SECTION MEDIUM-VOLTAGE CABLES PART 1 GENERAL
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1 SECTION MEDIUM-VOLTAGE CABLES PART 1 GENERAL 1.1 SECTION INCLUDES A. Medium voltage cable. B. Cable terminations. C. This specification describes single conductor EPR (Ethylene-propylene-rubber) insulated, shielded power cables for use in grounded neutral circuits not exceeding 15,000 volts phase-tophase at conductor temperatures of 90 degrees Centigrade for continuous normal operation, 130 degrees Centigrade for emergency overload conditions, and 250 degrees Centigrade for shortcircuit conditions. Cables shall be type MV-105 for CT use in applications covered by the NEC. Otherwise, they are intended for general purpose power cable applications in wet or dry locations, including conduit, cable tray, duct, direct burial, and aerial installation. 1.2 RELATED REQUIREMENTS A. Section Electrical Underground Ducts and Manholes: Cable racks in manholes. B. Section Identification for Electrical Systems. 1.3 REFERENCE STANDARDS A. IEEE 48 - IEEE Standard Test Procedures and Requirements for Alternating-Current Cable Terminations 2.5 kv through 765 kv; Institute of Electrical and Electronic Engineers; 1996 (R2009). B. All termination kits shall meet IEEE No. 48 standard. 1. NEMA WC 74 - S5-46 kv Shielded Power Cable for Use in the Transmission and Distribution of Electric Energy; National Electrical Manufacturers Association; C. All termination kits shall meet IEEE No. 48 standard. D. NETA STD ATS - Acceptance Testing Specifications for Electrical Power Distribution Equipment and Systems; International Electrical Testing Association; E. NFPA 70 - National Electrical Code; National Fire Protection Association; Most Recent Edition Adopted by Authority Having Jurisdiction, Including All Applicable Amendments and Supplements. F. UL Standard 1072 for Medium-Voltage Solid-Dielectric Cable. 1.4 SUBMITTALS A. See Section Administrative Requirements, for submittal procedures. B. Product Data: Provide for cable, terminations, and accessories. MEDIUM-VOLTAGE CABLES
2 C. Manufacturer's Instructions: Indicate application conditions and limitations of use stipulated by product testing agency specified under Regulatory Requirements. Include instructions for storage, handling, protection, examination, preparation, and installation of product. 1.5 QUALITY ASSURANCE A. All cable terminations and splices shall be installed by workmen who are competent in termination and splicing of high voltage primary cable. Submit a sample termination and splice made by the individual who is intended to work this job. Also, a list of previous high voltage cable work performed by this individual. The Architect/Engineer shall retain the right to disapprove this individual. The Architect/Engineer shall retain the right to disapprove any worker who demonstrates less than average skill in the work of high voltage termination/splicing and shall require his removal and replacement with a competent worker approved by the Architect/Engineer. PART 2 PRODUCTS 2.1 MANUFACTURERS A. Cable shall be manufactured by Rome, Kerite, Okonite, Southwire, or BICC General Cable. 2.2 CABLE A. Medium Voltage Cable: NEMA WC 70 rubber insulated cable. 1. The primary cable shall be suitable for operation on a 15 kvolt, 3 phase, 3 wire distribution system. The cable shall be single-conductor, AWG or MCM size as noted on the drawings, shielded, 133% insulation level, EPR, Class B stranded annealed uncoated or coated copper. B. CONDUCTOR SHIELD 1. Extruded layer of semiconducting EPR thermossetting compound with a volume resistivity not in excess of 100 ohm meters at 105C shall be applied over the conductor. The compound shall have a minimum elongation after an air oven test at 136C for 168 hours of 100% and a brittleness temperature not warmer than -40C. 2. The shield shall be clean stripping from the conductor and inseparably bonded to the overlying insulation. 3. On conductor sizes greater than 1000 kcmil there shall be the option of applying one layer of semiconductive tape under the extruded semiconducting EPR thermosetting compound. 4. The thickness of the extruded conductor shield shall be: {AWG = inches (mm)} 8-4/0 =.006 (.15); =.008 (.20); =.010 (.25); 1001 & greater =.012 (.30). The thickness of the shield is measured and controlled by means of a laser micrometer. C. INSULATION 1. Directly over the conductor shielding shall be applied a homogenous wall of EPR insulation. The average thickness of insulation shall be as specified by IPCEA. Minimum thickness at any point shall be not less than 90 percent of the specified thickness. The EPR shall not contain polyethylene. Ethylene content of elastomer used in the EPR shall not exceed 72%. D. SHIELDING MEDIUM-VOLTAGE CABLES
3 1. The insulation shield shall be an extruded semi-conducting EPR compound with a volume resistivity not in excess of 100 ohm-meters at 90C when tested per AEIC No. CS6. 2. The extruded shield shall be clean stripping and shall have a peel strength from the insulation between 4 to 24 lbs./0.5 inch width when tested per AEIC No. CS6. This compound shall have a minimum elongation after an air oven test at 136C for 168 hours of 100% and a brittleness temperature not warmer than -40C. 3. The thickness of the extruded shield shall be in accordance with the following: 4. The outer surface of the insulation shield shall be continuously printed with white ink - "Semi-conducting - Remove When Splicing or Terminating." E. SEPARATOR TAPE 1. A 5 mil copper separator tape with 12-1/2% overlap shall be applied over the cable shielding system. F. JACKET 1. A PVC jacket shall be applied overall meeting the requirements of paragraphs 4.4.5, 4.4.9, or of IPCEA and the Sunlight Resistance requirements of UL Standard The average thickness of the jacket shall be as specified in Table 4-6 of IPCEA. The minimum thickness at any point shall be not less than 80 percent of that specified. G. IDENTIFICATION 1. All cable shall be identified by means of surface ink printing indicating manufacturer, size, insulation type, voltage rating, and UL designations. H. SPLICES AND TERMINATIONS 1. Splice and termination kits shall be manufactured by 3M, G.E., or Elastimold. 2. Stress cones shall be as follows: a. Terminations (EPR): The power cable terminations shall be capable of normal continuous operation at (*5) (*15) (*35) kv phase to phase. The terminations shall consist of: a high quality molded rubber stress cone made of track-resistant EPDM rubber insulation and conductive rubber shield with stainless steel ground trap; a silicone rubber cold shrink skirted insulator. See drawings for additional requirements. 3. All cable terminations and splices shall: a. Have voltage ratings not less than (*5) (*15) (*35) kv b. Be properly sized terminations for the type of cable used c. 75 kv BIL-5 kv, 110 kv BIL-15 kv, 150 kv BIL-25 kv, 200 kv BIL-34.5 kv d. have 133% insulation value PART 3 EXECUTION 3.1 EXAMINATION A. Verify that conduit, duct, trench, or manholes are ready to receive cable. 3.2 PREPARATION A. Use swab to clean conduits before pulling cables. MEDIUM-VOLTAGE CABLES
4 3.3 INSTALLATION A. Avoid abrasion and other damage to cables during installation. B. Use suitable lubricants and pulling equipment. South Dakota State University C. Sustain cable pulling tensions and bending radii below recommended limits. D. Ground cable shield at each termination and splice. E. Install cables in manholes along wall providing longest route. F. Arrange cable in manholes to avoid interference with duct entrances. G. Fireproof cables in manholes using fireproofing tape in half-lapped wrapping. Extend fireproofing 1 inch into duct. 3.4 PRIMARY CABLE TESTING A. All new cable and all associated terminations and splices installed under this contract shall be field tested in the presence of the Architect/Engineer before being energized. All tests shall be in accordance with and under the direct supervision of an authorized, qualified representative of a certified testing company. B. The type of cable test shall be a DC-Hypot test conducted on each phase (A, B and C). C. The maximum test potentials are indicated in the table below. The cable manufacturer s recommended tolerances shall not be exceeded. Test potentials shall be applied for 10 minutes. Allow 1 minute for voltage stabilization. Take 10 step readings. The following information shall be recorded: 1. The amount of leakage current in micro-amps or milli-amps at full test voltage after 10 minutes. 2. The discharge time down to 7 kv DC between each phase conductor and ground. 3. The voltage after one (1) minute discharge beginning immediately after each test. 4. Voltage Phase to PhaseBIL kvdc HI-POT Test Voltage: a b c d e D. In addition to the above recorded information, proper graphs shall be plotted to show the following relationships: 1. Leakage current in micro-amps versus time in minutes. 2. Leakage current in micro-amps versus applied potential (kv DC). E. Care shall be taken to properly identify the phase conductors tested in all test recordings and graph plottings. F. If during the field acceptance testing a high resistance fault or low resistance fault in the cable, splice, termination, etc., is apparent, the fault shall be cleared, necessary repairs made, and the cable retested in accordance with this specification. MEDIUM-VOLTAGE CABLES
5 G. If the acceptance test indicates a cable with possible moisture penetration, locate the cable affected, remove same, and install new cable which is free from moisture. H. If after proper testing of the cable the independent testing representative and/or the Architect/Engineer do not approve the cable, the cable which is not approved shall be removed and a new cable installed. All cables must be tested and approved by the Architect/Engineer before final acceptance. Supply all additional cable that is required. I. Three (3) copies of all acceptance test recordings and graphs shall be submitted to the Architect/Engineer before final acceptance of the distribution system will be authorized. 3.5 TERMINATIONS A. The installation instructions and approved shop drawings for the cable termination kit shall become part of this specification. B. The splice/termination manufacturer shall conduct a 4 hour instruction seminar with the workmen and Contractor. C. Provide proper slack and creepage distance on cables. D. Ground all cable insulation shields. E. Provide all skirts, lug connections, crimps, clamps, for a complete termination or splice. All splice connects shall have copper compression connections. All terminal lugs shall be copper. 3.6 FIELD QUALITY CONTROL A. If any termination or splice does not meet with the approval of the Architect/Engineer in terms of conformance to the manufacturer s instructions for application, it shall be removed and replaced with a new termination or splice. If cable is damaged by improper work, the damaged cable shall be removed and new cable installed and retested before a new termination or splice is begun. 3.7 FIREPROOFING INSTALLATION A. After the cable has been installed, spliced, tested, and inspected, fireproof all exposed cables in manholes, buildings, and cable vaults and trenches of load centers, distribution centers, and pullboxes. B. Cable surfaces to be fireproofed shall be clean and dry. Oil, grease, or cable pulling compound shall be removed with rags and suitable solvents. C. All primary feeder cable (consisting of 3-single-conductor cables) shall be grouped together and wrapped as one (1) assembly with fireproofing tape. D. The fireproofing shall be applied in the following sequence of steps: 1. Wrap cable with 3-inch wide x.055 inch thick fireproofing tape. Tape shall be heat resistant organic fabric, one side coated with flame retarding self-extinguishing elastomer. Tape shall withstand fault arc temperature of 20,000 degrees Fahrenheit for 200 cycles. Install either 2 layer butt lapped or 1 layer half lapped. 2. Install glass cloth, 1/2 inch wide x inch thick tape at three foot intervals and at each end of the fireproofing tape. The tape shall be applied in bands with two complete wraps. MEDIUM-VOLTAGE CABLES
6 3.8 FIELD QUALITY CONTROL A. Perform field inspection in accordance with Section B. Inspect exposed cable sections for physical damage. C. Inspect cable for proper connections as indicated. South Dakota State University D. Inspect shield grounding, cable supports, and terminations for proper installation. 3.9 PROTECTION A. Protect installed cables from entrance of moisture. END OF SECTION MEDIUM-VOLTAGE CABLES
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