26 05 13.00 00 69kV Transmission Cable.pdf

SECTION 26 05 13.00 00

69kV TRANSMISSION CABLE 08/26

1. GENERAL

1.1. REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASSOCIATION OF EDISON ILLUMINATING COMPANIES (AEIC)

AEIC CS9 (2013) Specification for Extruded Insulation Power Cables and Their Accessories Rated Above 46kV Through 345kV AC

ASTM INTERNATIONAL (ASTM)

ASTM B8 (2011; R 2017) Standard Specification for Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft

ASTM D746 (2014) Standard Test Method for Brittleness Temperature of Plastics and Elastomers by Impact

INSULATED CABLE ENGINEERS ASSOCIATION (ICEA)

ICEA S-108-720 (2013) Standard for Extruded Insulation Power Cables Rated Above 46kV through 500kV AC

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 48 (2009) Standard for Test Procedures and Requirements for Alternating-Current Cable Terminations Used on Shielded Cables Having Laminated Insulation Rated 2.5 kV through 765 kV or Extruded Insulation Rated 2.5 kV through 500 kV

IEEE 400.2 (2013) Guide for Field Testing of Shielded Power Cable Systems Using Very Low Frequency (VLF)

IEEE 48 (2009) Standard for Test Procedures and Requirements for Alternating-Current Cable Terminations Used on Shielded Cables Having Laminated Insulation Rated 2.5 kV through 765 kV or Extruded Insulation Rated 2.5 kV through 500 kV

IEEE 404 (2012) Standard for Extruded and Laminated Dielectric Shielded Cable Joints Rated 2500 V to 500,000 V

INTERNATIONAL ELECTRICAL TESTING ASSOCIATION (NETA)

NETA ATS (2017; Errata 2017) Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems

NETA MTS (2015) Standard for Maintenance Testing Specifications for Electrical Power Equipment and Systems

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2020; ERTA 20-1 2020; ERTA 20-2 2020; TIA

20-1; TIA 20-2; TIA 20-3; TIA 20-4)

National Electrical Code

1.2. DEFINITIONS

High voltage power cables shall mean all cables rated above 46,000 to 500,000 volts.

1.3. GENERAL REQUIREMENTS

Section 33 71 01.00 UNDERGROUND ELECTRICAL TRANSMISSION applies to work specified in this section.

1.4. SUBMITTALS

Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-03 Product Data

Manufacturer's catalog data shall be provided for the following items:

Single Conductor 69 kV 2000kcmil Copper Shielded Cable Single Conductor 600V 4/0 Copper Ground Cable Cable Supports and Fittings Cable Tags Fireproof Tape Terminations Pull Rope Recommended Pulling Lubricant Splice Kits (including splice grounding)

SD-06 Test Reports

Submit test Reports in accordance with the paragraph entitled, "Factory Testing", of this section.

Insulation Resistance Test

Submit test Reports in accordance with the paragraph entitled, "Field Testing," of this section.

Qualification Test Reports

SD-07 Certificates

The Contractor shall prepare and submit a Pulling Plan including calculations of pulling tension and sidewall pressure anticipated, and the maximum allowable pulling tension for each pull.

Listing of Products Installed shall be provided showing qualifications of person installing cable terminations to the JEA Project Manager 15 days prior to performing specified work. Proof of a Terminator Certifications issued by the cable termination manufacturer who has provided a manufacturer's approved training program, witnessed the making of test terminations, and examined and tested the test terminations to certify that they are in accordance with all the manufacturer's requirements. Cable termination installer certifications shall be submitted for approval. Cable termination installer certifications shall be in accordance with the paragraph entitled, "Qualifications" of this section. Submittal shall include technician name, experience, training and certification on specific type and classification of cable terminations being provided under this contract.

Submittal shall also include an outline of the cable termination installer manufacturer's training program and an expiration date of certification.

Certificates shall be provided for the following showing that the cable manufacturer has made factory-conducted tests on each shipping length of cable. Certified copies of test data shall show conformance with the referenced standards and shall be approved prior to delivery of cable.

Conductor Resistance Accelerated Water Absorption Test

Water Immersion Test High-Voltage Partial Discharge Test Manufacturer's Testing Schedule

SD-08 Manufacturer's Instructions

Manufacturer's instructions shall be provided showing the recommended sequence and method of installation for the following:

Single Conductor 69 kV Shielded Cable Terminations

1.5. QUALIFICATIONS

Qualifications of cable splicers shall be provided.

Personnel performing High Voltage (HV) terminations shall have 5-year minimum experience in cable terminations of the type used in this project. In addition, the cable splicer shall submit Splicer Certifications issued by the cable termination manufacturer who has examined and tested a test termination of each type required by this contract for each cable splicer. The certification shall identify which terminations it applies to. If the contractor does not have an individual with the manufacturer's certification as described, each individual with the required 5 years high voltage terminating who is to perform cable terminating shall be required to perform a minimum of one termination of each type in the presence of a manufacturers' representative. Each termination shall be submitted to the manufacturer for testing and subsequent certification. Proof of certification will be verified by the EOR prior to installation of any terminations.

Once a termination has been started, the same installer shall complete that particular termination. Each termination shall be started and completed in one continuous work period.

1.6. CABLE VOLTAGE RATINGS AND USE

High-voltage power cables shall include single-conductor cables rated as follows, phase-to-phase, for grounded neutral systems:

Cables rated 69,000 volts, shall be used on 69,000-volt, three-phase, 60-hertz distribution systems.

Cables shall be installed in a duct and manhole system.

The primary insulation (Ethylene Propylene Rubber) shall have a performance record demonstrating a minimum of thirty-five (35) years successful operating experience in utility cable applications in the United States.

The ampacity rating of the cable shall be capable of sustained 140 MVA at rated voltage of 69,000V with a 75% Load Factor. The Contractor shall provide the JEA Project Manager in writing the ampacity of the cable at the normal and emergency operating temperatures. Typical assumptions for evaluating ampacity are 90 rho and 20 degrees C.

The temperature for normal operation is applicable to operating load cycles typical of electrical power systems. The temperature for short circuit operation represents the highest conductor temperature attained by any part during a short circuit event. Maximum conductor temperature operations are as follows:

1.6.1. Normal Operation 90 degrees C

1.6.2. Emergency Operation 130 degrees C

1.6.3. Short Circuit Operation 250 degrees C

1.6.4. Storage and Working Temperature Range -40...+90 degrees C

1.6.5. Installation & Handling Temperature Range -10...+40 degrees C

1.7. FACTORY TESTING

Certified evidence shall be submitted that the cable manufacturer has made factory-conducted tests on each shipping length (reel) of cable; certified copies of test data shall be submitted in accordance with applicable provisions of the referenced standard. Tests on each length of cable shall include conductor resistance; high voltage; partial discharge test. JEA Project Manager or designee shall have the option of witnessing required factory testing at no additional cost. A Manufacturer's Testing Schedule shall be provided 4 weeks in advance to permit such witnessing, if desired.

Submit certified Qualification Test Reports in accordance with AEIC CS9 showing cable material and manufacturing meet the requirements of the referenced standards.

Prior to manufacturing, data regarding degradation of proposed insulating material and cable performance due to water immersion test as specified in this specification shall be provided to Owner or designee. Information shall indicate A.C. breakdown stress in kV/mm or V/mil versus immersion time. A complete cable description and condition under which cable was tested shall accompany the test information. Accelerated water absorption test shall also be submitted.

1.8. SHIPMENT

Listing of products installed shall be submitted.

The shipment of cable shall be made on reels in such a manner that the cable will be protected from mechanical injury. Each end of each length of cable shall be hermetically sealed using heat-shrinkable molded cable end caps to exclude moisture and securely attached to the reel.

The minimum diameter of the reel drum shall be 14 times the overall diameter of the cable. Those reels less than 60 inches in diameter shall have arbor holes sized for 2-1/2 inches spindles; those greater than 60 inches in diameter shall have arbor holes sized for 3-inch spindles. Reel sizes shall accommodate reel lengths specified in purchase order. Each reel shall contain only one length of cable cut to order.

Each reel shall have an arrow and appropriate wording stenciled in plain view on each side to indicate proper rotation of reels. Each reel shall be plainly marked on each side, and on a tag attached to the cable end inside the lagging, with the following information:

a. Purchaser's order number:

b. Complete description of cable including manufacturer, cable size, voltage rating, percent insulation rating, insulating material, conductor size(s), year of manufacture.

c. Actual shipping cable (reel) length.

d. Reel number (e.g. 1 of 2);

e. Gross weight (i.e. with reel) and net weight (i.e. cable only).

Reels shall be shipped in a vertical position, sufficiently blocked in the bed of shipping vehicle to preclude movement.

2. PRODUCTS

2.1. CONDUCTORS

2.1.1. Material

Core (phase) conductor material shall be annealed copper in accordance with ASTM B 8.

2.1.2. Stranding

Conductors shall be Class B stranded.

2.2. CABLE IDENTIFICATION

Cables shall have printing on the outer jacket showing the cable type, name of the manufacturer, the year in which the cable was manufactured, sequential cable reel length markings and a unique number for identification purposes.

2.3. 69 kV 2000kcmil CABLES

2.3.1. General; 69 kV Cable

Single conductor 69 kV shielded cable assemblies shall consist of: Conductor core described above, an extruded semiconducting or non-conducting shield over the conductors, 650 mils of ethylene-propylene-rubber (EPR) insulation, an extruded semiconducting insulation shield, and a polyethylene (PE) jacket. The cable shall be rated for minimum 90 degrees C continuous conductor temperature and 130 degrees emergency overload.

One additional single conductor 600V 4/0 copper cable shall be installed with each set of 3-2000kcmil cables.

2.3.2. 69 kV Cable Conductor Shielding (Strand Screen)

The conductor shielding shall be semiconducting thermoset ethylene propylene rubber. The semiconducting shielding shall be in accordance with AEIC CS9. Note: A conductor energy suppression layer is also acceptable. In addition to its energy suppression function, this layer shall provide stress relief at the conductor/primary insulation interface.

2.3.3. Insulation; 69 kV Cable

The insulation shall be a high quality, heat, moisture, impact, and ozone resistant flexible thermosetting ethylene propylene rubber-based elastomer. The ethylene content of the elastomer used in the insulation compound shall not exceed 72% by weight of ethylene nor shall the compound contain any polyethylene. The insulation thickness shall be 650 mils. The cable manufacturer shall compound the insulation in its own facility using a closed system to insure maximum cleanliness. The insulation shall be triple tandem extruded with the conductor and insulation screens and be applied in accordance with the above industry standards. Extrusion shall be performed by three in-line extruder heads thereby permitting the measurement and accurate individual control on each layer of compound as the cable is being manufactured.

2.3.4. Non-metallic Insulation Shield; 69 kV Cable

The minimum average insulation thickness shall be 650 mils. The minimum and maximum thickness of the insulation shall not vary from the average by more than 10%.

The insulation shall be tested for voids and contaminants per AEIC CS9.

The insulation shield shall be a semiconducting thermoset ethylene propylene rubber compatible with the EPR conductor insulation. The allowable operating temperature shall be greater than or equal to the conductor insulation. The insulation shield shall conform to the requirements of AEIC CS9.

2.3.5. Jacket; 69 kV Cable

Polyethylene (PE) shall be extruded to a minimum thickness of 140 mils.

The outer jacket shall be linear low density black polyethylene with three (3) extruded red stripes 120 degrees apart. The jacket shall be free stripping with no void existing between jacket or insulation shield. The jacket shall meet all requirements of ICEA S-108-720

2.3.6. TESTING

Cables shall meet all AEIC CS-9, and ICEA S-108-720 testing requirements.

2.3.7. QUALIFICATION

The cable manufacturer shall submit a complete qualification test report.

2.3.8. INSPECTION

All cable will be inspected and approved by purchaser. Any cable not specifically meeting the requirements of this specification without the direct approval of the purchaser may be rejected at the option of the purchaser. Rejected cable will be returned at the supplier's expense.

2.3.9. IDENTIFICATION AND MARKING

The manufacturer's name, conductor size, insulation thickness, date of manufacture, cumulative footage figure, type EPR and voltage rating shall be permanently and continuously marked at a minimum of every 24 inches on the jacket of the cable.

2.3.10. PACKAGING

The cable ends shall be sealed with a heat-shrinkable cap to prevent water or moisture intrusion. Reels shall be non-returnable. All reels shall be labeled with purchaser's name, address, purchase order number, name of supplier, full cable description per 2.3.10 above, manufacturer's reel number, weight of reel and starting and ending sequential footage numbers.

2.3.11. WARRANTY

The cable specified shall be warranted for 40 years defects in materials and workmanship when installed in accordance with manufacturer's specifications. This warranty shall include a provision for labor cost reimbursement for a failure during the first 40 years after the cable installation.

2.3.12. MANUFACTURER

Single-conductor, ethylene-propylene-insulated, polyethylene-jacketed, shielded cable shall be manufactured by Okonite, Kerite or Prysmian and conform to ICEA S-108-720 and AEIC CS9.

Approved Manufacturers:

Okonite Kerite (Marmon Utility) Prysmian

2.4. SPLICES

Provide heat shrink splice kits which are the product of a single manufacturer. Ensure the power cable splice meets the requirements of IEEE 404 for a 69 kV rating and must be rated by the manufacturer for use on 69 kV class cable systems. Ensure splices are rated for continuous operation at 221 degrees F, with an emergency overload temperature rating of 284 degrees F. Ensure the kit is capable of splicing cables with copper conductors sized as indicated in the contract drawings or accommodate a conductor size transition. Provide splices specifically designed for the cable and grounding provisions.

Provide heat shrink splices which include but are not limited to the following:

2.4.1. Inner heat shrink stress control tube with external end sealant, additional heat shrink tube over inner tube and inner tube end sealant.

2.4.2. Heat shrink outer wraparound sleeve with heat sensitive indications on both the tube and rail/channel area to indicate proper torch heating, stress relief material, mastic, sealant, shielding mesh, and silicone grease.

2.5. TERMINATIONS

Terminations shall be Class 1 per IEEE Std 48.

2.6. CABLE SUPPORTS AND FITTINGS

See Section 33 71 02.00 UNDERGROUND ELECTRICAL TRANSMISSION for Cable supports, related fittings, and accessories.

2.7. CABLE TAGS IN FEEDER PULL BOXES AND AT TERMINATIONS

Provide tags for each cable or wire located in feeder pull boxes and at each termination.

2.7.1. Polyethylene Cable Tags

Provide tags of polyethylene that have an average tensile strength of 4500 pounds per square inch; and that are 0.035-inch thick, non-corrosive non-conductive; resistive to acids, alkalis, organic solvents, and salt water;

and distortion resistant to 300 degrees F. Provide a one-piece nylon, self-locking tie at each end of the cable tag. Ties shall have a minimum loop tensile strength of 175 pound. The cable tags shall have black letters, numbers, and symbols 1 inch high on a yellow background. Letters, numbers, and symbols shall not fall off or change positions regardless of the cable tags orientation.

2.8. FIREPROOF TAPE

Fireproof tape shall be approximately 30 mils thick by 3 inches wide. The tape shall consist of a flexible, unsupported elastomer that expands in fire to provide a thick char buildup between the flame and the cable. The tape shall not give off a smoke when subjected to flames or support combustion. The tape shall not deteriorate when subjected to oil, water, gases, salt water, sewage and fungus.

3. EXECUTION

3.1. INSTALLATION

High-voltage cables shall be installed in accordance with NFPA 70.

The 600V 4/0 copper cable shall be connected to all system grounds.

The Contractor shall notify the Owner 7 working days prior to testing for phasing and phase rotation of 69 KV high voltage electrical systems. The Contractor shall identify and tag the phasing at equipment and shall provide to the JEA Project Manager in writing, the results of phasing and phase rotation tests. The Contractor shall be responsible for maintaining the phasing and phase rotation tests. The Contractor shall be responsible for maintaining the phasing and shall match the existing phase rotation and phasing when installing conductors in existing electrical systems.

Cable shall be installed in conduit above and below grade; on racks; and in manholes.

3.1.1. Duct Cleaning

Ducts shall be thoroughly cleaned before installation of power cables. A standard flexible mandrel shall be pulled through each duct to loosen particles of earth, sand, or foreign material in the line.

3.1.1.1. PVC Duct

Mandrel length shall be not less than 12 inches long and shall have a diameter 1/2 inch less than the inside diameter of the duct. A brush with stiff bristles shall then be pulled through each duct to remove the loosened particles. Brush diameter shall be the same or slightly larger than the diameter of the duct.

3.1.2. Pulling Cables in Ducts and Manholes

A pulling plan shall be submitted. The pulling rope shall be of adequate strength to exceed pulling calculations.

High-voltage cables shall be pulled into ducts with equipment designed for this purpose, including power-driven winch, jamb skid, cable-feeding flexible tube guide, long radius quadrant block cable pulling sheaves, pulling eyes, and lubricants. A sufficient number of trained personnel and equipment with two-way radio communication capability shall be employed to ensure the careful and proper installation of the cable.

Cable reel shall be set up allowing the cable to enter through the opening without reverse bending. Flexible tube guide shall be installed through the opening in a manner that will prevent the cable from rubbing on the edges of any structural member (feeder pull box, duct, etc.).

Two long-radius (30 inches minimum) quadrant block cable pulling sheaves and necessary jamb skid support shall be used at the pulling end to ensure that sidewall pressures during pulling will not be excessive. A dynamometer shall be used in the pulling line to ensure that the pulling force is not exceeded. The pulling force shall not exceed the smaller of allowable tension on pulling device, allowable tension on cable, or the tension which produces the allowable sidewall pressure. The allowable tension on the pulling device is 6500 pounds for pulling eyes. The allowable tension on cable shall not exceed the value computed from the following equation:

TM = X N X CM

Where: TM = maximum allowable pulling tension in pounds

N = number of conductors in the cable (N=2, not 3, for parallel pulls)

CM = cross-sectional area of each conductor in circular mils

The allowable sidewall pressure is the smaller of 1000 pounds per foot of bend radius or the cable manufacturer's recommended maximum value. The pulling plan submittal shall show the calculations for allowable tension and sidewall pressure as well as the anticipated tension and sidewall pressure for each pull in the project.

Cable shall be unreeled from the top or bottom of the reel. Payout shall be carefully controlled. Cable to be pulled shall be attached through a swivel to the main pulling wire by means of a pulling eye installed by the factory.

Pulling eyes shall be attached at the factory to each of the cable conductors.

Minimum bending radius during cable pulling operations shall be 60 inches. For permanent cable bending/racking the minimum bending radius shall be 12 times cable diameter.

Cables shall be liberally coated with Polywater NN (or approved equal) cable-pulling lubricant as it enters the tube guide or duct. Grease and oil lubricants shall not be used. Cables shall be covered with wire-pulling compounds which have no deleterious effects on the cable. Rollers, sheaves, or tube guides around which the cable is pulled shall conform to the 60 inches minimum bending radius of the cable during the pulling operations. Cables shall be pulled into ducts at a speed not to exceed 50 feet per minute and not in excess of maximum permissible pulling tension specified by the cable manufacturer. Cable pulling using a vehicle shall not be permitted. Pulling operations shall be stopped immediately with any indication of binding or obstruction and shall not be resumed until such difficulty is corrected. Sufficient slack shall be provided for free movement of cable due to expansion or contraction.

Cables in manholes shall be racked as shown on the drawings, and firmly supported on cable racks as indicated.

Cables cut in the field shall have the cut ends immediately sealed to prevent entrance of moisture with heat-shrinkable molded cable end caps. Tape is not acceptable.

3.1.3. Terminations

Cables shall be terminated in approved cable terminations, rated Class 1 per IEEE Std 48. Terminations shall be provided with adequate means for making external connections to the cable conductors of single-conductor cables; protecting the cable insulation against moisture, oil, or other contaminant; physically protecting and supporting cables, and maintaining the insulation level of the cable.

Terminations shall be field fabricated from termination kits and in accordance with the termination manufacturer's recommendations for the type, size, and electrical characteristics of the cable.

Installation shall include built-up or prefabricated heat shrink stress-relief cones at the terminals of all shielded cables.

3.1.4. Termination and Splice Certification

The Contractor shall secure the services of the manufacturer of the termination and splice kits being used during the installation of this project to witness, examine and test, and to certify the competence of the technicians performing terminations and splices. The certification shall confirm in writing that the installer has constructed the terminations and splices in accordance with the manufacturer's approved training and/or installation instructions. The certification shall be for a specific time period determined by the manufacturer.

Certification for various types of terminations that may be used on the project shall include but not be limited to the following - single conductor 69 kV EPR terminations.

3.1.5. Fireproofing

Provide fireproofing (Arc Proofing) for individual cable conductor in feeder pull boxes.

Tightly wrap strips of fireproofing tape around each cable spirally in half-lapped wrapping. The tape shall extend 1 inch into the ducts. To prevent unraveling, random wrap the fireproofing tape the entire length of the fireproofing with pressure-sensitive glass cloth tape.

3.1.6. Cable Tag Installation

Install cable tags in each feeder pull box and at each termination as specified. Install cable tags over the fireproofing and position the tags so that they are clearly visible without disturbing any cabling or wiring in the manholes and equipment.

3.2. FIELD TESTING

After the installation of power cables has been completed, including terminations, and before the cable is energized, each high voltage cable shall be subjected to field testing in accordance with NETA ACCEPT, NETA MAINT and the following requirements.

Test equipment, labor, and trained technical personnel shall be Contractor provided as necessary to perform the electrical acceptance tests.

The Contractor shall provide Cable Test Report forms prior to commencing Field Testing. All tests shall be recorded on forms.

Arrangements shall be made to have tests witnessed and approved by the Owner and Manufacturer.

Each power-cable installation shall be completely isolated from extraneous electrical connections at cable terminations. Safety precautions shall be observed.

Each power cable shall first be given an insulation resistance test using a megohmmeter with a voltage output of at least 2,500-volts. Test shall be applied for a long enough time to fully charge the cable (no less than one minute).

Readings shall be recorded as indicated on forms provided. Minimum reading shall be 5000 megohms at an ambient temperature of 68 degrees F. Readings taken at other than 68 degrees F ambient temperatures shall be corrected accordingly.

Upon successful completion of the insulation resistance test, the cable shall be subjected to a Very Low Frequency (VLF) AC high potential test. General VLF testing measures, parameters, considerations, and results shall adhere to the following:

3.2.1. Test voltage duration shall be continuous duty for 30 minutes (non-interrupted), per each phase of the cable installation.

3.2.2. The Contractor shall provide the test equipment and acceptable test form to test the cable capacitance in microfarads and record on a High Voltage AC Hi-pot test form (VLF).

3.2.3. The Contractor shall provide Tan Delta (TD) in accordance with Section 5.4 of IEEE 400.2.

3.2.4. The Contractor shall provide the test equipment to generate the test voltages required for the 30 minute test duration and adhere to the following table:

VLF Test Voltage for sinusoidal waveform

Cable Rating Acceptance phase to phase (phase to ground test values)

(New cable)

(rms voltage, KV) (peak voltage, KV) 69 119

3.2.5. The sinusoidal test frequency shall be 0.1 Hertz.

3.2.6. The test shall not be performed on cable attached to equipment.

NOTE: Acceptance test values to include but not limited to peak voltage, frequency and duration with respect to the cable rating shall be identified on the test submittal, with pass/fail results identified per cable installation. Reference IEEE Std 400.2

Terminations shall be clean and dry and shall be tested per IEEE Std 48. Radiographic tests shall be performed on all terminations at the discretion of the Owner to determine if voids exist in the termination. Unacceptable cable, terminations shall be reworked at no additional expense to the Owner.

3.3. EXCEPTIONS

Any exception taken to this specification must be specifically stated as an exception to the specification and submitted with the quotation. Failure to comply with requirement will be cause for disqualification of the quotation.