Professional Documents
Culture Documents
MEDIUMVOLTAGEPOWERCABLES
ANDACCESSORIES
2011InternationalConferenceofDobleClients
Thursday,March31,2011
7:30AM12:00PM
WestinCopleyPlaceHotel
AmericaNorth,4thFloor
Insulated Cable
Engineers Association
(ICEA)
Standards Review
I. Overview of ICEA
Energy Division Power Cable Section
II. Industry Wide Input & Standards Coordination
III. ICEA Cable, Test & Application Standards
That Apply To Power Cables
IV. Navigating The ICEA Website
Overview of ICEA
Composed strictly of engineers who are employed by
cable manufacturing companies.
These companies are sponsors of the association.
Members cannot be involved in sales, pricing or order placement.
IPCEA was formed in 1925 by a group of power cable engineers.
Evolved into 3 separate sections Control & Instrumentation
Cables, Power Cables & Portable Power Cables.
In 1979 Communication Cables were added and the name was changed
to Insulated Cable Engineers Association (ICEA).
Overview of ICEA
The organization was later reorganized into two Divisions
Energy Cables
Communications Cables
The Energy Cables Division retained
Control & Instrumentation (C&I)
Power
Portable
The Communication Cables Division was further subdivided into
Copper
Fiber
Overview of ICEA
The association meets quarterly in March, June, September
and December.
The association maintains a website at ICEA.net
The association is a Not-For-Profit organization whos sole
support is from member dues & fees and standards sales.
Since 1925 the objective has been to ensure safe, economical
and efficient cable systems utilizing proven state-of-the-art
materials and concepts.
Test Standards
Application Standards
About ICEA
The Insulated Cable Engineers Association (ICEA) is a professional
organization dedicated to developing cable standards for the
electric power, control, and telecommunications industries. Since
1925, the objective has been to ensure safe, economical, and
efficient cable systems utilizing proven state-of-the-art materials
and concepts. Now with the proliferation of new materials and
cable designs, this mission has gained in importance. ICEA
documents are of interest to industry participants worldwide, i.e.
cable manufacturers, architects and engineers, utility and
manufacturing plant personnel, telecommunication engineers,
consultants, and OEM'S.
ICEA is a "Not-For-Profit" association whose members are
sponsored by over thirty of North America's leading cable
manufacturers. The technical development work is performed in
four semi-autonomous Sections; namely, the Power, Control &
Instrumentation, Portable, and Communications Cable Sections. In
addition there are currently two very active major Technical
Advisory Committees, one for Telecommunications Wire and Cable
Standards (TWCS TAC) and another Utility Power Cable Standards
(UPCS TAC).
Back
Energy Documents
Back
AEIC (Cont)
Includes investor-owned, federal, state,
cooperative, and municipal systems
Associate members include organizations
responsible for technical research and for
promoting, coordinating, and ensuring the
reliability and efficient operation of the bulk
power supply system (e.g. EPRI).
AEIC Committees
Research
and Service
Power Apparatus
Power Delivery
Power Generation
Cable Engineering
Meter
Engineers
CEC Purpose
CEC Procedures
Goals:
Reaffirm,
PILC
High Pressure Pipe Type
CS3-90 Low Pressure Gas-Filled Type
CS4-93 Low and Medium Pressure Self-Contained
Liquid Filled Cable
CS31-95 Pipe Filling Liquids
CS2-97
10
11
CEC Guides
CS1
through CS4
CS2
CS9
CS8,
S-94-649, S-97-682
13
CS8,
CS1,
CS8
14
15
Specification for
Impregnated PaperInsulated MetallicSheathed Cable,
Solid-Type
11th
Edition, October
1990
Revision in progress
16
CS1-90 Scope
This specification applies to impregnated
paper-insulated, metallic-sheathed cable
of the "solid" type which is to be used for
the transmission and distribution of
electrical energy on electric utility systems.
Cables Rated 1 kV to 69 kV
17
CS1-90 Scope
18
Specification for
Impregnated Paper
and Laminated Paper
Polypropylene Cable,
High Pressure PipeType
6th
Edition, March
1997
Revision in progress
19
Specification for
Impregnated Paper
Insulated Metallic
Sheathed Cable, Low
Pressure Gas Filled-Type
3th
Revision
20
Specification for
Low and Medium
pressure SCLF
cable
8th
Edition,
January 1993
Revision in
progress
21
22
CS8-07 Scope
Supplements ANSI/ICEA S-94-649 and
S-97-682
This specification covers cables rated 546 kV, which are used for the distribution
of electric energy on electric utility
systems.
23
Industry
CS6
158
190
max
min
176
26
165
min
205
max
27
Example
Install two joints and a short piece of new
cable into section of failed old cable
Both cables 1000 kcmil 260 mil 25 kV
Old cable manufactured in 1979 to AEIC
CS5-79 Specification
New cable manufactured to ANSI/ICEA
Standard
28
AEIC
1645
ANSI/ICEA
95
X 1515
265
1665
120
1660
Z
1500
60
1550
1600
160
1650
1700
1750
1800
1850
Diameter in mils
29
30
10
31
CS9-06 Contents
General
Cables
Terminations
Joints
Sheath Bonding/Grounding Systems, Link Boxes, and
SVLs
Qualification Tests on System
Prequalification Tests on System
Electrical System Test After Installation
Quality Assurance
Shipping
Appendices (informative)
33
11
CEC Guidelines
In the early days of the cable industry, no
other guidelines were available within the
industry concerning cable operations,
installation, and maintenance.
CEC decided to begin developing some
guidelines for utilities to use.
34
35
12
37
CG6-05 Scope
This guide primarily covers temperatures
limits for extruded dielectric cable in
underground installations.
Some guidance is provided for other
applications such as aerial installations
and riser pole applications.
38
39
13
CG5-05 Scope
Outlines the pulling parameters that need
to be considered when installing
underground power cable in duct.
Based on EPRI Project EL-3333
Maximum Safe Pulling Lengths for Solid
Dielectric Insulated Cables
Some sidewall pressure and tension
recommendations differ from those of
cable manufacturers
40
41
14
CG5-05 Contents
Cable Removal
Economic Considerations
Design Criteria and Pulling Limits
Pulling Tension Formulae
Sidewall Bearing Pressure Formulae
Sample Calculations
References
43
44
CG7-05 Scope
Covers extruded dielectric utility
distribution system cables rated 5-46 kV
Includes options for cable replacement
and cable life extension based upon
current options within the industry today.
45
15
CG7-05 Contents
Identifying Problem Cable Systems
Decision Making Tools
Selection and Implementation of Solution
or Corrective Action
Reliability and System Enhancements to
Reduce Cable Failures
46
47
CG8-10 Scope
Techniques and procedures that an
electric utility may use to establish a
quality assurance program for extruded
dielectric power cable
Helps to ensure that the utility consistently
receives cable with the characteristics it
desires
48
16
CG8-10 Contents
The Utility Cable Specification
Manufacturing Plant Audits
Cable Inspection and Testing
Keeping Records of Installation and
Operating Experiences
Outline of a Cable Specification
Manufacturer Questionnaire
Inspection List
49
50
CG9-00 Scope
Lead-covered cables have been in use for
over 80 years and have demonstrated
exceptional service reliability.
Two of the most common constructions in
use are paper-insulated lead-covered cable
(PILC) and lead-covered extruded-dielectric
cable.
51
17
52
53
CG9-00 Contents
Manholes
Cable Handling
Cable Installation in Duct and Direct Buried
Cable Accessories (Joints and Terminations)
Grounding
Identification and Installation Records
Inspection and Maintenance
54
18
55
CG10-10 Scope
This guide describes the various choices
that an engineer must consider when
developing a medium voltage (5-46 kV)
cable specification for utility use.
It is designed to acquaint the user with
those criteria necessary to ensure the
cable will perform as intended.
56
CG10-02 Contents
57
19
58
CG11-02 Scope
Replacing smaller PILC cables in existing,
space-limited infrastructure.
Provides general information to be used
when specifying and using cables with
reduced diameters.
59
CG11-02 Contents
Design Variables
Insulation
Jacket
Metallic Shield
(Flat Strap or
Longitudinally
Corrugated Tape)
Insulation
Shield
Center Conductor
Conductor Shield
60
20
Operating Conditions
Maximum
Conductor Temperatures
Operating Temperatures
Metallic Shield Short Circuit Rating
Ampacity Requirements
Emergency
61
Field Considerations
Duct
Clearances
Configurations
Terminations and Joints
Pulling Methods
Cable Handling
Proof Testing
Duct
62
63
21
CG12-05 Scope
This guide provides general information
that can be used to minimize the initial
purchase cost of extruded dielectric cable
rated 5-46 kV.
The variables allow the user to be aware of
some options to consider when attempting
to reduce the initial purchase cost of their
cable.
64
CG12-05 Contents
Design Variables
Insulation
Jacket
Insulation
Metallic Shield
Shield
(Concentric Neutral or
(Semicon)
Tape Shield)
Center Conductor
(Strand-filled)
Conductor Shield
65
66
22
Conclusions
Wikipedia.org
68
69
23
70
71
72
24
requirements
73
74
ANSI Scope
ANSI oversees the development of
voluntary consensus standards for
products, services, and processes in the
United States.
ANSI also coordinates U.S. standards with
international standards so that American
products can be used worldwide.
75
25
76
Connectors
Aluminum-to-Aluminum or
Aluminum-to-Copper
77
From
http://en.wikipedia.org/
Consensus Process A group decision
making process that not only seeks the
agreement of most participants, but also the
resolution or mitigation of minority objections.
78
26
79
80
81
27
82
IEEE Background
IEEE was formed in 1963
Power and Energy Society (PES)
(Formerly Power Engineering Society)
Main group of the IEEE PES that develops
standards for cables and accessories is
the Insulated Conductors Committee (ICC)
83
84
28
b.
NEC (Cont)
86
87
29
NESC (Cont)
NESC (Cont)
Applicable to the systems operated by
utilities, or similar systems and equipment of
an industrial establishment or complex
under the control of qualified persons.
NESC Abstract, 2007 Edition
Part 3 Safety Rules for the Installation and
Maintenance of Underground Electric
Supply and Communication Lines
Section
Section
33 Supply Cable
35 Direct-buried Cable
89
International Electrotechnical
Commission (IEC)
The IEC is a not-for-profit, nongovernmental international standards
organization that prepares and publishes
international standards for all electrical,
electronic, and related technologies
Instrumental in developing the International
System of Units (SI) (metric system)
90
30
IEC (Cont)
ANSI is represented on the IEC through
the US National Committee
IEC Technical Committee 20 is
responsible for Electric Cables
91
92
93
31
94
Publications or Guides
ICEA
P-32-382-2007 Short-Circuit
Characteristics of Insulated Cable
Test Methods
ANSI/ICEA
Standards
ANSI/ICEA
96
32
Background
Joe Zimnoch Jr
Sr Applications Engineer- Okonite
27 years
8 Years in HV Lab
Remainder in Application Engineering
Conductors -Purpose
Conductor
Semiconducting Strand Screen
Insulation
Semiconducting Insulation Screen
Metallic Shield
Protective Covering
Jacket / Armor
Conductor Terminology
Conductors
Conductivity
100%
Copper
61%
Aluminum
16.6%
Steel
15%
Tin
8%
Lead
108%
Silver
Shapes Class B
Concentric Compressed - Compact
Other Classes C,D,H, ..
Example
Thus for a solid #10 awg wire
Diameter = 0.1019 or 101.9 mils
CM area = (101.9)2 = 10,380 circular mils
AWG- American Wire Gauge
Conductors - Classes
500 mcm
Class B 37 wires (116.2 mils/wire)
Class C 61 wires (90.5 mils/wire)
Class H 427 wires (34.2 mils/wire)
Class I 1225 wires (20.1 mils/wire)
1/0
105,600
4/0
211,600
250 mcm
250,000
500 mcm
500,000
Conductors Class B
1
1+6=7
1 + 6 + 12 = 19
1x, 7x, 19x, 37x, 61x, 91x, 127x, etc
7 wires
19 wires
37 wires
#24-#2
#1 4/0
250-500 mcm
61 wires
750-1000 mcm
500 mcm (37 strand) Diameters Differences
0.813
0.788
(-3%)
0.736
(-10%)
NO Trapped
air
Rope Strand
350 kcmil
37 Ropes
24 wires/rope
37x34=888 wires total
1 wire OD=20 mils
202= 400 cm/wire
400 x 888=355 kcmil
Flex
Compressed
Compact
Round, C/R
Which is compact? A or B?
Which is compact? A or B?
A=Compact Conductor
A=Compact Conductor
(notice SQUARED strands
on left side of picture)
B=Compressed Conductor
(notice ROUNDED strands
on left side of picture)
B=Compressed Conductor
500
mcm
400
mcm
Diff
Length
3.53
3.00
-0.53
OD
1.06
0.965
-0.095
ID 0.841
0.767
-0.074
Wall 0.110
0.100
-0.010
Why?
Connectors are designed based on compression
ratio.
The compression ratio is the area of the
conductor (not counting the air gaps between
the strands) and the area of the connector
before and after the crimp.
The area of the conductor (again not counting
the air gaps between the strands) is the same
for both the compressed and compact
conductor.
Connectors for
Pre-Molded Accessories
( Elbows, Tee-Bodies, Splices, etc)
Shorter crimp length
Heavy wall of rubber
PULL DIRECTION
OD = 0.10
Area = 10, 380 circular mils
DC Resistance = 1 ohm/mft (copper)
Weight = 10 (or 31.4 lbs/mft)
Not
Not - Function: adverb Etymology: Middle
English, alteration of nought, from nought,
1 used as a function word to make negative
a group of words or a word
2 used as a function word to stand for the
negative of a preceding group of words <is
sometimes hard to see and sometimes not>
The Nots
You can determine the OD of 40 different sizes from
a #36 up to a 4/0. Using:
To determine the the OD of a #24, substitute 24 for n;
likewise for a #1, n = 1.
In order to determine the next larger size above #1
(remember there are 40 sizes) n = 0 (Or 1 zero aka
1/0).
Now for a 2/0 substitute n = -1, for 3/0 n = -2 and for
4/0 n = -3.
Calling the sizes -1,-2 and -3 does not play well, so
they are are called 1/0, 2/0, etc..
AWG Trivia
An increase of 1 AWG size
12.3% OD increase
26.1% Area increase
# 2 to #1 (solid)
257.6 mils * 1.123 = 289.3
66,360 cm * 1.261 = 83,680
Bobbins loaded w/drawn wire. Approx 600 lbs of wire per bobbin.
Bobbin
loaded
onto head.
Conductor Screen
EPR or XLPE
Insulation
Insulation Screen
Equal Terms
Discharge Resistant
Okonite
Company X
Company A
Company B
Vulcanizing
Curing
Cross-linking (XL)
Company C
Company D
Company J
Company F
Company G
Company H
Company M
Company J
Thermoset state
Thermoplastic
Can be melted back to liquid
Fair deformation resistance (memory)
Limited temperature rating (75C)
Thermoset
Cannot be melted back to liquid
Excellent deformation resistance (memory)
Higher temperature rating (90C to 105C)
Thermoplastic
Melts back to its
original liquid form
Thermoset burns
but never reverts
back to its
original liquid form
Thermoset
Ethylene Propylene Rubber (EPR)
Crosslinked Polyethylene (XLPE)
Tree Retardant Crosslinked Polyethylene (TR-XLPE)
Thermoplastic
Polyethylene (PE)
Polyvinyl Chloride (PVC)
PVC/Nylon
Insulation Thicknesses
Voltage
Rating
Insulation Thicknesses
100 %
133%
5 kV
(shielded)
15 kV
90 mils
115 mils
175 mils
220 mils
25 kV
260 mils
345 mils
35 kV
345 mils
420 mils
100 %
133 %
For 3 phase
systems
173%
Indefinite
Fault
Extrusion
Deformation process.
Shaping by pushing material through a die.
CYLINDER
DIE
RAM
ORANGEBURG
MANUFACTURING
CV Equipment
CV Curing Tube
CV Curing Tube
Curved
CV Curing Tube
Support Beam
Straight
Conductor
Conductor Screen
Insulation
Insulation Screen
CV Curing Tube
Curved to Accommodate
Catenary Shape of Cable
5 kV NS at 4160 volts
5 kV NS at 4160 volts
Discharge
from
phase-tophase
and
phase-toground
Shielding
Lead Sheath
Fault Capability
-10 cycles (kA)
18,974
3.22
20,494
3.48
25,100
4.26
5 Cu LCS, overlap
31,000
5.26
6 x 20 x 175 Cu Straps
26,738
4.54
32,870
5.58
45,197
7.67
73,959
12.55
103,423
17.55
511,100
86.74
SHIELD
CONDUCTOR
CURRENT FLOW
SHIELD
VOLTS
25 to 100 V
DISTANCE
GRAPHIC OF MULTI-POINT
GROUND
TRANSFORMER EFFECT OF
MULTI-POINT GROUND
SHIELD
CONDUCTOR
CONDUCTOR
SHIELD
SHIELD
VOLTS
CONDUCTOR
SHIELD
0V
DISTANCE
1-1/C 500 kcmil Cu, 220 Okoguard, 1/3rd Neutral Cables per 3
duct, 3 ducts 7.5 on center
THREE PHASE
4/0 ALUM
ANY VOLTAGE
ANY VOLTAGE
1/0 AWG AL
Ampacity Comparison
Single Point
vs.
Multi-point
Grounding
1/0 AWG AL
4/0
11 x #14 WIRES
- EQUAL TO 1/3RD
OF A 4/0 AL
Ampacity Comparison
1/C per Duct
vs.
3-1/Cs per Duct
(Both Multi-point grounded)
Source : NRECA
207
187
231
206
4/0 (1/3)
308
276
340
301
350 (1/3)
405
362
430
376
500 (1/3)
488
432
499
431
750 (1/3)
593
521
578
494
1000 (1/6)
698
609
666
570
Shield/Neutral Summary
Controls voltage stress in the insulation.
Some shields can also be used as a neutral.
Multi-point grounding recommended to
reduce shield voltage and for safety.
Shield must also be designed to carry the
available phase-to-ground fault current
The more copper in the shield, the greater
the circulating current depending on the
physical arrangement and load current.
Jackets
Cable Jacket Nonmetallic Outer Covering
of a Cable
Two Broad Categories: Thermoset and
Thermoplastic
For each application, the operating
temperature and environment must be
considered
PHYSICAL
CHEMICAL
TEMPERATURE
MOISTURE
AGING
FLAME
SMOKE
Thermoplastic
PE (Polyethylene HD, MD, LD, LLD)
PP (Polypropylene aka living hinge)
PVC (Polyvinyl Chloride)
TP-CPE (Thermoplastic-Chlorinated Polyethylene)
TPPO (Thermoplastic Polyolefin - low smoke zero halogentransit industry)
Thermoset
Neoprene (PCP - Polychhloroprene)
Hypalon (CSPE Chlorosulfonated Polyethylene)
(discontinued)
TS-CPE (Thermoset-Chlorinated Polyethylene)
XLPO (Cross Linked Polyolefin - low smoke zero halogentransit industry)
Factory Tests
DC Conductor Resistance
Insulation Resistance (Megger)
Shield Continuity
Corona (4 times operating; <5 pico Coulombs)
AC Withstand (200 v/mil, 5 minutes)
AC Withstand 5 Minutes
200 v/mil
Nominal
AC Test
Wall
Voltage
Thickness
(kV)
(mils)
5 kV-100%
90
18
5 kV-133%
115
23
5/8 kV-133/100%
140
28
15 kV-133%
175
35
15 kV-133%
220
44
25 kV-100%
260
52
28 kV-100%
280
56
25 kV-133%
320
64
28/35 kV-133/100%
345
69
35 kV-133%
420
84
200 v/mil x 220 mils = 44,000 v or 44 kV
Nominal Voltage
Rating
150%
200%
250%
30
55
80
1975
20
35
50
1982
20
35
50
1973
300%
400%
80
10
1996
Cable
Prep
80%
80%
Min/Max
(mils)
30/60
1.001-1.5
40/75
1.501-2.0
55/99
Cable Sizes
(conductor/insul thickness)
#2 to 3/0,220
#1 to 2/0, 260
4/0 to 750, 220
3/0 to 500, 260
1/0 to 350, 345
1000, 220
750 to 1000, 260
500 to 1000, 345
Min/Max
(mils)
24/60
1.001-1.5
32/60
1.501-2.0
40/75
Cable Sizes
(conductor/insul thickness)
#2 to 3/0,220
#1 to 2/0, 260
4/0 to 750, 220
3/0 to 500, 260
1/0 to 350, 345
1000, 220
750 to 1000, 260
500 to 1000, 345
32/60
1.5012.0
40/75
Cable Sizes
(conductor/insul
thickness)
#2 to 3/0,220
ICEA
#1 to 2/0, 260
now allows
4/0 to 750, 220
3/0 to 500, 260 24 mils
1/0 to 350, 345ALL SIZES
1000, 220
750 to 1000, 260
500 to 1000, 345
Question?
A
Pull Direction ?
A to B ?
B to A ?
Cradled
Triplexed or Triangular
and
Tension, Lbs
Conductor Size
No. of Conductors
AWG
Cir. Mils
n=1
n=2
n=3
66,360
530
1060
1595
83,690
670
1340
2010
0.008 is the maximum force per circular mil area that can be
exerted on the conductor without exceeding the tensile strength of
the conductor.
1/0
105,600
845
1690
2535
2/0
133,100
1065
2130
3195
3/0
167,800
1342
2684
4026
Examples
4/0
211,600
1693
3386
5079
250 mcm
250,000
2000
4000
6000
350 mcm
350,000
2800
5600
8400
500 mcm
500,000
4000
8000
10000
EXAMPLES
OF
COMPRESSION TYPE
PULLING EYES AND BOLTS
Pulling eye.
Pulling bolt.
750 mcm
750,000
6000
10,000
10000
1000 mcm
1,000,000
6000
10,000
10000
1250 mcm
1,250,000
6000
10,000
10000
1500 mcm
1,500,000
6000
10,000
10000
2000 mcm
2,000,000
6000
10,000
10000
Pipe Cable
Pull
3/C Common
Pulling Eye
Condux
Re-useable Pulling Eye
Completed
Tapping in Wedge
Line
Tensiometer
Sidewall Pressure
Simplified
For Single Conductor:
SWP = Tout/rbend
Expressed in Lbs/foot of radius
SWP on Rope
1000 LBS/1 ft=
1000 lbs/ft of radius
Kirk
1000 LBS
SWP on Rope
1000 LBS/10 ft=
100 lbs/ft of radius
George
1000 LBS
NEC fill limits were designed to prevent fire hazards. They did not
want an electrician installing 20 - #12 wires in a conduit and
creating a fire.
Insulation
Thkns
175 mils
220 mils
580 mils
508 amps
509 amps
510 amps
JR=2.8
JR=3.2
JR=2.8
JR=3.2
In Elongated Sweeps:
at 2.8 there is enough room for them to jam in the vertical direction
at 3.2 there is enough room for them to jam in the horizontal direction
Jamming
If the jam ratio falls between 2.8 and 3.2, it does
not mean the cables will automatically jam; it just
means there is a possibility of jamming.
The tendency to jam increases with pull length and
the number of bends. Both of these increase
tension.
Remember, each bend increases tension
significantly.
It is always better to set up a pull with the majority
of the bends closest to the feed location (reel).
Triplexed
Cable
Jam Ratio
and
% Fill
and
Weight
Correction
Factor, c
Coincidentally, percent
fill values between 29
and about 40% usually
land up in the 2.8 to 3.2
Jam Ratio range.
Straight Section
T=LxWxCxf
T = Tension at pulling eye (lbs)
L = Length of run (ft)
W = Weight of cable (lbs/ft)
C = Weight correction factor
f = Coefficient of friction
Straight Pull
Bends (Sweeps)
Incline
Vertical
Cradled = 1.44
Triangular = 1.22
C=1
C = 1.44
C = 1.22
D-d
1
Triangular: c =
d 2
1-
D-d
d=Cable OD
D=Conduit ID
Cradled:
Bends (Sweeps)
Friction between cable and duct increases as
cable traverses bend
Act as tension multipliers
Tension increases exponentially due to
change in direction
Analogy: Tension in household extension
cord increases as it is pulled around edge of
doorway
cfa
e
Tout = Tin
Tout = Tension out of the bend (lbs)
Tin = Tension into bend (lbs)
e = Naperian Log Base (2.7180)
f = Coefficient of friction
a = angle of bend (radians)
cfa
Values of e
For Conduit Bends
cf
0.30
0.35
0.40
0.50
0.60
0.85
30
1.17
1.20
1.23
1.30
1.37
1.48
45
1.27
1.33
1.37
1.48
1.60
1.80
60
1.37
1.45
1.52
1.69
1.88
2.20
90
1.60
1.74
1.88
2.20
2.57
3.25
Hi f
Hi C
90 Bend
Question?
A
Pull Direction ?
A to B ?
B to A ?
Answer - A to B
1000 lbs IN
cfa
Tout = Tin e
Tout =1000 lbs x (3.25
)
Tout = 3250 lbs
200
Quadrant block
Roller assemblies are
designed to fit
through the chimney
of the manhole.
Multi-wheel Sheaves
Larger Radii, can fit thru
MH openings
Model No.
HQB18R
HQB24R
HQB30R
HQB36R
HQB48R
HQB60R
Radius
18''
24''
30''
36''
48''
60''
Sheaves
5-6x5
6-6x5
5-12x7
5-12x7
6-12x7
7-12x7
Actual Radius
1 ft
4 inches
1.5 ft
7 inches
2 ft
10 inches
Swivels
Swivel Photo
Back-Out or Z-ing
Swivels that are part of the
Basket Grip do not spin
when tension is applied.
Z-ing
Z-ing
Z-ing
Z-ing
Z-ing
(knuckles)
No Loose Winds
Equipment
Elaborate
Reel Brake
Using
Disc Brake
Simple Reel Brake/Tensioner
18
Tree Cable
Tree Cable
Summary
Pull thru max number of bends as early as possible
(when possible).
Use sweeps with larger radius on difficult pulls to
minimize SWP .
Use plenty of lube.
Use BB Swivels.
Dispose of a few feet of cable adjacent to basket
grip.
If unsure of pull, perform a pulling tension calc in
both directions.
Available
as a binder
or CD
Pull-Planner
Cable Pulling
Software
Reel Trouble
Oops!!!
Conductor
The conductor is really a
resistor. If you put amps
thru it, heat will be
produced, but how much?
Conductor
Size
#10
1/0
1000
Aluminum
DC Resistance
@ 25C
(ohms/1000)
1.7
0.168
0.0177
Copper
DC Resistance
@ 25C
(ohms/1000)
1.04
0.102
0.0108
Watts/1000 ft
5660
5379
1104
Okoguard (EPR)
Dielectric Losses
0.00007
0.00514
Conductor Losses
5.66
5.66
Neutral Losses
5.379
5.379
Total Losses
11.03907
11.04414
Difference
% Difference
E = 0.0051 w/ft
Watts/ft
5.66
5.379
11.04
0.00507 watts/1000
--
+ 0.046/1000
3M Company
Sandy Cox
EMD Technical Service
1
3M 2008. All Rights Reserved.
Agenda
Termination Theory & Design Considerations
Splice Theory & Design Considerations
Installation What is critical?
2
3M 2008. All Rights Reserved.
3
3M 2008. All Rights Reserved.
4
3M 2008. All Rights Reserved.
5
3M 2008. All Rights Reserved.
6
3M 2008. All Rights Reserved.
7
3M 2008. All Rights Reserved.
8
3M 2008. All Rights Reserved.
9
3M 2008. All Rights Reserved.
10
3M 2008. All Rights Reserved.
11
3M 2008. All Rights Reserved.
12
3M 2008. All Rights Reserved.
13
3M 2008. All Rights Reserved.
Definition of a Termination
To terminate a shielded power cable
means to discontinue, or end, its
insulation shield.
Cable Shield Terminus
Stress Concentration
Near Cable Shield End
16
3M 2008. All Rights Reserved.
Electrical Stress
ELECTRICAL STRESS is the
concentration of electrical
potential (voltage) over a
defined distance.
TYPICAL UNITS: V/mil or kV/cm
Geometrical Stress-Control
A stress-cone is used to reduce the stress at the shield
discontinuity by extending the shield and gradually increasing
the thickness of insulation under the shield.
18
3M 2008. All Rights Reserved.
19
3M 2008. All Rights Reserved.
20
3M 2008. All Rights Reserved.
21
3M 2008. All Rights Reserved.
Insulation
K1
K 2 > K1
Tan
Tan
K2
K1
22
3M 2008. All Rights Reserved.
23
3M 2008. All Rights Reserved.
80%
80%
24
3M 2008. All Rights Reserved.
Tracking
Three conditions must exist in order for tracking to take place:
CONTAMINATION
MOISTURE
- Dust
- Humidity
- Chemicals
- Salt
- Other Airborne Particles
VOLTAGE
Fog
Condensation
Mist
Snow
Rain
Dew, or
Light Rain
Frost
UV
Cosmic Rays
Surface
Degradation
Rapid Changes
In Temperature
Differential
Thermal
Expansion
Temperature
Rise: Chemical
Degradation
Acceleated
Increased
Rapid Changes
In Temperature
Differential
Thermal
Expansion
Chemical Degradation
Surface Contamination
Hydophobicity Affected
Dust
Carbon Particles
Abrasion
Electric
Stress
Soluble Matter
SO 2, NH3, NO 2
Salt Spray
Surfacing Conduction
Heating & Evaporation
Dry Band Formation
Erosion
Surface Wets Hydrofillic
Heavy Rain
May Clean
Surfaces
Fog
High
Relative
Humidity
May
Reduce
Flashover
Voltage
Across
Insulators
Surface
Wets
Stress
Concentration
Surface Discharges
Hydrofillic
Flashover
Chemical Degradation
To Carbon
TRACKING
28
3M 2008. All Rights Reserved.
30
3M 2008. All Rights Reserved.
10
Silicone is Hydrophobic
31
3M 2008. All Rights Reserved.
32
3M 2008. All Rights Reserved.
2.
3.
4.
5.
33
3M 2008. All Rights Reserved.
11
34
3M 2008. All Rights Reserved.
35
3M 2008. All Rights Reserved.
36
3M 2008. All Rights Reserved.
12
37
3M 2008. All Rights Reserved.
Splice Theory
Splice design is totally different than termination
design
A splice moves the stress from cable to splice and
back to cable instead of trying to control the stress
as it enters the air
A splice basically rebuilds the cable layers
Considerations for the three main areas of a splice
electrode, insulation, and semi-con
38
3M 2008. All Rights Reserved.
Splicing
A splice can be defined as two or more conductors
joined with a suitable connector and reinsulated,
reshielded, and rejacketed with compatible materials
applied to a properly prepared surface.
39
3M 2008. All Rights Reserved.
13
40
3M 2008. All Rights Reserved.
41
3M 2008. All Rights Reserved.
42
3M 2008. All Rights Reserved.
14
Insulation
z
43
3M 2008. All Rights Reserved.
44
3M 2008. All Rights Reserved.
15
47
3M 2008. All Rights Reserved.
Insulation
Insulation thickness should be such that there will be
an average of about 30 to 40 volts/mil electrical
stress through the insulation
This will vary some with the dielectric constant of the
material and the cleanliness of the material
48
3M 2008. All Rights Reserved.
16
QSIII-5418 Connector
Temperature Profile
132
130
128
126
124
122
120
118
116
Conductor
61
49
53
57
37
41
45
25
29
33
13
17
21
112
114
Conductor
Peak reading/day
61 days
Conductor
Connector
Connector
49
3M 2008. All Rights Reserved.
Shield
Maintains continuity of the cable
shielding system
Electric field containment
Safety
Provides geometry for electric
field control
Ensures adequate ground path for
fault protection
Provides critical environmental seals
for the splice-cable interface
50
3M 2008. All Rights Reserved.
51
3M 2008. All Rights Reserved.
17
52
3M 2008. All Rights Reserved.
53
3M 2008. All Rights Reserved.
Connector growth
Crimping tools
Manufacturing tolerances
Bend in cable
54
3M 2008. All Rights Reserved.
18
56
3M 2008. All Rights Reserved.
Common Elements
Critical Issues
Conductor connections
Stress Control
57
3M 2008. All Rights Reserved.
19
Workmanship
Good cable preparation is the key to all accessories
performing properly
Dimensional tolerances are typically plus or minus
0.25 for most accessories.
Uniformity of shrinking is critical for electrical
performance.
Poor practices still persist even after many initiatives
58
3M 2008. All Rights Reserved.
Splices IEEE-404
Factory tests
Partial Discharge
1 min AC withstand.
59
CABLE PREPARATION
Medium Voltage
Shielded Power Cables
Dimension A
Tape Marker
Clean
Cable
Semi-con
Metallic
Shield
Cable Jacket
Conductor
O.D.
Primary
Insulation
60
3M 2008. All Rights Reserved.
20
61
3M 2008. All Rights Reserved.
62
3M 2008. All Rights Reserved.
63
21
64
3M 2008. All Rights Reserved.
65
3M 2008. All Rights Reserved.
66
3M 2008. All Rights Reserved.
22
67
3M 2008. All Rights Reserved.
3M is a trademark of 3M Company.
Important Notice
Before using this product, you must evaluate it and determine if it is suitable for your intended
application. You assume all risks and liability associated with such use.
68
3M 2008. All Rights Reserved.
3M Company
69
3M 2008. All Rights Reserved.
23