AMENDMENT_5_-_RFP_ATTACHMENT_7_-_SPEC_+_DETAIL_FIBER_OPTIC.pdf

USDA Forest Service Project Specifications

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SECTION 26 04 00

UNDERGROUND CONTROL CABLE AND POWER DISTRIBUTION

1. PART 1 - GENERAL

1.01 DESCRIPTION

A. These specifications provide for installation of underground distribution, pad mount transformers, and underground power conductors and control cables, using trenching methods, conduit and underground secondary service.

1.02 REFERENCES

A. 26 00 10 General Technical Provisions B. 26 00 50 Basic Materials and Methods C. 26 01 15 Specialized Electrical Materials D. 31 20 00 Excavation and Backfill for Utilities

1.03 SUBMITTALS

A. Submit shop drawings and equipment catalog data and manufacturer's installation operating and maintenance instructions for approval of the following items in accordance with Section 260010:

B. Provide both hard copy and manufacturer’s original PDF files with submittals in electronic form with items marked to be submitted with all accessories.

C. Submit three copies of the following:

1. Conductor and Cable: Catalog data, cuts showing conductor and cable construction, thicknesses and material. Provide one foot sample of each cable or conductor with submittals provide sample that shows manufacturer, catalog number size and and other ratings.

2. Power and Control Cable Splices: Catalog data showing construction of all materials and installation procedures.

3. Splice Vault: Catalog data and shop drawings.

4. Pedestals: Catalog data showing construction, terminals, breakers, materials, etc.

5. Transformer, Switchgear: Complete electrical drawings, shop drawings, electrical parameters including percent resistance, percent reactance and percent impedance, overload rating, voltage, and taps. Transformers tests in accordance with American Standard Test Code for Transformers.

6. Metallic Core Marking Tape: Catalog Data.

7. Tracer conductor: Catalog data

8. Nameplates for cable identification provide engraving list with submittal.

1.04 QUALITY ASSURANCE

A. Follow the latest edition of the National Electrical Safety Code and NEC except where local regulations are more stringent.

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B. Provide certifications that persons who install and terminate and splice underground control cable have experience in the telecommunications field and have terminated and splices these cables.

1.05 DELIVERY, STORAGE AND HANDLING

A. Protect all material and equipment to be incorporated in construction from the elements.

B. Handle cable carefully at all times to avoid damage. Excessive bending of the cable will not be permitted.

C. Seal the ends of the cable against moisture at all times with suitable end caps. Where it is necessary to cut the cable, terminate or seal ends immediately after the cutting operation.

2. PART 2 - PRODUCTS

2.01 CONDUITS

A. Install all power, communications, telephone, and fiber optic cables in conduit as shown on drawings.

B. See drawings and 26 00 50 for conduit types and construction materials.

2.02 POWER CONDUCTORS – UNDERGROUND INSTALLED IN CONDUIT

A. Conform to REA Specification (XLP-USE-2 insulation, cross-linked polyethylene) U-1 for primary and U-2 Type 2 for 600 volt secondary unless otherwise shown on the drawings, and as described below.

B. All conductor-sizes on drawings are for copper conductors. Aluminum will not be allowed.

2.03 SECONDARY POWER CONDUCTORS (600V and less)

A. Meets REA and IPCEA S-95-658 & Nema WC70 with additional features as described below:

1. Listed for RHH, RHW-2, USE-2

2. Standards: UL 854, ASTMB3, ASTMB8 Federal Spec A-A-59544

3. Conductor: Copper annealed coated, Class B Stranded.

4. Insulation: XLP-USE chemically cross-linked thermosetting polyethylene.

Conductor Line Insulation Thickness, Inches

12 – 10 AWG 0.045

8 - 2 AWG 0.060

1 - 4/0 AWG 0.078

250-500 kcmil 0.094 600-1000 kcmil 0.109

2.04 PRIMARY CABLE CONSTRUCTION (over 600V)

A. Meets IPCEA S-66-524 with additional features described below:

1. Conductor: Copper annealed coated, Class B Stranded.

2. Conductor Shield: .030 extruded conducting cross-linked polyethylene bonded to conductor, maximum volume resistivity 100,000 ohm-centimeters at 130 degrees C.

3. Insulation: XLP chemically cross-linked thermosetting polyethylene.

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Voltage Insulation Thickness, inches

15KV 0.175

25KV 0.260

35KV 0.345

B. Insulation Shield: Conducting cross-linked polyethylene, minimum .030" thick, resistivity less than 50,000 ohm-centimeters at 75 degrees C.

C. Concentric Neutral: Provide full size annealed coated copper straps applied spirally over insulation shield to (1) provide conductance not less than insulated power conductor and (2) to cover not less than 90% of area of insulation shielding. Strap thickness minimum 0.020". Width not more than 0.250".

2.05 CONTROL CABLE-DIRECT BURIAL (Single Jacket)

A. Provide direct burial control cable as shown on the drawings, 12 pair, or 18 pair, 25 pair or

50 pair, No. 22 AWG CU., Superior-Essex type CASPIC F. Cable meets REA - PE-39 B. Cable Construction: Cable construction shall be as follows, inside to outer shield.

1. Inner Core - 12, 18, 25, or 50 No. 22 AWG copper conductors: SOLID INSULATION, filled with 15% low density polyethylene, 85% petroleum jelly.

2. Core Tape: Core covered with a non-hygroscopic polyethylene tape.

3. Filling compound as above.

4. .008" corrugated aluminum tape protected on both sides with a fused and chemically bonded polyethylene film (FPA).

5. Filling compound as above.

6. .006" Continuous overlapped corrugated steel tape.

7. Thermoplastic Flooding Compound over steel tape.

8. Polyethylene HMW outer jacket: .045".

9. Nominal Cable Diameter: .8" OD. for 12 pr others proportional.

C. Electrical Parameters:

1. Conductor Resistance: Maximum DC Resistance, 35.0-ohms per KFT. per two conductors for #22 AWG CU.

2. Insulation resistance minimum: 5,280 kilofoot-megohms.

3. Mutual Capacitance maximum: .083 MF/mile at 1000 Hz.

2.06 CONTROL CABLE-DIRECT BURIAL (Double Jacket)

A. Provide direct burial control cable as shown on drawings, 12, 18, 25, 50 pair, No. 22 AWG

CU., General Cable type, Qualpeth - FPA-GP-FC; Anaconda type AP-ALP-TF-SP; Essex type SEALPIC F+M-PQ; Superior type WT=APFSP/SN; or North Supply type ALP-DJ-G- F. Meets REA spec PE-39

B. Cable Construction: Cable construction shall be as follows, inside to outer shield.

1. Inner Core - 12, 18, 25 or 50 pr 22 AWG copper conductors solid polyethylene insulation filled with 15% low density polyethylene, 85% petroleum jelly.

2. Core Tape - Core covered with a non-hygroscopic polyethylene tape.

3. Filling compound as above.

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4. .008" corrugated aluminum tape protected on both sides with a fused and chemically bonded polyethylene film (FPA).

5. .006" continuous overlapped corrugated steel tape.

6. Thermoplastic flooding compound over steel tape on both sides.

7. Inner jacket polyethylene HMW .065" thick.

8. .006" continuous overlapped corrugated steel tape.

9. Thermoplastic flooding compound over steel tape on both sides.

10. Polyethylene HMW outer jacket: .045".

11. Nominal cable diameter: 1.1" OD for 50 pair cable.

C. Electrical Parameters Conductor Resistance:

1. Maximum DC Resistance, 35-ohms per KFT, 22 AWG per two conductors.

2. Insulation resistance minimum: 5,280 kilofoot-megohms.

3. Mutual capacitance maximum: .083 MF/mile at 1000 Hz.

2.07 CONTROL CABLE-DIRECT BURIAL (Double Jacket Double Shield) A. Provide direct burial control cable as shown on drawings, 25, 50 pair, No. 22 AWG CU., Essex type CASPIC F+M or approved equal.

B. Cable construction shall be as follows, inside to outer shield:

1. Inner Core - 25 or 50 pr 22 AWG copper conductors, solid polyethylene insulation filled with 15% low density polyethylene, 85% petroleum jelly.

2. Core Tape - Core covered with a non-hygroscopic polyethylene tape.

3. Filling compound as above.

4. .008" corrugated aluminum tape protected on both sides with a fused and chemically bonded polyethylene film (FPA).

5. .006" continuous overlapped corrugated steel tape.

6. Thermoplastic flooding compound over steel tape on both sides.

7. Inner jacket polyethylene HMW .065" thick.

8. .006" continuous overlapped corrugated steel tape.

9. Thermoplastic flooding compound over steel tape on both sides.

10. Polyethylene HMW outer jacket: .045".

11. Nominal cable diameter: 1.1" OD for 50 pair cable.

C. Electrical Parameters:

1. Conductor Resistance: Maximum DC Resistance, 35-ohms per KFT, 22 AWG per two conductors.

2. Insulation resistance minimum: 5,280 kilofoot-megohms.

3. Mutual capacitance maximum: .083 MF/mile at 1000 Hz.

2.08 UNDERGROUND POWER CONDUCTOR CONNECTORS AND SPLICES (600V)

A. Utilize 3M Company "Scotchcast" urethane resin insulation in poured kits, splices and compression connectors for underground direct burial cable No. 12 to 750 MCM or approved equal.

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B. Provide Scotch 3M 82A series poured resin splice enclosures or approved equal for straight inline splices

C. Provide Scotch 3M 90-B1 enclosures for “Y” tap splices D. Provide Scotch 3m Multimold 85-CP kit for lager splice enclosures.

E. Provide molded plastic enclosure, pouring funnels, closure tape for splices kits.

F. Provide 3M™ Scotchcast™ Electrical Insulating Resin 4, two-part epoxy insulating and encapsulating resin used to splice solid cables up to 8 kV.

G. Provide copper tubular lug splice connectors for power cable as described in 26 05 00 under

LUGS AND CONNECTORS. Provide copper compression lugs for all splices.

1. Provide copper compression lugs with hydraulic compression tool die which imprints manufactures name when splice is properly compressed.. Fill all lugs with Penetrox before crimping splice.

H. Heat shrink tubing or cold splice enclosures are not acceptable for splice kits.

2.09 UNDERGROUND RE-ENTERABLE CONTROL CABLE SPLICES

A. Provide 3M Company 78-R series re-enterable filled splice enclosures in kits for each direct burial control cable splice or approved equal. Provide reenterable urethane encapsulate which can be removed by hand from splice after curing without damaging control cable splices. Provide splice connectors as described below. Furnish with Scotch 4462 shield connector and insulated strain relief/bond bars, and spacer webbing.

B. Enclosure: 3M 78R series enclosures or equal size as required with additional accessories described above. Provide single or double end caps as required.

C. Control Cable Connectors: Splice 19 - 22 AWG solid Direct Burial Copper Control Cable with Scotch Lok UAL, UB, UCC, UDW, UG, OR ULG, 2, 3, and 4 port jelly filled compression butt and T Tap connectors or approved equal. Install splice buttons with factory recommended parallel jaw tool. Not all variations are shown below:

1. Inline 1 pair splice for 2 #19 – 24AWG Polycarbonate body

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2. Inline to “T” tap #19 – 24AWG Polycarbonate body

3. Inline to “T” tap #19 – 24AWG Polycarbonate body

D. E9J 10:1 mechanical crimp tool for use with above splice connectors

E. Encapsulate: 3M 2123 re enterable electrical insulating resin or approved equal. Cures translucent, repairable with complete bonding to entered splice.

F. 3M™ Scotchcast™ Re enterable Electrical Insulating Resin 2123 is used in the 3M™

Scotchcast™ Re enterable Signal and Control Cable Splicing Kits 78-RSeries. Typical data has been provided for both resin and kits as follows:

1. Scotchcast 2123 Re enterable Resin Electrical Insulating and Sealing Compound

G. RE-enterable splice encapsulate and Electrical splice enclosure & properties listed below:

Encapsulate Physical Properties

Splice Enclosure Physical & Electrical Properties

Test Method Typical Value Test Method Typical Value* Isocyanate Content Not Isocyanate

Based Insulation Resistance @1000 V after 24 hr submersion 3.1 x 1015 ohms

Viscosity Mixed (25˚C) (3M Test Method) Brookfield Viscometer

670 cps UL 486 D, Sequence A

Gel Time (min) Sunshine Gel Meter Dielectric Withstand (1 min)@ 2200 V, after 24 hr submersion UL 486 D, Sequence A Pass

(100 g mass) 4˚C (4˚F) 24˚C (75˚F) 43˚C (110˚F) 105 min 62 min

34 min

Insulation Resistance @ 1000 V, after 72 hrs @90˚C, flexing and twisting, 24 hr.

submersion

1.68 x 1015 ohms

Maximum Exotherm UL 486 D, Sequence A 180 g mass in Calorimeter 23˚C (75˚F) ambient

6˚F Rise Dielectric Withstand (1 min) @2200 V, after 72 hrs @90˚C, flexing and twisting, 24 hr.

submersion

Pass

Heat Aging (% Wt. loss 95˚C (203˚F) for 168 hrs) 2 UL 486 D, Sequence A Copper Corrosion West Elect. Spec.

AT-8612 (MS 17000, Sec 1139) None

Insulation Resistance@1000 V, after 4 hrs @-18˚C, flexing and twisting, 24 hr submersion UL 486 D, Sequence A

3.5 x 1015 ohms

Water Absorption (3M Test Method) (% Wt. Gain) 0.2 Insulation Resistance@ 1000 V, after 25 cycles heat and submersion 2.1 x 10 ohms

Fungus Resistance (ASTM 621) "0" Growth UL 486 D, Sequence A Electrical Properties Typical Value Insulation Resistance@ 1000 V, after 50 cycles heat and submersion 2.0 x 1013 ohms

Dielectric Strength (ASTM D 149-64) (volts/mil) 125 mil thickness > 240 UL 486 D, Sequence A Insulation Resistance (ohms) West Elect. Spec. (MS 17000, Sec 1182) > 4 x 10" Dielectric Withstand (1 min) @2200 V, after

50 cycles heat and submersion Pass

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UL 486 D, Sequence A Leakage Current Test 600V, after 50 cycles heat and submersion 0.10 mA

UL486 D, Sequence A Impact Test after 2 hrs @ -10˚C after 168 hrs

@ 113˚C UL 486 D, Sequence A Pass Pass

2.10 PAD MOUNT TRANSFORMERS

A. General: Provide totally enclosed, pad-mounted type transformers designed, tested and assembled in accordance with applicable standards of NEMA, IEEE, ANSI and F.S. W-T- 6312C, Type III, Class 1 and Class 2.

B. Ratings: Units shall be described or rating as shown on drawings of KVA and voltage ratings indicated on drawings. Transformers shall be rated 65 degrees Centigrade temperature rise when carrying full rated load at rated voltage.

C. Manual Tap Changers: Provide four, approximately 2-1/2% rated KVA taps in the high voltage winding, two above and two below rated high voltage. The external manually operated tap changer shall be suitable for operation when the transformer is deenergized.

D. Liquid Preservation: Provide a sealed tank with welded-on cover for preservation of transformer liquid.

E. Neutral Bushing: Include a low-voltage, neutral bushing.

F. Maintenance Devices: Furnish the following maintenance devices:

1. Nameplate on inside of low-voltage compartment door.

2. Operating handle for tap changer in high-voltage compartment.

3. Ground pads in high-voltage and low-voltage compartments.

4. Lifting lugs.

G. Tamperproof Construction: Design and construction of the transformer and associated terminal compartments to be completely tamperproof. There shall be no exposed screws, bolts or other removable fastening devices. No openings shall be provided through which foreign objects such as sticks, rods or wires might be inserted to contact live parts. Any possible access by birds or animals shall be positively prevented.

H. Terminal Compartments: Terminal compartments shall be full-height, air-filled compartments with padlockable hinged doors. The incoming and outgoing line compartments shall be located side-by-side with the incoming compartment on the left.

The incoming compartment shall be accessible only after the door to the outgoing compartment has been opened. Provide a removable door sill on compartments to permit rolling or skidding of unit into place over conduit stubs in foundations.

I. Incoming Compartment Equipment: Provide the following:

1. Dead-front primary bushing construction with high-voltage incoming line terminals utilizing ESNA "flower-pot" universal bushing wells and ESNA load-break/ load-make plug-in type elbow receptacle.

2. Primary fuses (three for three-phase, one for single-phase) sized to conform to all applicable standards and coordinate with the indicated secondary protective system.

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J. Outgoing Compartment Terminals: Provide standard spade-type, low-voltage bushings with standard drilling except that not less than one pair of holes shall be provided for each indicated secondary conductor. Where indicated, provide Alcoa TTB series transformer terminals, silver plated, designed for ET series compression-type cable terminals. Provide special spade-type terminals where indicated.

2.11 SPLICE VAULT (Control Cable)

A. Provide concrete splice vault approximately 62"L x 27"W x 22"H with removable ends and cable slots in end pieces of approximately 6" x 10". Weight of concrete vault approximately 1100 lbs. Cover - 1/4" galvanized diamond plate steel with 2-3/8" recessed pentahead bolts. Provide one locking matching wrench with each vault. See detail on Drawings. Oldcastle. 38-TA or approved equal.

2.12 SPLICE VAULT (Light Weight)

A. Provide light weight plastic vault with open bottom, mouseholes, and locking cover. Cover to be secured with stainless steel standard pentahead bolt.

B. Provide Quazite Composolite vault with mouseholes part number PX1730BB16 with locking cover part number PX1730CA00.

2.13 SPLICE VAULT / PULL VAULT (Power & Control Cable)

A. Provide precast concrete splice vault approximately 4' x 4' x 4', 2905 lbs. with hinged and spring locked steel cover, 36" x 36" Oldcastle 444-LA with 44-332-P cover or approved equal.

B. Provide precast concrete splice vault approximately 2' x 2' x 2', weight approximately 800 lbs. with hinged and spring locked steel cover, 24" x 24" Oldcastle 3030-LA with 44-332-P cover or approved equal. Provide locking latch mechanism to accept padlock. Provide traffic rated lid or approved equal.

2.14 METALLIC CORE MARKING TAPE

A. Furnish plastic covered aluminum marking tape for power and control conductors.

B. Tape width: 2".

C. UNDERGROUND DETECTABLE - 5 MIL 2 Mil Polyethylene Film Reverse Printed And

Laminated To Aluminum Foil Then Laminated To 2 Mil Polypropylene Film D. Color: Power- Red, Control Cable-Orange.

E. Inscription: Power Conductors "Caution, Buried Power Line", Control Cable "Caution, Buried Telephone Line".

1. Red- Buried Electrical Line Below

2. Blue- Buried Water Line Below

3. Green- Buried Sewer Line Below

4. Yellow- Buried Gas Line Below

5. Orange- Buried Telephone Line Below

2.15 TRACER CONDUCTORS

A. Provide copper insulated tracer conductors for marking location of underground conduits.

B. Conductor shall be #10 AWG, XLP-USE insulation 0.045” thick.

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C. Conductors shall be installed above conduits and tie wrapped to conduit as shown on drawings.

2.16 CABLE IDENTIFICATION NAMEPLATES

A. See 26 00 50 for nameplate construction

3. PART 3 - EXECUTION

3.01 INSPECTION AND INVENTORY OF BURIED POWER AND CONTROL CABLE

A. Before any backfilling operations are begun, the Contractor and COR shall jointly inspect all trenches, cable placement, splice vaults, risers, marking tape, tracer conductors and other construction not accessible after backfilling.

3.02 PREPARATION

A. Trenching and backfill for electrical conduits shall conform to Section 31 20 00 .

3.03 POWER AND CONTROL CABLE INSTALLATION

A. Conduit Cleaning

1. Prior to pulling cable thru conduits clean all conduits by swabbing out conduits to remove all debris. Cap ends after cleaning prior to installing conductors.

B. Placing of Cable in Trenches: Do not lay cable when the outside temperature is below the minimum temperatures specified by the cable manufacturer.

1. Power, communications cable and fiber optic cable shall be installed in conduit only.

Direct burial is not allowed.

2. Wherever possible, cable shall be played out from the reel mounted on a moving vehicle or trailer. Support the reel on a stand. Place cable in the trench by hand.

3. Inspect the cable as it is removed from the reel in laying operations to be certain that it is free from visible defects.

4. Cable must be pulled through conduit; duct or other locations shall be lubricated with a suitable cable lubricant approved by cable manufacturer prior to pulling into conduit or duct.

5. Do not exceed cable pulling tension as recommended by manufacturer.

a. Provide a pulling dynamometer to measure pulling tension on all pulls.

6. Leave a minimum of 24" slack on each cable at all risers, splices, transformer pads, pedestals and terminal points.

C. Cable Minimum Bending Radius: Measure radius to the surface of the cable on the inside of the bend.

1. Secondary service cable (600V or less) 6 times the overall diameter of the cable.

2. Primary cable (more than 600V) 12 times the overall diameter of the cable.

3. Control cable - two feet radius.

D. Splices: Not more than one splice for each 2000' of power or control cable installed in any one continuous run.

1. See Section 260010 and 260115 Splices and Terminations, Underground Conductors.

2. Make Cable splices in accordance with the spice manufacturer's instructions.

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3. Provide written certification those persons making the splice on buried control cable have demonstrated previous experience in splicing underground telephone cable.

4. Splice details are shown on the drawings.

5. Use pre-formed molded case poured "potted" splice kits installed in accordance with manufacturer's recommendations. See Section 260050.

6. Make all splices in splice vaults or at pedestals. Vaults or pedestals shown on drawings are the minimum number required.

7. Bends will not be permitted within 12 inches of the ends of splice.

8. The cable or circuit numbers and the exact location of the splices shall be noted and given to the COR.

3.04 PULLING STRESSES

A. Maximum 500 pounds as measured by a dynamometer or less if recommended by cable manufacturer.

B. Do not use pulling eyes or other attachments connected directly to the conductor.

3.05 MARKING TAPE INSTALLATION

A. Install metallic core marking tape above each electrical conduit as shown on drawings

3.06 TRACER CONDUCTOR INSTALLATION

A. Install tracer conductor above each electrical conduit as shown on drawings B. Tracer conductor shall be tie wrapped with nylon straps to conduit every 10’.

C. Bring conductor up above grade at each termination and in each pull or splice vault. Coil 6’ of conductor at each location.

3.07 BACKFILLING

A. Conform to Section 31 20 00 B. Provide electrical bedding material on all conduits installed in trenches for 6” surrounding conduits.

3.08 CONDUIT

A. All exposed ends of conduit shall be plugged during construction.

B. Remove burrs or sharp projections that might injure the cable.

3.09 TRANSFORMER PADS

A. Locate pads adjacent to, but not over the trench.

B. Clear the area around the pad of all debris within 2 feet of the edge of the pad and excavate to provide a level surface for installation of the pad.

C. Place a 2-inch layer of gravel or sand over the cleared area as a base for the pad. Compact and level the gravel or sand layer and level prior to installation of the pad.

D. At Contractor's option, either precast or poured-in-place concrete pads may be used. See drawings for pad details.

3.10 TRANSFORMER INSTALLATION

A. Position and connect transformer in accordance with the drawings or specifications.

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3.11 WARNING SIGNS AND DIRECTIONAL MARKERS

A. Install a warning sign at each transformer housing and pedestal.

B. Place directional arrows on the top of the enclosure to indicate the direction of cables entering and leaving the enclosure.

3.12 TERMINATIONS CONTROL AND POWER CABLE

A. Make terminations in accordance with the manufacturer's instructions.

3.13 CONTROL CABLE TERMINATIONS AND ROUTING

A. Provide bundling of all control cable by binder groups and route input and output cables to lightning arrestors so that cable paths do not cross. Keep input and output cables separated to lightning protectors.

3.14 LABELING AND NUMBERING

A. Label each pair of control cable with a mach made wire number for each pair number from

1 to the end number of cable pairs wrapped around each pair. See 26 00 50 for wire number construction.

3.15 CONTROL CABLE FILLING COMPOUND CLEANING

A. Clean all pairs of control cable at each splice and termination of filling compound with control cable manufacturer approved solvent, not harming insulation.

3.16 BENDS

A. No bends shall be permitted within six inches of the ends of stress cones.

3.17 GROUNDING

A. Grounding shall conform to Section 26 00 10.

B. Ground shield of control cable at all terminations and at all splices. Bond control cable shields together at all splices. See detail on drawings.

C. Provide a suitable ground installation at each transformer and pedestal location.

D. Solidly connect the lead from the grounding electrode to the primary neutral, unless shown otherwise on the drawings, the secondary neutral and the ground connection of all equipment at the location.

E. For ground test see Section 26 00 10 GROUNDING SYSTEM.

3.18 IDENTIFICATION OF CABLES

A. In each pull / slice vault and at each termination, provide engraved plastic nameplates tie wrapped to conduit in all splice and pull vaults or to wall if in buildings to identify the cable as follows on each nameplate:

1. Circuit Voltage, phase, cable size either in AWG or control cable pair number and

AWG size, source and termination of each cable.

B. See 260010 for nameplate construction and lettering height

3.19 CABLE MARKERS

A. Mark power and control cable location with permanent cable markers 200 feet maximum interval and at all changes in direction greater than 30 degrees.

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B. Provide cable direction marker as shown on drawings.

C. Install two-inch wide labeled metallic core plastic warning tape above cables as shown on drawings. Provide a separate marking tape for power cable and a separate tape for control cable.

D. Provide locating conductor above each conduit as described above and below

3.20 CONTROL CABLE TEST EQUIPMENT

A. Control Cable Insulation Resistance & Continuity Tests: Make measurements with digital type ohmmeter with a 10,000 megohm minimum scale range, Fluke 289 or equivalent. Limit test voltage to 10 volts D.C. (Fluke meets this requirement).

B. Meter must have nano siemens scale to measure up to the required insulation resistance of 10,000 meg ohms, and continuity resolved to 0.1 ohm.

3.21 EXISTING CONTROL CABLE TESTING

A. For existing control cables that will be modified or re terminated for this project, prior to any work on the cable perform control cable continuity and insulation resistance testing on each pair of control cable as described below.

B. Record results of this testing and provide to CO. This pre-construction test data will be the basis for the final project cable testing after modification and re-termination. Note any defects found during tests that do not meet control cable allowable test values.

3.22 PRELIMINARY CONTROL CABLE TESTS

A. Conduct all control cable tests in the presence of the COR on each length of underground control cable in the system, with terminations in place but disconnected. See Section 260010 TESTS for test report format and general provisions. These tests apply to cable direct buried or pulled in conduit.

B. Submit all control cable test results in both hard copy and PDF format.

C. Provide an independent testing firm(s) that specializes in testing telephone cable, with demonstrated minimum of 3 years in testing cable. Provide the appropriate testing equipment for, continuity and insulation resistance testing, and for fault locating.

D. Preliminary Continuity and Insulation Resistance (Control Cable): After installation, and prior to backfilling, perform a test on each separate length of control cable, and after any splice or tap is made on the whole length of the cable from the source to each termination prior to encapsulation of splice.

1. Repeat same tests after encapsulation if any and placement of backfill.

2. Note splices are not allowed on segments less than 2000’ long.

3. All cable pairs must pass insulation and continuity tests described below.

4. Perform tests as required below.

3.23 PRELIMINARY & FINAL CONTROL CABLE INSULATION RESISTANCE TEST

A. Disconnect all cable conductors and shields at both ends.

B. If this cable has two shields they should be tied together and treated as one shield for testing purposes. Scrape off plastic coating when connecting shields together.

C. Drive a 5-foot ground rod near cable end test point.

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D. Set voltmeter to the 200 D.C. millivolt range.

E. Measure the voltage between the shield and ground rod, and record. The voltage should be less than .01 volts (ten millivolts). If the voltage is more than .01 volts, this indicates cracks or cuts in the outer cable insulation, which must be repaired before the remaining tests are performed. If the measured voltage is less than .01, proceed to the next step.

F. Set meter to the 200 nanoseimen range. .

G. Note: To convert nanoseimens to megohms, use the following formula:

H. Megohms = 1,000/ns. Reading - 1.0 then megohms - 1,000/1.0 = 1,000 or use conversion chart supplied with Fluke meter.

I. Measure and record insulation resistance between:

1. Each conductor and every other conductor.

2. Each conductor and cable shield.

3. Each conductor to the ground rod, for cables installed in conduit ground shield after this test is done and repeat the tests.

4. Cable shield to the ground rod. For cables installed in conduit perform this test.

J. All individual resistance measurements shall exceed 5,280 KFTM (kilofoot-megohms).

K. KFTM. (Insulation Resistance) = Length of cable in kilofeet x measured resistance in megohms. 1 kilofoot (KFT) = 1,000 ft.

L. Example:

1. Cable length = 2,640 feet (2.640 KFT), Measured resistance of cable shield to ground rod = 2,400 megohms; so, Insulation Resistance (KFTM) = (2.640) KFT x (2,400) megohms = 6,336 KFTM.

2. This is acceptable, as it exceeds the minimum of 5,280 kilofoot-megohm specification.

3.24 PRELIMINARY & FINAL CONTROL CABLE CONTINUITY TEST

A. Make measurements with digital type ohmmeter with a 10,000 megohm minimum scale range, Fluke 289 or equivalent. Limit test voltage to 10 volts D.C. (Fluke meets this requirement).

B. Procedure

1. Disconnect all cable conductors at both ends.

2. Short both conductors of each pair together at one end of cable.

3. Set meter to measure resistance in the expected range, and measure the resistance of each pair in the control cable at the opposite end, and record.

4. The resistance of any pair should not exceed 38 ohms for each 1,000 feet of #22

AWG CU., control cable tested, for one way distance.

5. Acceptable measured pair resistance = (cable length in feet) divided by 1,000 x (38 ohms per 1,000 feet).

C. Example:

1. Cable length = 1,255 feet, Measured resistance = 45 ohms. so, (1,255/1,000 x (38) =

47.69 ohms. (Acceptable maximum)

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2. Actual measured resistance = 45 ohms and is acceptable because this is less than maximum specified resistance allowable.

3.25 CONTROL CABLE INSTALLATION PRECAUTIONS

A. For control cable protection, conduit containing control cable should be surrounded by at least 6 inches of fine sand. Care must be taken to prevent damage to the cable or insulation by falling rocks, sharp shovels or other tools, crushing by heavy equipment or machinery.

B. The insulation thickness is only .045" and a small puncture of the insulation will allow moisture and contaminates to contact the shield material, causing electrolysis which will eventually destroy the shield of the cable. More and more moisture enters over a period of time and finally the cable has to be replaced.

C. Insulation cuts or puncture faults without damage to the shield or conductors may be encased in a poured resin type splice container (without splicing) in lieu of replacing cable.

If a splice is made a splice vault must be installed.

3.26 CONTROL CABLE FAILURES

A. Cable and splices that do not meet the above tests shall be corrected by replacement if conductor length is less than 2000’ in any one continues section or if longer than 2000’ splice and the test procedure repeated until cable/splice meet test requirements.

B. Replace defective length of cable and splice in new length using cast in-line re-enterable splice enclosures.

C. All Splices if allowed by length shall be installed in splice vaults.

3.27 PRELIMINARY POWER CABLE TESTS

A. Conduct tests in the presence of the COR on each length of underground power in the system, with terminations in place but disconnected. See Section 260010 TESTS for test report format and general provisions. These tests apply to cable direct buried or pulled in conduit.

B. Provide an independent testing firm(s) that specializes in testing power and telephone cable, with demonstrated minimum of 3 years in testing cable. Provide the appropriate testing equipment for high-pot, continuity and insulation resistance testing, and for fault locating.

C. Preliminary Continuity and Insulation Resistance (Power Cable): After installation of the power cable and prior to backfilling and the high potential test specified below, perform a simple continuity test on the system by shorting each conductor pair together at the source and checking for continuity from the end of each tap or line with an ohmmeter. Megger each conductor to ground (includes neutral) and to each other conductor to test for insulation faults prior to doing hipot tests below. See 26 00 10 PRELIMINARY TESTS for insulation requirements. Ground one lead to a 5 foot driven ground rod and connect the other lead to conductor with terminations disconnected. Measure insulation resistance to ground and between phases with a DC Megger, 2,500 VDC, prior to doing hi pot test described below. After backfilling perform high - pot tests described below.

3.28 HIGH POTENTIAL (POWER CABLE)

A. After successful continuity, insulation resistance tests and backfilling, perform high potential tests on each length of cable in the system.

B. Maintain for a minimum of five minutes a DC test potential voltage as follows:

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C. 600 volt Secondary Cable

1. XLP-USE Insulation

Size Insulation Thickness In. Field DC Acceptance Voltage AWG or MCM Inches Test Volts

12 .0450 4.8KV

10 .0450 4.8 KV

8-2 0.060 4.8kV

1-4/0 0.080 6.4 KV

250-500 MCM 0.095 8.0 kV

600-1000 MCM 0.110 9.6 KV

D. Primary Cable

1. XLP-USE INSULATION

2. Rated Voltage

AWG or MCM Insulation Thickness In Field DC Acceptance Voltage

15kV 0.175 52.8kV 25kV 0.260 78.0kV

E. The voltage may either be increased continuously or in steps to the maximum test value.

F. If increased continuously, increase uniformly to maximum voltage in not less than 10 seconds and in not more than approximately 60 seconds. Apply maximum test voltage for a total of five minutes.

G. If applied in steps, increase from one step to the next uniformly with each step long enough for the absorption current to attain reasonable stabilization (one minute minimum). Take current and voltage readings at the end of each step duration. The number of steps shall be from five to eight.

H. Plot leakage current in microamps DC vs. test voltage. Continue plot for five minutes.

I. Correct point faults by enclosing fault area in cast in-line splice enclosure, WITHOUT

SPLICING. If wire is damaged remove and replace failed conductor with in-line compression splice lugs and poured urethane splice as above.

J. Install any splice or fault area described above in a splice vault or pedestal.

K. Submit all test results in hard copy and PDF.

L. All faults discovered by this test shall be corrected and the tests rerun until cable splice meet requirements.

M. Warning: Following these tests, a hazardous voltage may exist on the power cable. The conductor shall be grounded to permit any charge to drain to earth.

END OF SPECIFICATION 26 04 00

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TYPE 2 TRENCH

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POWER AND / OR COMMUNICATIONS

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SAND BACKFILL, 6" MIN. TOP COVER AND 4" MIN BEDDING. TYP. OF ALL UTILITIES.

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NATIVE BACKFILL

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WARNING TAPE, BURY 12" BELOW SURFACE.

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PAVED AREAS

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2" MOUND

AutoCAD SHX Text 12" FOR RSC TYPICAL FROM AN ADJACENT PULL BOX TO ITEM SERVED (i.e. LIGHT POLE, GATE, LOADING PIT, ECT)

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MAINTAIN 1" MIN. SEPARATION BETWEEN CONDUITS.

H. Heat shrink tubing or cold splice enclosures are not acceptable for splice kits.

G. RE-enterable splice encapsulate and Electrical splice enclosure & properties listed below:

J. Outgoing Compartment Terminals: Provide standard spade-type, low-voltage bushings with standard drilling except that not less than one pair of holes shall be provided for each indicated secondary conductor. Where indicated, provide Alcoa TTB seri...