Section 13 — Electrical

Power Cable 5KV and Above

IPE Engineering Practice IPE-EP-13-8-2

Document number: IPE-EP-13-8-2 · Section: 13 — Electrical

1.0

1.1

1.2

1.3

1.4

1.5

2.0

SCOPE

This Practice, including the Power Cable Data Sheet, EP 13–8–2 DS. covers the requirements for single conductor and three conductor 5 KV to 46 KV EPR or XLP insulated, shielded, jacketed and/or metal sheath covered power cable.

This Practice is appropriate for attachment to an inquiry or purchase document when accompanied by the referenced IPE Engineering Practices and completed data sheets.

Any deviation from this Practice must be approved by the procedure described in EP 1–1–3. Table 9 records the vendor drawing and data requirements.

A revision bar indicates all changes made to this Revision.

REFERENCES

Cables shall be in compliance with the latest standards and codes listed below and are a part of this Practice unless amended herein.

STANDARDS AND PUBLICATIONS

STANDARDS AND PUBLICATIONS (CONT.)

DEFINITIONS

• Contractor – Company or business that agrees to furnish materials or perform specified services at a specified price and/or rate to the Owner.
• Inspector – A Inflection Point Engineering, LLC appointed engineer or inspector.
• Manufacturer – The recipient of a direct or indirect purchase order for materials and/or equipment. In this context, a direct order is one issued to a Manufacturer by a Contractor or the Owner. An indirect order is one issued to a Manufacturer by a vendor (recipient of a direct order) for materials, fabricated components, or subassemblies.
• Owner – Inflection Point Engineering, LLC.
• Owner’s Engineer – A Inflection Point Engineering, LLC appointed engineer.
• Purchaser – The party placing a direct purchase order. The Purchaser is the Owner’s designated representative.

SERVICE CONDITIONS

• Installation

The cable shall be suitable for installation in heavy industrial plants, either indoors or outdoors, where a multiplicity of cable support systems are employed, including installation in rigid metallic conduit, plastic or fibre conduit, concrete encased duct systems, cable trench or trough (including tunnel), cable tray or wireway, aerial support systems and direct burial.

• Exposure

The cable shall be suitable for installation in petrochemical complexes with possible exposure to

• continuous sunlight (b) rain and a continuous moisture condition (c) ambient temperature variations between –15ºF and 120ºF (d) contact with hydrocarbon, acid and alkali and shall withstand all of these exposures without loss of cable life and reliability.
• Operation

The cable shall be capable of operating continuously in both wet and dry locations at a conductor temperature of 90ºC under normal operating conditions, 130ºC under emergency operating conditions, and 250ºC under short circuit conduction. The emergency operating temperature shall be applicable for an average, over several years, of one period of not more than 36 hours per year and for a total of not more than three periods in any 12 consecutive months.

DESIGN, CONSTRUCTION AND MATERIALS

• General
• All cables shall be UL listed and designated as MC or MV–90 in accordance with NFPA 70.
• All cables shall conform and be in compliance with the current issue of AEIC CS5 or CS6 including testing. Certified AEIC test results (reports) shall be made available to the Owner if requested, for the cable products being offered.
• Unless specified otherwise by the Owner, all power cable shall be supplied with EPR insulation.
• Conductors
• All power cables shall have copper conductors. The copper conductors shall be annealed, uncoated copper in accordance with ASTM B 3 and B 8.
• The copper conductors shall have its physical and electrical properties in conformance with ICEA Standards and with Class B concentric lay stranding in accordance with ASTM B 8.
• Class B stranded, compact copper conductors, when specified, shall comply with the requirements of ASTM B 496.
• Strand Shielding
• Insulation strand shielding
• The strand shield shall consist of an extruded semi-conducting thermosetting copolymer material applied uniformly over the conductor. The material shall be compatible with the conductor metal and insulation. It shall be uniformly and firmly bonded to the overlying insulation, and shall be free stripping from the conductor.
• A non–wicking, semi–conducting tape may be applied over the conductors when required to prevent extruded material from sinking through loose strands of the conductor.
• The extruded conductor shield shall have a minimum average and minimum point thickness as shown in Table 3.
• Insulation
• Vulcanized ethylene propylene rubber (EPR)
• Vulcanized EPR insulation, when specified, shall be a high quality heat, moisture, ozone and corona resistant high dielectric strength ethylene propylene thermosetting rubber compound.
• The insulation shall be extruded directly over the surface of the semi–conducting strand shielding, forming a homogeneous void–free mass.
• XLP and TR–XLP crosslinked polyethylene
• Crosslinked polyethylene insulation, when specified, shall be high quality heat, moisture, ozone, and corona resistant suitable for operation at conductor temperature of 194ºF.
• The insulation shall be extruded directly over the surface of the semi-conducting strand shielding, forming a homogeneous, void–free mass.
• Insulation Thickness: The average thickness of the insulation shall not be less than the values given in Table 4. The minimum thickness at any cross–section of the insulation shall not be less than 90 percent of the thickness given in Table 4.

• Unless specified otherwise, all power cable insulation shall be supplied at the 133% level for the voltage class specified.
• Insulation Shielding (Screen)
• A semi–conducting thermosetting shielding compound shall be extruded directly over the surface of the insulation. The semi–conducting shielding shall adhere to and remain in contact with the insulation and shall strip clean from the insulation for makeup of terminations and splices.
• The XLP and EPR insulation shield shall be of a semi–conducting thermosetting copolymer material compatible with the insulation and overlaying metallic shield.
• The minimum and maximum allowable insulation shield thickness shall be in accordance with Table 5.
• Metallic Shielding
• The metallic shielding system shall be constructed/engineered to withstand the fault current magnitude and duration as specified on the Data Sheet.
• Unless specified otherwise, the type of metallic shield shown in Table 6 shall be provided.
• Metallic tape shield (Helical)
• One bare uncoated copper tape helically applied with a lap not less than 12.5 percent of its width shall form the metallic shielding.
• The tape shall have a minimum average thickness of five mils. The tape shall be substantially free from burrs, soldering or brazing.
• Metallic (Longitudinal)
• One bare uncoated copper tape longitudinally applied with a lap not less than 0.25 inches. The copper tape shall be corrugated.
• The tape shall have a minimum average thickness of five mils. The tape shall be substantially free from burrs, soldering or brazing.
• The overlapped joint of the metallic tape shall be protected by a mylar strip cover for cases when required to provide a smooth surface over which to apply the overall jacket.
• Wire metallic shield shall consist of non–magnetic, soft drawn uncoated copper wires (#24 AWG minimum size) helically applied over the insulation shield. The total cross sectional area of the wire shield shall be no less than 5000 CM per inch of insulated conductor diameter. The wires shall be served substantially equidistant from each other around the insulated and screen conductor. The metallic shield shall be horizontally wrapped with a mylar/polyester tape (2 mil minimum thickness) with a 12.5% minimum overlap.
• “Unishield” products shall only be provided when specific approval is obtained from the Owner.
• Three Conductor Assemblies
• Three conductor cables, when specified on the Data Sheets, shall be formed in a cylindrical configuration.
• The “Lay” of the conductors shall be in direction and length to conform with ICEA standards.
• “Fillers” of non–wicking, flame retardant material shall be used where necessary to provide a uniform spacing of conductors in a firm cylindrical shape.

• A “Grounding Wire”, if specified on the Data Sheet, shall be of the same conductor material as that used for the basic conductors. If marked “green insulation” they shall be covered with 65 mils of the same insulation as that used for the basic conductors. If marked “bare” the insulation shall be omitted. The grounding conductor shall be sized in accordance with UL 1072 and NFPA 70, unless specified otherwise.
• “Binders” of glass reinforced tape shall be applied over the conductor assembly if required to retain its shape.
• “Cover Over the Cable Assembly” shall consist of a mylar or non–wicking, flame retardant fabric tape material that shall be applied with a helical lap not less than 12.5% of its width directly over the binder, if used, and insulation shielding.
• When specified, three unjacketed cables shall be used to assemble the three conductor assembly and shall comply with paragraphs 5.7.1 through 5.7.6 above.
• When specified, three jacketed cables shall be used to assemble the three conductor assembly. In addition to compliance with paragraphs 5.7.1 through 5.7.6 above the following shall also apply: The individual conductor jacket shall comply with or exceed the ICEA and UL thickness for this construction, the physical properties per paragraph 5.8.1, and markings per paragraph 5.8.3.
• Jacket
• A polyvinyl chloride (PVC) jacket shall be tightly extruded over the underlying core. The jacket shall meet or exceed the UL 1072 and ICEA S–66–524 physical and aging requirements. The jacket shall be rated 75ºC or higher and be suitable for the service conditions stated on the Data Sheet and contract documents.
• The average thickness of the jacket shall not be less than the values specified in Table 7. The minimum thickness of the jacket at any point shall not be less than 80 percent of the specified thickness as given in Table 7.
• The overall jacket shall be printed at intervals not exceeding 24 inches with the following information:
• Manufacturer’s name
• Plant of manufacture (Designation Code)
• Tradename
• Insulation type and thickness
• Number, type and size of conductors
• Maximum working voltage and insulation level
• UL type designation of Cable (MV–90)
• UL identification – (‘UL’)
• UL rating(s), as applicable:
• ‘Sun Res’ Sunlight Resistant Jacket
• ‘Oil Res I’ Oil Resistant Jacket, Class I
• ‘Oil Res II’ Oil Resistant Jacket, Class II
• ‘For CT use’ For use in Cable Tray
• Year of manufacture
• The color of the jacket material shall be black, unless designated otherwise on the Data Sheet.

• CT cable shall be provided when installation in cable tray is specified on the Data Sheet or other applicable contract documents.
• Metal Clad Cable
• General
• When specified on the data sheet, UL type MV–MC cables constructed with EPR or XLP insulating systems shall be furnished with either a continuous corrugated and welded sheath or an interlocking tape armoring with metal types as identified.
• A copper grounding conductor shall be provided in one section or segmented, and shall be sized in accordance with UL 1072 and NFPA as a minimum.
• Three conductor assemblies shall comply with paragraph 5.7 of this Practice. In addition, a suitable nonmetallic bedding tape shall be applied over the cabled core.
• Interlocking tape armor
• The cable assembly shall be encased in a close fitting, helically applied flat metallic tape that is formed into interlocked, convoluted armor. The helically wound metal tape overlaps the cable core on successive turns to form a strong, flexible, protective structure.
• An aluminum or galvanized steel interlocked armor, as specified on the data sheet, shall be employed and meet the requirements of the referenced specifications, including the performance criteria defined in the UL standards for Type MV and MC cables.
• Continuous corrugated impervious welded armor
• The cable assembly shall be enclosed by a metal tape which is longitudinally folded around the core, then welded and corrugated to form a continuous, impervious, corrugated metallic sheath.
• An aluminum or copper sheath, as specified on the data sheet, shall be employed and meet the requirements of the referenced specifications including the performance criteria definitions in the UL standards for Type MV and MC cables.
• Overall jacket
• When an overall jacket is specified, a flame resistant PVC jacket shall be tightly extruded over the corrugated or interlocked tape armor. The jacket shall be colored black, unless otherwise specified on the data sheet.
• The average thickness of the jacket shall not be less than the values specified in Table 8. The minimum thickness of the jacket at any point shall be not less than 70 percent of the specified minimum average thickness.
• Jacket surface markings shall be the same as those identified in paragraph 5.8.3 of this Practice.

TESTING

• General

All medium voltage power cable shall be tested and pass all the current AElC and ICEA Qualification Tests. AEIC Qualification Test Data (type test) shall be available to the Owner upon request for the specified product (s).

• Routine Tests on Factory Reel Lengths
• Conductor Resistance: Conductor DC resistance shall comply with UL 1072, ICEA S–68–516, ICEA S–66–524, AEIC CS5, and AEIC CS6 requirements as applicable.

• High Voltage AC Test, when specified on the data sheet: Each reel of completed cable shall withstand for a period of 5 minutes the 60 cycles AC test voltage as specified in the applicable portion of Table 1. The test voltage shall be applied between conductor and shield with the cable in air in accordance with ICEA, UL and AEIC standards as applicable.
• Insulation Resistance: Each reel of completed cable shall be measured for insulation resistance. The measured resistance in megohms per 1,000 feet at a temperature of 60ºF, shall not be less than that calculated from the expression:

R  K log10 (D / d )

Where: R = Insulation Resistance in megohms/1000 feet at a temperature of 60ºF.

K = Constant of 20,000 (XLP)

20,000 (EPR)

D = Diameter over insulation (Inches)

d = Diameter under insulation (Inches)

Test Voltage = 1000 volts minimum

• Partial Discharge (Corona) Test: Each reel of completed cable shall be subjected to the partial discharge extinction level test performed in accordance with the current (applicable) Section E of AEIC CS6 or AEIC CS5. The partial discharge in picocoulombs shall not exceed the values in the applicable section of Table 2.
• Voids and Contaminants: Tests shall be conducted to ensure compliance as specified in accordance with the current (applicable) AEIC CS6/AEIC CS5 Section B.
• Pressure Tests for Continuous Corrugated Impervious Welded Armor (CCW): The integrity of the CCW shall be verified by application of 3 psi pressure to the cable for 12 hours without any appreciable loss of pressure occurring. Other standard factory test methods to verify CCW integrity can be performed in lieu of the above after review and approval of the Owner.
• Witness Test

When a witness test is specified, the Owner shall witness the complete testing of all items detailed in 6.1 and 6.2 of this Practice and special tests as indicated on the data sheets and contract documents.

DRAWINGS AND DATA REQUIREMENTS

• Information to be Supplied with Quotation
• Specific listing of any exceptions to those requirements specified.
• Features included but not necessarily specified.
• Diameters and thickness on each size and voltage class quoted.
• Overall cable diameter (average minimum and average maximum).
• Thickness of extruded strand shield.
• Insulation thickness (average minimum and average maximum).
• Thickness of insulation shield.
• Thickness of metallic shield.
• Thickness of PVC jacket.

• Reactance and AC resistance (ohms to neutral) of each size and voltage class of cable, in both magnetic and non–magnetic duct, based on 3–1/C cables or 1–3/C cable in one duct.
• Provide details of standard “packaging” of reels (i.e. lagging, banding, etc.). Provide cost for lagging if not a standard packaging practice.
• Splicing and terminating instructions including diagrams, dimensions and material lists.
• Identify any special tools and/or materials required to cut, strip, and clean the semi–conducting material from the insulation.
• Weight per 1000 feet.
• Provide recommended DC hi–potential test methods, test voltages and corresponding leakage current for initial cable installation tests and future installed maintenance testing. Also include recommended testing intervals for inservice maintenance testing.
• Cable pulling information
• Maximum allowable pulling tension in pounds.
• Minimum allowable bending radius.
• Recommended pulling compounds to be used for the cable products being offered.
• The cable Manufacturer shall provide an additional alternate quotation for extended warranty cable, if available. In addition to price information details concerning unique cable construction, installation criteria or other conditions involved with obtaining the extended warranty must be fully defined. Include, but not limited to, warranty periods of 20 years and 30 years.
• Provide complete calculations demonstrating the capability of the cable metallic shield to withstand the ground fault current/duration specified.
• Information to be Submitted for Owner Approval After Receipt of Order

All the information requested in 7.1 of this Practice for materials ordered.

• Certified Information to be Supplied
• All the information requested in paragraph 7.2 of this Practice.
• Test reports for all testing required in Section 6.0 of this Practice, the Data Sheets and the contract documents.
• Detailed description of recommended handling, storage, installation, operating and maintenance procedures.

SHIPPING

• All wire and cable shall be shipped on cable reels.
• The cable shall be placed on the reels so that it will be protected from damage during shipment. Each end of the cable shall be firmly and properly secured to the reel. Care shall be taken to prevent looseness of reeled cable. Each end of the cable shall be accessible while the cable is on the reel without having to de–reel the cable.
• The reels shall be lagged or covered with suitable material to provide physical protection of the cable during transit and during ordinary storage and handling operations.

• Returnable reels shall be so identified with return shipping instructions marked on the cable reel.
• Special handling instructions will be indicated on the Data Sheet.
• Each reel shall have a weather–proof (metal or plastic) tag firmly attached, indicating Owner’s purchase order number, manufacture, conductor size, length, Manufacturer’s type, temperature rating, voltage class and gross weight of reel and cable.
• Water–tight seals shall be applied to the ends of the cable to prevent entrance of moisture during transit or out–of–doors storage.

9.0 TABLES

TABLE 1

HIGH VOLTAGE TESTS

TABLE 2

PARTIAL (CORONA) DISCHARGE TEST

NOTE:

(1) The AC test voltages in Table 1 for the specified walls should not be exceeded.

TABLE 3 SHIELD THICKNESS

TABLE 4

REQUIRED MINIMUM AVERAGE INSULATION THICKNESS

TABLE 5 INSULATION SHIELD THICKNESS

TABLE 6

METALLIC SHIELD TYPE REQUIRED

NOTE:

Special metallic shielding systems to accommodate available ground fault current may include copper wire shield as part of the shielding system.

TABLE 7 JACKET THICKNESS

TABLE 8

TABLE 9

CERTIFIED INFORMATION REQUIRED IN ELECTRONIC FORMAT FOR ELECTRICAL PER EP 13–8–2

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