750 MCM EPR CABLE SPEC June 2020 381019swk.pdf

#750 EPR Insulated Medium Voltage Power Cable Page 1 June 2020

TECHNICAL SPECIFICATION FOR

#750 MCM EPR INSULATED MEDIUM VOLTAGE POWER CABLE

A SCOPE

A. 01 INCLUDED: This Specification details the requirements for 15 kV, solid dielectric, ethylene propylene rubber insulation, triplexed aluminum cable with jacketed concentric, copper, neutral conductors. Cable shall be suitable for use on 13.8 kV, 60 hertz, solidly grounded systems.

A. 02 CONDUCTOR SIZE: Refer to the purchase order for the conductor sizes and quantities. Reel lengths given are subject to change. Final lengths of each reel must be approved prior to manufacture.

A. 03 INSTALLATION: Cable shall be suitable for installation in wet or dry locations, in an underground duct distribution system or direct buried in earth.

B CONDITIONS

B. 01 APPLICABLE STANDARDS: The publications listed below form part of this Specification. Each publication shall be latest revision and addendum in effect on the date of subcontract award, unless noted otherwise. Except as specifically modified by the requirements specified herein, the work included under this Specification shall conform to the provisions of these publications:

a. AEIC (Association of Edison Illuminating Companies).

b. ANSI (American National Standards Institute)

c. ASTM (American Society for Testing and Materials).

d. ICEA (Insulated Cable Engineers Association).

e. NEMA (National Electrical Manufactures Association).

f. NFPA (National Fire Protection Association)

1. NFPA 70 (National Electric Code)

g. The Wire Association International "Electrical Wire Handbook."

Should a conflict occur between the above referenced standards, the AEIC standard will prevail.

Any conflict, however, shall be brought to the attention of Fermilab.

This Specification shall be the operative norm where it exceeds the listed standards.

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B. 02 SUBMITTALS:

a. Complete set of exceptions shall be submitted with the proposal and as follows:

1. Exceptions shall be specifically outlined, clearly explained, and supported with the necessary details, drawings and data.

2. Any exceptions shall be cross referenced to the Specification and Specification paragraph number.

3. Should no exceptions be taken to the Specification, a statement shall be provided indicating that no exceptions to the Specification are taken.

b. Complete shop drawings shall be submitted for review in accordance with provisions included hereafter, showing compliance with all provisions of this Specification. The submittal schedule for these and other related documents is as follows:

Required Document Submittal Date

1. Exceptions to the Specification With Proposal

2. Cable Construction Information With Proposal

3. Cable Data and Information With Proposal

4. Cable Test Procedures With Proposal

5. Statement of Compliance With Proposal

6. Proposed Steel Reel Sizes With Proposal

7. Recommended cable testing procedure With Proposal upon receipt by Fermilab.

8. Recommended cable testing procedure With Proposal after 5 years service

9. Quality Assurance Program With Proposal

10. Warranty Period and Coverage With Proposal

11. Cable Construction Drawings 30 Days ASA

12. Final Cable Reel Lengths Prior to Manufacture

12. Certified Test Reports Prior to Shipment

13. Actual Shipping Length Report With Shipment

ASA - After Subcontract Award

The above listed drawings shall be submitted to Fermilab for Review. Five (5) working days shall be provided for Fermilab review of the drawings.

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c. Supplier shall submit suitable electronic files of shop drawings as called for under the various headings of this Specification.

1. Supplier shall indicate, by signed stamp on the drawings, that the shop drawings have been checked for correctness, the work shown is in accordance with the subcontract requirements and that the drawings are dimensionally correct. These drawings shall contain all required detailed information.

2. Shop drawings which relate to a complete assembly, structure or system with various parts shall not be submitted until all drawings required to completely detail that assembly structure or system are complete, so that the drawings may be reviewed in relation to each other.

d. Shop drawings shall be transmitted along with the form "Material Submittal for Approval" identical to the form attached. The form shall be completed in its entirety with each drawing or exhibit listed separately.

e. Fermilab will review the submittal documents for compliance with this Specification and will indicate approval or disapproval thereon.

1. If the submittals are "Approved as Submitted," Fermilab will return the submittal to the Supplier who, in turn, shall be responsible for distributing to his organization.

2. If the submittals are "Approved with Comments," Supplier shall revise the shop drawings to reflect the comments and resubmit following the procedure as described above. Fermilab, however, may clearly indicate that resubmittal of the documents is not required. Supplier may proceed with fabrication or manufacture, but shall not erect or assemble the equipment until the shop drawings have been resubmitted and approved by Fermilab.

3. If the submittals are "Disapproved," the reason will be indicated and returned to the

Supplier who shall expeditiously revise the submittals to comply with the Specification requirements. Supplier shall resubmit following the procedure as described above.

Approval of the submittal documents by Fermilab shall not relieve the Supplier from meeting any of the requirements of this Specification.

f. Each submittal shall have the following information clearly marked:

1. Medium Voltage Power Cable.

2. The name of the Contractor - Fermi National Accelerator Laboratory

3. The name of the Supplier.

g. Catalog cuts and brochures are acceptable material for submittal for review and are to be submitted as prescribed in the above procedure for shop drawings.

B. 03 QUALITY ASSURANCE:

a. Only firms regularly engaged in the manufacture of cable assemblies and who have cable assemblies in satisfactory use in similar service for at least fifteen (15) years shall be considered acceptable manufacturers. Only the following manufactures will be considered:

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1. Okonite

2. Prysmian

3. Southwire

b. Manufacturer shall maintain a Quality Assurance program during the fabrication and assembly of cable assemblies. All quality inspection records signed by the Quality Control Inspector shall be available for Fermilab's review. Fermilab reserves the right to visit and inspect the manufacturing operation.

c. Manufacturer shall submit a copy of the quality assurance program with proposal to ensure a product of highest quality will be provided.

d. Insulation compounding shall be done at the cable assembly facility in an enclosed environment to prevent contamination.

B. 04 PRODUCT DELIVERY, HANDLING AND TAGGING: Upon successful completion of testing and inspection requirements described herein, delivery shall be made according to the following:

a. Cables not meeting this specification shall not be shipped by the Supplier. Cables shipped which are found not in compliance with this specification will be rejected by Fermilab and returned, at no cost to Fermilab, to the Supplier.

b. Cables shall be shipped on returnable steel reels. Steel reels shall have a maximum outside width of 69 inches. The supplier shall be responsible for loading of exchange reels at Fermilab.

c. Cables shall be furnished on reels with lengths as specified. Cable furnished in lengths shorter than specified, will be rejected and cable furnished in lengths longer than specified shall not result in any additional charges to Fermilab.

d. Cable shall be shipped in one continuous length per reel.

e. Heat shrinkable, watertight seals shall be furnished to all cable ends.

f. Each cable reel shall be provided with a permanent tag on each flange with the identification number that appears on the test reports.

g. Each reel shall be permanently marked on both the inside and outside of one reel flange with the manufacturers name, cable length, designation, weight, footage markers, and Fermilab purchase order number and date of shipment.

h. The cable manufacturer shall indicate the firm cable delivery date in calendar days after receipt of order (to Fermilab's receiving dock).

C. MATERIALS

C. 01 RATINGS:

a. Cable assemblies shall operate on a 13.8 kV (phase-to-phase), 60 hertz, wye connected, solidly grounded system.

b. Cable shall be rated 15 kV.

C. 02 CENTER CONDUCTOR:

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a. The center conductor shall be uncoated, electrical grade aluminum alloy 1350, three-quarter hard drawn, H16 Grade temper meeting the requirements of ASTM for tensile, elongation and brittle requirements.

b. The conductor shall be concentric lay Class B stranding with 1% to 3% compressed concentric lay.

c. Compatible semiconducting, high viscosity compounds shall be used to completely fill the interstices of the stranded conductors.

d. The conductor shall have a minimum tensile strength as prescribed by ASTM standards.

e. Splicing of conductors is strictly prohibited. Cables shall be shipped in continuous unspliced lengths.

C. 03 STRESS CONTROL LAYER (CENTER CONDUCTOR SHIELD):

a. Center conductor shield shall be extruded, conducting or preferably non-conducting, thermosetting compound with a minimum average thickness of 18 mils. Supplier shall distinguish at the time of bid whether the center conductor shield is conducting or non-conducting.

b. Stress control layer material shall be compatible with conductor and insulation materials.

c. Stress control layer material shall have an allowable operating temperature at least equal to that of the insulation system.

d. Stress control layer shall be bonded to the overlying insulation yet be easily removed from the conductor without leaving residues.

C. 04 INSULATION:

a. The insulation shall be ethylene propylene-rubber resistant to heat, moisture, impact, ozone and discharge.

b. The insulation system shall be suitable for a minimum continuous conductor temperature of 90°C, an emergency temperature of 130°C and short circuit temperature of 250°C. At the time of quotation, the cable supplier shall clearly indicate the cable thermal specifications (continuous, emergency, and short circuit) of the product they are proposing.

c. The minimum average thickness of the insulation shall be 175 mils.

d. Insulation physical and electrical properties shall be in accordance with ICEA Paragraph

3.6 (Type 1 Insulation).

e. Insulation shall contain no polyethylene compounds.

C. 05 INSULATION SHIELD:

a. The insulation shield shall be an extruded thermosetting semiconducting compound.

b. Insulation shield physical and electrical properties shall be in accordance with AEIC requirements.

c. Insulation shield shall be free-stripping leaving no conducting particles or residue on the insulation surface.

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d. Insulation shield shall be identified as being conductive.

C. 06 CONCENTRIC NEUTRAL CONDUCTORS:

a. Concentric neutral conductors shall be solid, bare, annealed, uncoated, round copper spirally applied over the insulation shield with uniform spacing between wires.

b. Concentric neutral conductors shall be provided in accordance with ICEA S-68-516 Table

7.6.5 and twenty-four (24) #12 AWG conductors shall be provided for 750 MCM nominal concutor center size.

c. The concentric neutral spacing shall be uniform with the length of lay not less than six (6) nor more than ten (10) times the diameter over the concentric wire layer.

C. 07 JACKET:

a. A non-conducting encapsulating linear, low-density, polyethylene jacket shall be provided over the concentric neutral conductors.

b. Jacket shall be in accordance with ICEA and AEIC Standards.

C. 08 IDENTIFICATION:

a. All cable shall be identified on each conductor by means of surface printing to indicate:

1. Manufacturer's name.

2. Cable size.

3. Insulation type and thickness.

4. Voltage rating.

5. Year of manufacture.

6. Sequential footing marking.

7. Phase – A, B or C

C. 09 TESTING AND QUALITY ASSURANCE FOR EACH REEL: All testing as noted in this section pertains to factory tests conducted at the time of manufacture. Results of these tests will be made available to the Fermilab Standards Engineer prior to the shipment of cable reels as noted in Appendix II requirements to the supplier.

a. Insulating shield stripping tests:

1. The semiconducting or non-conducting material shall be cut longitudinally using a scoring tool radial depth of one (1) mil less than the minimum point. A second parallel cut shall be made radially 1/2" from the first cut. The shielding shall be removable for 12" of length without tearing or leaving conducting material on the insulation. Stripping tension shall be 20 lbs. (maximum).

b The completed cable shall be tested in accordance with Sections E and F of AEIC CS6 for ac voltages only.

1. The partial discharge shall be 5 pC or less for all voltages. Manufacturer shall provide X-Y plots as part of the certified test reports or the cable insulation shall be qualified using the ASTM D2275-89 "Standard Test Method for Voltage Endurance

#750 EPR Insulated Medium Voltage Power Cable Page 7 of Solid Electrical Insulating Materials Subjected to Partial Discharges (Corona) on the Surface".

c. An inspection shall be made and reported for the surface of each conductor to assure that the outer surface of the conductor is clean and free of water blocking compound or any foreign matter.

1. A water penetration test shall be made for each shipping reel to assure that each stranded conductor is properly filled with an approved water blocking compound.

2. Test results for water penetration tests and inspection of conductor surface shall be included as part of the certified test reports.

d. A water migration test shall be provided at least once for each cable shipment or at intervals of each 25,000 conductor feet as an on-going performance indicator of the longitudinal water blocked jacket. Results shall be included as part of the certified test report.

e. Certified test reports shall be forwarded with each reel and shall include oscillograms, test reports, and drawings required to comply with this Specification.

f. Fermilab reserves the right to witness all testing, and shipment commitments shall allow five (5) days for advance notification.

D. WARRANTY

D. 01 RESPONDERS TO REQUEST FOR QUOTATION: In reply to Fermilab's request for quotation, Suppliers shall respond to the terms and conditions of AEIC CS6 for cable being proposed to include warranty period and coverage. Cable shall be designed and manufactured to provide a life expectancy for a minimum 40 year period commencing upon delivery to Fermilab. The Supplier shall clearly indicate the cable manufacturer's inclusive warranty period and conditions for the cable being supplied to Fermilab.

Replacement costs associated with premature cable failure due to inadequate design or faulty manufacturing shall be the full responsibility of the Supplier.

D. 02 WARRANTY CABLE REPLACEMENT: The following describes the special conditions associated with a cable failure and warranty replacement. It is intended as a guideline should a cable fault occur and Fermilab determines that it may have resulted from a manufacturing defect.

a. Definition of a cable segment:

1. A cable segment is a single or triplex cable from the termination point on one end to the termination point on the other end.

2. A stand alone single-faulted cable or a single-faulted cable within a triplex bundle that may be direct buried, in PVC conduit, or in a ductbank.

3. If a single conductor of a triplex group has faulted, then the entire triplex bundle (a triplex cable section) is considered failed at that point due to thermal stresses.

b. Test of faulted segment:

1. When a cable segment has failed, Fermilab will remove the faulted section. This faulted segment will be sent by Fermilab to an independent testing laboratory for analysis.

2. The independent test laboratory will test the faulted cable segment to determine why the cable failed. If the failure is determined to have resulted due to a manufacturing

#750 EPR Insulated Medium Voltage Power Cable Page 8 failure in the insulation or protective jacket, cable replacement by the manufacturer will be handled as noted in (c) below.

c. Cable replacement by the manufacturer:

1. A cable segment determined to have faulted because of a manufacturing defect will be replaced in its entire segment length (single or triplex) by the cable manufacturer.

This replacement will include all costs associated with manufacturing, manufacturer's required testing, cable reel, and delivery charges (i.e., f.o.b.

Fermilab shipping dock).

E. SUPPLEMENTARY SPECIFICATION

E. 01 ICEA/NEMA Standards Publication for Ethylene-Propylene-Rubber-Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy, ICEA Publication No. S-68-516, NEMA Publication No. WC8.

E. 02 NEMA Standards Publication for Wire and Cable Packaging, WC-26.

E.03 ANSI Standard C2, National Electric Safety Code.

E. 04 ANSI Standard C119.4, Connectors for Use Between Aluminum-to-Aluminum or Aluminum-to-

Copper Bare Connectors.

E. 05 ICEA Publication T-31-610, Guide for Performance Of a Longitudinal Water Penetration Test for

Sealed Conductor.