ;ransactions on &o0er Aaratus and %/stems, 6ol1 &A%.--,
!o1 6, !o2DDec #-$01
+61 7a0son, =ead, 7om*ardi, Anelli, LFatigue and Cree &"enomena in 'il.Filled
%uertension Ca*lesM, IEE Conference &u*lication no1 #?6, International Conference on
&rogress in Ca*les and '2er"ead 7ines for 220 B6 and A*o2e, 2
nd
, 7ondon, England,
ages #$#.#$?, %et1 6, #-?-1
+?1 =a2ard, L%election of Ca*le %"eat" 7ead Allo/s for Fatigue 4esistanceM, IEEE
;ransactions on &o0er Aaratus and %/stems, 6ol1 &A%.-6, no1 #, Januar/DFe*ruar/
#-??1
+$1 ArBell, Arnaud, %Bier, L;"e ;"ermo.8ec"anical Design of =ig" &o0er, %elf
Contained Ca*le %/stemsM, aer 2#.0,, CIG4E #-?41
+-1 =oldu, 'cc"ini, %Bier, L;"ermo.8ec"anical (e"a2iour of 7arge Conductor
Ca*lesM, IEEE &aer +# ;& 6?.4?$, Jul/ #-6?1
401 =olttum, L;"e Installation of 8etal %"eat"ed Ca*les on %aced %uortsM,
&roceedings of t"e IEE, 6ol1 #02, &t1 A, ages ?2-.?421
4#1 (auer, !ease, LE2aluation of Ca*le 8o2ement Due to C/clic 7oadingM, AIEE &aer
,4.#0, Aril #-,41
421 %c"ifreen, L;"ermal E)ansion Effects in &o0er Ca*lesM, AIEE &aer ,#.22,
!o2em*er, #-,01
CS9-06 Pa$e &&
43. Schifreen, Cyclic Movement of Cable Its Causes and Efects on Cable Sheath
Life, AIEE Paper 44-131, May 1944.
CS9-06 Pa$e &6
APPE*-I+ % EE.EC(RICA. /I(1S(A*- A*- I*S,.A(I)* C))R-I*A(I)*
REC,IRE6E*(S ')R SPECIA..9 0)*-E-@ I*S,.A(E- 6E(A..IC S1IE.-4S1EA(1
S9S(E6S FI*')R6A(I#EG
References 1, 2, 3 and 4 describe the function of specially bonded cable systems, their
components and complete systems, for various applications.
1. Power Frequency Current Withstand Requirements
The metallic shield/sheath circuit consists of all electrical current paths that can be connected to
the cable shield/sheath. These include at least:
connections between shield/sheaths and ground at cable terminations, via link boxes, as
applicable
internal ground connections within cable termination connections between metallic joint
casings or to ground, via link boxes, as applicable
Each connection must be capable of withstanding the power frequency currents imposed due to
normal and emergency load currents fowing in the main conductor, as well as those arising
from internal and external faults.
2. Power Frequency Voltage Withstand Requirements
In addition, the insulation for each conductor in the metallic shield/sheath circuit must withstand
the power frequency voltages induced onto them during normal and abnormal operating
conditions. This insulation includes cable jackets, joint external coverings, joint sheath
sectionalizing insulators, cable termination mounting insulators, sheath bonding cables and
most link box internal components.
The worst case approximate values occur during fault conditions. Assuming a worst case
maximum sheath standing voltage of about 400 Volts (under consideration), corresponding to a
2000 A short time load current, then for an extreme 60 kA fault level, the temporary ac sheath
over-voltage would be about (60,000/2000) x 400 = 12.0 kV, until the fault clears.
The general worst-case power frequency withstand requirements would therefore be about 12.0
kVac.
3. Impulse Voltage Withstand Requirements
The shield/sheath conductor insulation must also withstand transient over-voltages.
CS9-06 Pa$e &=
IEC 60840 Annex H and IEC 62067 Annex D describe the impulse voltage qualifcation test
requirements for the outer coverings of joints and joint sectionalizing insulators. The information
is summarized in Table A3-1 below. IEC 60229 also describes the impulse voltage test
requirements for cable jackets, which corresponds to the values in the right column of Table A3-
1. By extension, the Table A3-1 values should apply to all sheath circuit insulations.
Table A3-1: Metallic Shield/Sheath Insulating Covering Impulse Voltage Withstand versus
BIL for Main Insulation
BIL for Main Insulation
(kV crest)
Impulse Test Level
Between Parts Each Part to Earth/ground
Bonding
Lead Length
3m
(kV)
Bonding Lead
Length
> 3 m 10 m
(kV)
Bonding
Lead Length
3m
(kV)
Bonding Lead
Length
> 3 m 10 m
(kV)
250 to 325 60 60 30 30
550 to 750 60 75 30 37.5
1050 60 95 30 47.5
1175 to 1425 75 125 37.5 62.5
The magnitude of surge voltage developed in a bonding cable is dependent on its length,
especially at the higher frequencies created by disconnector operation in GIS, or due to lightning
strikes near outdoor cable terminals. It is therefore recommended that for general applications,
the highest impulse levels be used, assuming 10 m bonding leads.
The sheath sectionalizing insulators in joints, the central insulation in concentric bonding leads
and some insulators in link boxes must withstand the Table A3-1 values Between Parts. All
other components must withstand half these values.
Since the Table A3-1 values are much higher than any power frequency over-voltages
anticipated for HV and EHV cables, they are used as the basis for insulation design. The
recommended approach is to design the insulating coverings for metallic shield/sheath circuit
components to withstand these values throughout their design life, but to also provide additional
protection against transient over-voltages by applying sheath voltage limiters (SVLs) with lower
protective levels.
CS9-06 Pa$e &>
4. Transient Over-voltage Protection
Select zinc oxide sheath voltage limiters (SVLs) to provide a protection level to the metallic
shield/sheath circuit insulation that is less than the unprotected impulse withstand values
described in the foregoing, using procedures described in Reference 4:
The SVL units must be capable of withstanding continuously the sheath standing voltage
applied to it during full load or emergency overloads.
The rated voltage of each SVL unit shall be at least equal to the maximum sheath
standing voltage due to external system faults.
The residual voltage of SVLs (for a 10 kA 1.2 x 50 sec wave) shall be less than the
minimum impulse withstand voltage of the metallic shield/sheath insulating circuit.
The surge current capability of SVLs (20 sec wave) shall be greater than the maximum
induced surge current.
The discharge energy capability of SVLs shall be greater than the maximum energy in
the surge current.
The SVL shall be able to dissipate the energy generated by fault induced voltages for the
declared fault clearing time, and any subsequent automatic fast re-closing operations.
5. Concentric versus Single Core Bonding Cables
As explained in Appendix 3 Reference 3 below, although concentric cables have superior
transient performance, single core cables can also be used and may ofer other advantages,
such as needing simpler joint protection systems. It is however recommended that in single
core applications, go/return leads be tie-wrapped together. In those conditions where the link
boxes are very close to the joints, bundling the cables may not be practical, or even needed, due
to the lower inductance of short connections.
1.Working Group 07 of CIGRE Study Committee 21, The design of specially bonded
cable circuits (Part I), Electra No. 28, May 1973.
2.Working Group 07 of CIGRE Study Committee 21, The design of specially bonded
cable circuits (Part II), Electra No. 47, July 1976.
3.Working Group 18 of CIGRE Study Committee B1, Technical Brochure 283 Special
Bonding of High Voltage Power Cables, October 2005.
4.Engineering Recommendation C.55/4, Cables Consultancy Group, Insulated Sheath
Power Cable Systems, October 1989.
5.Working Group 07 of CIGRE Study Committee 21, Guide to the protection of
specially bonded cable systems to sheath over-voltages, Electra No. 128, January
1990.
CS9-06 Pa$e &9
6.IEC Technical Committee 20: Electric Cables, IEC 60840, Power cables with
extruded insulation and their accessories for rated voltages above 30 kV up to 150
kV Test methods and requirements, 1999.
7.IEC Technical Committee 20: Electric Cables, IEC 62067, Power cables with
extruded insulation and their accessories for rated voltages above 150 kV up to 500
kV Test methods and requirements, 2001.
8.IEC Technical Committee 20: Electric Cables, IEC 60229, Tests on cable
oversheaths which have a special protective function and are applied by extrusion,
2006.
CS9-06 Pa$e 60
APPE*-I+ ! E 0ASIS ')R +.PE E6ER2E*C9 (E6PERA(,RE REC,IRE6E*(S A*-
APPR)+I6A(E #ERI'ICA(I)* 09 (ES(I*2 A*- 6EAS,RE6E*( FI*')R6A(I#EG
The specifcation describes the requirements for a 105 C emergency operating temperature for
XLPE insulation cables. Operation at this temperature should be for no more than 72 hours
duration on average per year during the design life of the cable system, without exceeding 216
hours in any 12-month period. Assuming a 40-year design life, this implies that the cable
system should be able to withstand cumulative operation at 105 C for a total of 72 x 40 = 2880
hours.
The above requirements are based on the purchasers power system operating needs. It is the
responsibility of the manufacturer to verify that the cable system is capable of meeting these
requirements, by performing the appropriate development, qualifcation and pre-qualifcation
tests.
Operating Needs:
Following is the rationale for the purchasers requirements.
The 72-hour emergency duration is related to the average time to recover from a forced outage
on network equipment other than transmission cables, such as overhead transmission lines,
circuit breakers, transformers, etc.
In applying the 72-hour emergency temperature duration criteria, purchasers need to consider
the actual transmission network confguration and contingency analysis. This should include
review of the number of lines supplying loads, procedures for scheduling planned maintenance
outages on companion lines, the probable cable conductor temperature prior to the onset of an
emergency, thermal time constant of the cable system, etc. When coordinating the current
ratings of series connected overhead and underground transmission lines, it is useful to
conservatively consider the cable systems 72-hour emergency rating in relation to the overhead
sections normal maximum rating. The thermal time constant of overhead line conductors is
much less than 72 hours (typically 10 20 minutes).
The 216-hour emergency duration is related to the average time to recover from a forced outage
on major network equipment with long repair times, such as transmission power cables. This
does not imply that repairs can always be completed within this time, but rather allows sufcient
time to reconfgure the network to remove the emergency condition. Considering the pre-
emergency cable conductor temperature, long cable thermal time constants, and the usual
weekend reduction in loads, this emergency condition could provide approximately two weeks
for restoration.
CS9-06 Pa$e 61
Manufacturers Verifcation of Emergency Temperatures by Tests
Qualifcation and pre-qualifcation tests should be designed to verify satisfactory performance of
the cable system over its operating design life.
Following are the relevant existing qualifcation test protocols for load cycling to verify high
temperature thermal-mechanical-electrical efects:
ICEA S-108-720: 20 load cycles with 2 hours at 105 C (+0/-5 C); Vt = 2.0 x V
g

IEEE 48: 30 load cycles with 6 hours at 105 C (+0/-5 C); Vt = 2.0 x V
g
IEEE 404: 30 load cycles with 6 hours at 105 C (+0/-5 C); Vt = 2.0 x V
g
IEC 60840: 20 load cycles with 2 hours at 95 C (+5/-0 C); Vt = 2.0 x V
g
The IEEE 48 and IEEE 404 qualifcation test protocols approach verifying a total of 216 hours of
emergency temperature operation near 105 C (i.e. 30 x 6 hours = 180 hours), however the
others do not.
Following is the existing IEC 62067 pre-qualifcation test protocol for load cycling to verify high
temperature thermal-mechanical-electrical efects:
IEC 62067: 180 load cycles with 2 hours at 95 C (+5/-0 C); Vt = 1.7 x V
g
for 365
days
It can therefore be concluded that in order to verify a 216 hour emergency duration at a
conductor temperature of 105 C, the IEC 62067 pre-qualifcation test needs to be modifed to
include approximately 90 load cycles to 105 C (+0/-5 C), with V
t
= 1.7 x V
g
. This
acknowledges that because of the exponential rise and fall of temperature during the load
cycling test, the conductor temperature is actually within 5 C of 105 C for longer than 2 hours.
Similar pre-qualifcation tests (~90 load cycles to 105 C) have been described by at least one
supplier
1
and described in at least one national industry standard
2
.
Notwithstanding the above, users are reminded that the IEC 62067 pre-qualifcation test protocol
does not inherently verify that a cable system is capable of 40 years operation with a 90 C
conductor temperature. Neither does the modifed test protocol described in the foregoing
inherently verify that a cable system can withstand emergency conductor temperature operation
at 105 C for 72 hours on average each year, or 216 hours in any 12-month period, over a 40-
year life. For example, there are other considerations, such as described in Appendix 2, and
other test requirements to be met, such as those for accessory connectors described in IEC
61238-1
3
.
Transitions
CS9-06 Pa$e 68
During the transition period until more pre-qualifcation tests have been done to the section 1.9
emergency conductor temperatures, repeating qualifcation (type) tests to the emergency
temperature for approximately 30 - 90 load cycles may be considered acceptable, subject to
agreement between purchaser and manufacturer.
Purchasers Verifcation of Emergency Temperatures by In-service Measurement
Purchasers intending to use emergency conductor temperatures should consider installing
measurement and monitoring systems suitable for verifying safe in-service cable system
temperatures during emergency overloads
4
.
Distributed Temperature Sensing systems can provide confdence in knowledge about the cable
systems linear thermal environment, by installing optical fbers in close proximity to cables
throughout their length. The systems can also help to provide assurances that use of thermally
stable backfll materials are preventing local dry-out and thermal run-away conditions, which is
possible due to the high heat fux at cable surfaces during high temperature operation.
Dynamic Rating Systems can be used to provide ambient adjusted ratings and calculate
allowable emergency current durations based on pre-emergency conditions in real-time, and
thus add confdence that maximum emergency operating temperatures and durations will not be
exceeded during overload conditions.
References:
1.Moreau, Gahungu, Dubois, Sy, MirabeauMirebeau, Development and Prequalifcation of
Large Conductor VHV Cable Systems, Jicable 03.
2.EDF R&D, Standard C33-253 Insulated cables for power systems, single core cables
with polymeric insulation for rated voltages above 150 kV up to 500 kV, March 1995
(www.afnor.fr).
3.IEC 61238-1 Compression and mechanical connectors for power cables for rated
voltages up to 30 kV, Part 1: Test methods and requirements.
4.CIGRE WG B1.02, Technical Brochure 247 Optimization of power transmission
capability of underground cable systems using thermal monitoring, 2004.
CS9-06 Pa$e 6%
APPE*-I+ & E 2E*ERIC +.PE I*S,.A(I)* (1IC7*ESS FI*')R6A(I#EG
As described in the specifcation and other Appendices, there are many factors to consider
when selecting insulation thickness, for example:
whether a wet or dry insulation design
quality of insulation and semi-conducting shielding compounds
maximum operating temperatures
quality of core extrusion
allowances for cable core eccentricity
allowances for minimum point insulation thickness
nominal internal and external ac and impulse stress limits
allowances for 5% normal and 10 % temporary ac over-voltages
possible cable core deformation due to radial thermal expansion at clamps at maximum
operating temperatures
possible cable core deformation due to lateral conductor forces at bends at maximum
operating temperatures
whether phase surge arrestors will be installed at the cable terminals, to provide an
impulse protection level lower than BIL
completion of Qualifcation and Pre-qualifcation tests for similarly stressed cable
systems
etc.
Except for the Traditional Insulation Wall Thicknesses allowed in ICEA S-108-720 Appendix F,
CS9 and ICEA S-108-720 allow custom insulation thicknesses for each application described in
purchasers specifcations. However, there could be benefts to purchasers and manufacturers
alike, if agreement could be reached on standard insulation thicknesses for each rated voltage
level, spanning the complete conductor size range without exceeding electrical stress levels for
any conductor size. A basis for selecting Generic insulation thicknesses is described in Table
A5-1 below.
Table A5-1 Rated Voltage, Conductor Size Range, Nominal Internal ac Stress Limit,
Nominal External ac Stress Limit, and Generic Nominal Insulation Thickness*
Rated
Voltage
V
(kV)
Conductor
Size
(kcmil)
Conductor
Size
(mm
2
)
Nominal
Internal ac
Stress Limit
V/mil (kV/mm)
Nominal
External ac
Stress Limit
V/mil (kV/mm)
Generic Nominal
Insulation Thickness to
Fit Nominal Internal and
External ac Stress
Limits over Conductor
Size Range
mil (mm)
69 wet 500-4000 240-2000 100 (4.0) 50 (2.0) 650 (16.5)
69 dry 500-4000 240-2000 150 (6.0) 75 (3.0) 472 (12.0)
CS9-06 Pa$e 6!
115 750-4000 400-2000 200 (8.0) 100 (4.0) 590 (15.0)
138 750-4000 400-2000 200 (8.0) 100 (4.0) 709 (18.0)
161 750-4000 400-2000 225 (9.0) 100 (4.0) 787 (20.0)
230 1000-5000 500-2500 275 (11.0) 125 (5.0) 906 (23.0)
345 1000-5000 500-2500 350 (14.0) 150 (6.0) 1024 (26.0)
* For cables used with taped joints, the nominal internal and external ac stresses shall be
limited to 150 volts/mil (6.0 kV/mm) and 75 volts/mil (3.0 kV/mm) respectively.
Table A5-1 is provided as a guide only and describes Generic nominal insulation thicknesses
for XLPE insulation cable systems meeting the above conditions. Users should independently
confrm acceptability for use on any application.
It is acknowledged that there are other considerations which could override these generic
thicknesses, such as unusual applications, manufacturers specifc equipment efciencies and
proven cable system test results (Qualifcation and Pre-qualifcation for >150 kV). In addition,
for some manufacturers and applications, reduced insulation thicknesses could be used, with
possible cost savings without compromising performance.
Purchasers specifcations should describe the appropriate generic thickness if required for
their application.
CS9-06 Pa$e 6&
APPE*-I+ 6 E BAC7E( (1IC7*ESS C)*SI-ERA(I)*S FI*')R6A(I#EG
Users are cautioned that ICEA S-108-720 Tables 7-4 and 7-5 specify standard jacket thickness
as a function of diameter over the metallic shield or sheath. However, consideration should also
be given to possible jacket degradation during cable installation and operation, perhaps leading
to jacket faults and reduced cable life. For example, undetected jacket damage during
installation could eventually lead to electrical breakdown of the jacket, corrosion of metallic
moisture barriers, water permeation into high electrical stress areas of the cable and premature
electrical failure due to water and electrical treeing phenomena.
Some installation conditions are especially onerous for cable jackets. For example pulling
cables into rough or dirty ducts, or direct burial during hot weather in coarsely crushed granular
backfll, could cause jacket scoring or indentation. Although steps are usually made to try to
ensure clean ducts before pulling, it is rare to see a defnition given for clean, and sharp
particles could still remain at duct couplings, capable of scoring the cable jacket by 25 50 mils
(1 2 mm) or more.
To coordinate with the other insulated sheath system components, as described in Appendix 3,
approximately 50 mils (2 mm) of sound jacket thickness should remain after any damage during
installation. This should provide sufcient withstand against repeated ac and impulse voltage
applications in-service, long term moisture degradation, thermal degradation and an operating
factor of safety.
Unless purchasers are confdent that such occurrences will be avoided during cable installation,
it is recommended that the ICEA S-108-720 standard thicknesses be reviewed for suitability for
the intended application and increased thickness be provided in the purchasers specifcation,
where considered necessary.
CS9-06 Pa$e 66
APPE*-I+ = E E.EC(RICA. (ES(S A'(ER I*S(A..A(I)* FI*')R6A(I#EG
Although CS9 does not include installation of cable systems, the following information on
recommended tests is provided for consideration:
After pulling in the cables, but prior to jointing and terminating, the cable jackets shall
withstand a one minute dc test applied between the metallic shield/sheath and the jackets
semi-conducting outer coating. The test voltage level shall be 150 V/mil (6 kV/mm) of
average jacket thickness, to a maximum of 24 kV, as described in ICEA S-108-720.
After jointing, terminating and connection of all sheath bonding link boxes and
bonding/grounding cables, the complete metallic shield/sheath insulating circuit shall
withstand a one minute dc test between the metallic shield/sheath circuit and ground. The
test voltage level shall be 150 V/mil (6 kV/mm) of average jacket thickness, to a maximum of
24 kV.
After completion of the installation, the main insulation shall withstand a 1.4 x V
g
to 1.7 x V
g

ac test voltage for 1 hour. The actual test level and frequency (if a variable frequency
resonant test set is proposed) shall be as agreed to between the manufacturer and
purchaser and will depend on cable circuit length, ac test set availability and operational
considerations. Alternatively, at the option of the purchaser, a 1.0 x V
g
ac test may be done
for 24 hours. Partial discharge detection systems shall be used to monitor unusual discharge
levels at accessories during the test, subject to agreement between the purchaser and
manufacturer.
Once energized and on load, sheath bonding currents shall be measured and compared
with theoretical values calculated in accordance with Electra 128, or equivalent, to ensure
that sheath bonding connections have been made correctly. The measured values shall be
within 20% of the calculated values, otherwise it is an indication of an error in bonding cable
or link box connection.
The results of the tests after installation shall be recorded in a commissioning test report.
CS9-06 Pa$e 6=
CS9-06 Pa$e 6>
APPE*-I+ > E P,RC1ASER:S (EC1*ICA. I*')R6A(I)* 'I.E FI*')R6A(I#EG
The following information is provided as a guide for purchasers to use with a request for
proposals. It is intended to supplement the information described in ICEA S-108-720 section
1.3 and should be modifed and complimented with drawings and other descriptive information
to fully and clearly describe the intended application to prospective manufacturers.
The units of choice (Imperial or SI) should be added.
1. Characteristics of Systems on Which Cable and Accessories Are to be Used
a)desired ampacity for normal and emergency operation, including duration of emergency
b)system operating frequency
c)nominal phase-to-phase operating voltage
d)maximum phase-to-phase operating voltage
e)basic impulse insulation level (BIL)
f) maximum symmetrical and asymmetrical fault current and duration for conductor and
metallic shield/sheath, whether automatic circuit re-closing is used, and reclosing sequence.
g)daily load factor
h)system neutral efectively grounded or not
2. Description of Installation
a) Installation method:
I.cable in underground ducts or pipes
II.cable directly buried in ground
III.cable in air with or without solar radiation efects
IV.cable in tunnel and if there are special fre retardancy requirements
V.other installation type (describe)
b) Installation conditions:
I.ambient air temperature, maximum and minimum
II.ambient soil temperature at burial depth, maximum and minimum
III.minimum temperature when cable is to be installed
IV.if in ducts or pipes, number of cables in duct or pipe
V.if in ducts/pipes, duct/pipe material
VI.if in ducts/pipes, duct/pipe inside and outside diameter
VII.if in ducts/pipes, duct/pipe minimum bend radius
VIII.if in ducts/pipes, number of ducts/pipes, including those unoccupied
IX.if in ducts/pipes, duct/pipe geometrical confguration and cable location dimensions
CS9-06 Pa$e 69
X.if direct buried, number of direct buried cables
XI.if direct buried, geometrical confguration and cable location dimensions
XII.burial depth to centerline of confguration
XIII.corrective backfll dimensions
XIV.corrective backfll thermal resistivity
XV.native soil thermal resistivity
XVI.wet or dry location
3. Description of Cable System
a) Circuit Confguration
I.route layout drawings for installation
II.total circuit length
III.spare cable length
IV.approximate required shipping lengths
V.terminations in air, GIS or transformer
VI.joints in manholes, direct buried joint bays or tunnels
VII.longest distance between jointing/terminating accessories
b) Cable construction and design
I.conductor material
II.conductor cross-sectional area
III.conductor construction and wire stranding
IV.strand sealant requirement
V.insulation material
VI.nominal insulation thickness
VII.radial moisture absorbing layer requirement
VIII.metallic shield/sheath material
IX.metallic shield/sheath construction
X.jacket material
XI.jacket thickness
XII.maximum outside diameter (if limited by other considerations, such as conduits)
XIII.cable identifcation methods and markings
XIV.normal conductor maximum operating temperature
XV.emergency conductor maximum operating temperature
4. Cable Warranty
a)required warranty duration
b)criteria for start of warranty (i.e. delivery, energization, acceptance, etc.)
CS9-06 Pa$e =0
c)required delivery date
5. Delivery
a)required delivery date
b)delivery location
c)cable handling requirements
CS9-06 Pa$e =1
APPE*-I+ 9 E 6A*,'AC(,RER:S (EC1*ICA. -EC.ARA(I)* 'I.E FI*')R6A(I#EG
The following information is provided as a guide for use when preparing a purchasers
specifcation. It is intended as a reminder of possible information to supplement that described in
ICEA S-108-720 section 1.4. It should be edited as required to obtain sufcient information to
evaluate and compare proposals, in accordance with the specifc application. The quantity and
detail of information is aimed at long distance, high capacity 230 to 345 kV projects. Less
information could be requested for shorter, lower voltage applications.
The units of choice (Imperial or SI) should be added.
The Manufacturers Technical Declaration File is to be submitted by the manufacturer with the
Proposal, as guaranteed values.
1. Cable Electrical Characteristics
a)nominal phase-to-phase rated voltage
b)maximum phase-to-phase rated voltage
c)15 minute emergency rated voltage
d)basic impulse insulation level (BIL)
e)symmetrical and asymmetrical fault current magnitude/duration rating, for conductor and
metallic shield/sheath
2. Cable Thermal Characteristics
a)normal conductor maximum operating temperature, C
b)emergency conductor maximum operating temperature, C
c)normal jacket maximum operating temperature, C
d)emergency jacket maximum operating temperature, C
e)jacket maximum operating temperature during fault conditions, C
3. Cable Mechanical Characteristics
a)efective bending stifness (fexural rigidity) (EI)
b)efective axial stifness (longitudinal rigidity) (EA)
c)limiting value of pulling tension force
d)limiting value of sidewall force during installation
e)minimum bending radius, with limiting pulling tension force
f) minimum bending radius, without pulling tension force
g)weight of cable per unit length
CS9-06 Pa$e =8
4. Cable Conductor
a)material
b)cross-sectional area
c)construction, including reinforcing layer, if applicable
d)number and diameter of strands
e)strand sealant material (if sealant required by purchaser)
f) conductor outside diameter (mean value and tolerances)
g)conductor reinforcement outside diameter, if applicable (mean value and tolerances)
h)nominal and maximum dc resistance at 20 C
i) ac skin efect factor k
s

j) ac proximity efect factor k
p
k)limiting value of pulling tension force
5. Cable Conductor Shield
a)material description, including compound suppliers data sheet
b)thickness
c)external diameter
d)maximum protrusion/irregularity size
e)maximum void size
f) description of screen mesh sizes prior to extruder head
g)thermal resistivity
6. Cable Insulation
b)minimum point thickness
c)nominal insulation thickness
d)external diameter
e)ac nominal internal stress at V
g
f) ac nominal external stress at V
g
g)mean ac stress in insulation
h)nominal internal stress at BIL
i) nominal external stress at BIL
j) threshold ac test limit (reference ICEA S-108-720, clause 4.2.1)r
k)maximum eccentricity
l) coefcient of thermal expansion at 20 C (C
-1
)
m)coefcient of thermal expansion at 105 C (C
-1
)
n)maximum allowable insulation thickness deformation due to lateral pressure at bends, at 90
C (percent)
CS9-06 Pa$e =%
o)maximum allowable insulation thickness deformation due to lateral pressure at bends, at 105
C (percent)
p)description of screen mesh sizes prior to extruder head
q)dielectric constant at 20 C
r) dissipation factor at 20 C, (%)
s)thermal resistivity
t) Voltage-time aging life exponent n (see Appendices 1 and 4)
7. Cable Extruded Insulation Shield
b)thickness
c)external diameter
d)description of screen mesh sizes prior to extruder head
8. Cable Semi-conducting Tape Shield (if applicable)
a)material description, including supplier and product designation
b)thickness
c)external diameter
9. Cable Semi-conducting Bedding under Metallic Shield/Sheath (as applicable)
b)radial expansion allowance for underlying core from ambient to 105 C
c)thickness
d)external diameter
10. Cable Semi-conducting Longitudinal Waterblocking Layer (as applicable)
b)thickness
c)external diameter
d)thermal resistivity of waterblocking material (C-m/W)
11. Cable Metallic Shield (as applicable)
a)material
b)description and dimensions
c)cross-sectional area
d)dc resistance at 20 C
e)lay direction
CS9-06 Pa$e =!
f) lay angle
g)thickness
h)external diameter
12. Cable Continuous Metallic Sheath (as applicable)
a)material and alloy designation
b)cross-sectional area
c)dc resistance at 20 C
d)corrugation profle (if applicable)
e)description of sheath application equipment (welded, seamless, extruded, etc.)
f) limiting value of sheath cyclic strain for 40-year life (%)
g)thickness
h)external diameter
13. Cable Longitudinally Applied Metal Foil Moisture Barrier (as applicable)
a)material and alloy designation
b)limiting value of mechanical cyclic strain for 40-year life with 20 C jacket (%)
c)limiting value of mechanical cyclic strain for 40-year life with 80 C jacket (%)
d)thickness
e)external diameter
14. Cable Jacket
a)material description and compound suppliers data sheet
b)description of separator tape or adhesive under jacket
c)description of semi-conducting coating
d)thickness
e)external diameters, nominal and maximum
15. Cable General
a)provide a cross-section drawing of the cable, describing component materials, construction,
dimensions, weight and voltage ratings (ac and impulse)
16. Cable Insulation, Shielding Compounds and Extrusion Quality Assurance
a)quality assurance plans used in compound suppliers factory for compound cleanliness and
statistical analysis prior to shipping to cable manufacturer
b) copy of last audit report of compound supplier
CS9-06 Pa$e =&
c)quality assurance plans used in cable factory for cleanliness and statistical analysis of
incoming insulation and semi-conducting compounds
d)quality assurance plans used in cable factory to inspect/reject insulation compound
contaminants immediately prior to extrusion
e)systems used in cable factory to detect insulation contaminants during extrusion
f) systems used in cable factory to detect smoothness and protrusions/irregularities at the
extruded shield/insulation interfaces, during extrusion
g)systems used in the cable factory to monitor concentricity and thickness of extruded layers
during extrusion
h)alternate ac test value and duration for cable production test, if diferent than specifed, and
technical basis for recommended test protocol
17. Cable Core Degassing
a)methods used to ensure that cable core is adequately degassed prior to application of outer
concentric layers and production testing
b)temperature during degassing period
c)duration of degassing period
d)required percent weight loss of cross-linking byproducts, at end of degassing period
18. Terminations (provide for each type, as applicable)
a)termination manufacturer
b)rated ac phase-to-phase voltage
c)rated maximum continuous ac voltage to ground
d)rated maximum continuous current (40 C ambient air)
e)rated 1.2 x 50 sec full wave impulse withstand voltage
f) termination type (e.g., taped, taped molded, heatshrink, cold shrink, pre-molded, pre-
fabricated, etc.)
g)dielectric constant of feld-applied insulation or stress relief cone
h)ac and impulse electric stress at starting point of stress relief cone
i) ac and impulse voltage withstand rating of base plate support insulators
j) ac and impulse voltage withstand rating of sheath sectionalizing insulator, if applicable for
GIS termination
k)composition of external housing (porcelain, composite, polymer, etc.) and flling fuid
l) water vapor transmission rate of external insulating housing, if composite or polymer
material
m)pressure rating, as applicable for GIS
n)assembly drawing of termination, including mounting arrangement and dimensions
o)verifcation that termination meets seismic withstand requirements of IEEE 693
p)weight of termination
q)type of flling fuid or gas and operating pressure
CS9-06 Pa$e =6
r) expected shelf life of the individual splice materials
s)estimated person-days and duration to install a single phase termination
19. Joints
a)joint manufacturer
b)rated ac phase-to-phase voltage
c)rated maximum continuous ac voltage to ground
d)rated 1.2 x 50 sec full wave impulse withstand voltage
e)joint type (e.g., taped, taped molded, extrusion molded, heat-shrink, cold-shrink, pre-molded,
pre-fabricated, etc.)
f) dielectric constant of feld-applied insulation or stress relief cone
g)ac and impulse electric stress at starting point of stress relief cone
h)ac and impulse withstand rating of anti-corrosion covering
i) ac and impulse withstand rating of sheath sectionalizing insulator
j) ac and impulse withstand rating of internal shield interrupt
k)description of continuous metallic, water impervious joint casing, if applicable
l) assembly drawing of joint
m)weight of joint
n)expected shelf life of the individual splice materials
o)estimated person-days and duration to install a single-phase joint
20. Sheath Bonding Systems
a)ac, dc and impulse withstands of link box between terminals, with link bars in normal position
and SVLs disconnected
b)ac, dc and impulse withstands of sheath bonding cables
c)electrical characteristics of sheath voltage limiting arresters and suppliers data sheet,
including a description of valve element material, rated voltage, maximum continuous
operating voltage, residual voltage (10 kA, 1.2 x 50 sec wave), voltage-current
characteristics, discharge energy rating, etc.
d)sheath bonding cable construction, including conductor area and insulation thickness
e)assembly drawings of link boxes
21. Cable System Current Ratings
a)calculated cable system continuous current ratings based on normal maximum conductor
temperature, emergency maximum conductor temperature and the various installation
conditions described in the Purchasers Technical Information File
b)describe the current rating calculation methodology
22. Cable and Accessories Qualifcation Tests
CS9-06 Pa$e ==
a) Cable Tested
I.industry standard test for which cable was qualifed (i.e ICEA S-108-720, etc.)
II.cable conductor area, diameter and insulation thickness
III.data sheets for compound suppliers conductor shield, insulation shield and jacket
compounds
IV.ac and impulse stress at outside of conductor shield
V.ac and impulse stress at outside of insulation
VI.shield/sheath construction
VII.cable cross-section drawing
VIII.name of factory where cable was manufactured and identifcation of extrusion line used
to make the cable core
b) Joints Tested
I.joint type and manufacturer
II.industry standard test for which joint was qualifed (i.e IEEE 404, etc.)
III.joint construction (taped, taped molded, extrusion molded, heat-shrink, cold-shrink,
pre-molded, pre-fabricated, etc.)
IV.ac and impulse stress at starting point of stress relief cone
V.cable insulation and core diameter under stress relief cone
VI.joint assembly drawing
c) Terminations Tested (in air)
I.termination type and manufacturer
II.industry standard test for which termination was qualifed (i.e IEEE 48, etc.)
termination construction
ac and impulse stress at starting point of stress relief cone
III.cable insulation and core diameter under stress relief cone
IV.termination assembly drawing
d) Terminations Tested (in GIS)
I.termination type and manufacturer
II.industry standard test for which termination was compliant (i.e IEC 60859, etc.)
III.itermination construction
IV.ac and impulse stress at starting point of stress relief cone
V.cable core diameter under stress relief cone
VI.gas pressure rating of gas barrier cone
VII.gas pressure during dielectric type test
CS9-06 Pa$e =>
VIII.termination assembly drawing
e) Certifed Test Reports
I.a copy of certifed qualifcation test reports for proposed cable and accessories
II.a copy of certifed qualifcation test reports for proposed cable system, as required (cable
and accessories together)
23. Cable and Accessories System Pre-Qualifcation Tests (applicable for > 150 kV)
a)same data as for the qualifcation tests, preceding
b)a description of the test layout, including verifcation of similar installation conditions to those
for the intended application
c)a copy of certifed system pre-qualifcation test reports
d)a description of the number of load cycles to the conductor emergency operating
temperature
24. Cable System Manufacturing Quality Assurance Plan
a)a copy of overall manufacturing quality assurance plan
b)a copy of the cable insulation system quality assurance plan
c)preliminary copy of manufacturing inspection and test plan
25. Verifcation of Design Life for Cable System (reference clause 1.8 and Appendix 4)
a)description of design, testing and statistical analysis methodology used to verify design life
for main cable insulation
b)description of design, testing and statistical analysis methodology used to verify design life
and limiting fatigue strain for continuous metallic sheath or metal laminate moisture barrier
c)description of design, testing and statistical analysis methodology used to verify design life
for jacket
d)description of design, testing and statistical analysis methodology used to verify design life of
cable accessories (joints and terminations)
CS9-06 Pa$e =9
APPE*-I+ 10 E I*')R6A(I)* () 0E S,06I((E- A'(ER A/AR- )' C)*(RAC(
FI*')R6A(I#EG
Following is a preliminary list of possible information to be submitted by the manufacturer after
award of contract, for review and acceptance by the purchaser prior to start of manufacturing.
Additional or reduced information should be described in the purchasers specifcation, as
appropriate for the particular intended application. Level of detail will vary depending on the
cost and importance of the application.
1.Manufacturing and Delivery Schedule, updated monthly
2.Final Manufacturing Quality Assurance plan
3.Final Insulation System Quality Assurance plan
4.Final Manufacturing Inspection and Test Plan (ITP), showing agreed to Review, Witness
and Hold points for independent factory inspections
5.Manufacturers specifcations and standards for cable and accessories
6.Drawings for cable and accessories, including water impervious cable end caps and
pulling eyes
7.Drawings showing construction and dimensions of cable reels
8.Electrical schematic drawing for cable system to be installed
9.Sheath bonding schematic and arrangement drawing for cable system to be installed
10.Layout arrangement drawing for complete cable system
11.Dimensional arrangement drawings for manholes, joint bays and terminals
12.Dimensional arrangement drawings for cable and joint routing/racking in manholes, joint
bays or tunnels
13.Dimensional arrangements drawings for cable termination supports
14.Calculations confrming 40-year fatigue life for cable sheath/shield or laminated moisture
barrier components, for the intended cable installation confgurations and loadings
15.Calculations of short-circuit ratings for cable and accessories
16.Calculations of shield/sheath voltages during normal, fault and transient over-voltage
conditions
17.Calculations describing sheath insulation circuit insulation coordination and sheath
voltage limiter protection characteristics
18.Calculations of cable current ratings and temperatures
19.Instructions for cable installation
20.Installation instructions for accessories, including assembly drawings, step-by-step
procedures and feld inspection checklists
21.Commissioning test instructions and checklist
22.Operation and Maintenance Manual for complete cable system
23.Production Test summary report
CS9-06 Pa$e >0
CS9-06 Pa$e >1

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Specification for Extruded Insulation Power Cables

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