May 1998

Process Industry Practices

Electrical

PIP ELSWC01
Medium Voltage Power Cable - XLPE
 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these
technical requirements into a single set of Practices, administrative, application, and
engineering costs to both the purchaser and the manufacturer should be reduced. While
this Practice is expected to incorporate the majority of requirements of most users,
individual applications may involve requirements that will be appended to and take
precedence over this Practice. Determinations concerning fitness for purpose and
particular matters or application of the Practice to particular project or engineering
situations should not be made solely on information contained in these materials. The
use of trade names from time to time should not be viewed as an expression of
preference but rather recognized as normal usage in the trade. Other brands having the
same specifications are equally correct and may be substituted for those named. All
practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these practices or guidelines
should conflict with OSHA or other applicable laws or regulations, such laws or
regulations must be followed. Consult an appropriate professional before applying or
acting on any material contained in or suggested by the Practice.

©Process Industry Practices (PIP), Construction Industry Institute, The

University of Texas at Austin, 3208 Red River Street, Suite 300, Austin,
Texas 78705. PIP member companies may copy this practice for their
internal use.

Not printed with state funds.

 May 1998

Process Industry Practices

Electrical

PIP ELSWC01
Medium Voltage Power Cable - XLPE
Table of Contents

1. Introduction ..................................2 5. Inspection and Testing................ 6

1.1 Purpose..............................................2 5.1 Inspection and Testing Standards .....6
1.2 Scope .................................................2 5.2 Required Testing................................6
5.3 Optional Testing .................................7
2. References....................................2
2.1 Process Industry Practices (PIP) .......2 6. Shipping ....................................... 7
2.2 Industry Codes and Standards...........2 6.1 Cable Reel Identification ....................7
2.3 Conflict Resolution .............................3 6.2 Test Lead ...........................................7
6.3 Pulling Eyes........................................7
3. Definitions.....................................3 6.4 Preparation for Shipment ...................7

4. Construction.................................3 7. Documentation............................. 7
4.1 Conductors.........................................3 7.1 Documentation for Quotation .............7
4.2 Conductor Strand Shield ....................4 7.2 Documentation at Time of Shipping...8
4.3 Insulation............................................4
4.4 Insulation Shielding ............................4
4.5 Conductor Jacket ...............................5
4.6 Ground Conductor(s) .........................5
4.7 Fillers and Binder Tape ......................5
4.8 Armor Assembly.................................5
4.9 Outer Jacket.......................................5
4.10 Cable Identification.............................5
4.11 Cable Length Tolerance.....................5
4.12 Cable Approval...................................6

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PIP ELSWC01
Medium Voltage Power Cable - XLPE May 1998

1. Introduction

1.1 Purpose
The purpose of this Practice is to provide a specification for the purchase of 5 kV to
35 kV rated power cable for use in a petrochemical facility.

1.2 Scope
This Practice defines the minimum technical requirements for design, material,
construction, inspection, testing, and shipping of solid dielectric Cross-Linked
Polyethylene (XLPE) insulated copper cable. The scope includes 5 kV to 35 kV
single and multiple conductor shielded and 5 kV to 8 kV single and multiple
conductor non-shielded power cables.

2. References
All cable shall be designed, manufactured and tested in accordance with the applicable
sections of the latest edition of the following standards. Short titles will be used herein when
appropriate.

2.1 Process Industry Practices (PIP)

PIP ELSWC01D - Data Sheet for PIP ELSWC01, Medium Voltage Power
Cable - XLPE (completed for application)

2.2 Industry Codes and Standards

 Association of Edison Illuminating Companies (AEIC)

AEIC CS5 - Specifications for Cross-Linked Polyethylene Insulated Shielded
Power Cables Rated 5 Through 46 kV
 American Society for Testing Materials (ASTM)

ASTM B3 - Soft or Annealed Copper Wire

ASTM B8 - Concentric-Lay-Stranded Copper Conductors, Hard, Medium-
Hard or Soft

ASTM B496 - Compact Round Concentric-Lay-Stranded Copper
Conductors
 Insulated Cable Engineers Association (ICEA)

ICEA S-66-524 (NEMA WC7) - Cross-Linked Thermosetting Polyethylene
Insulated Wire and Cable for the Transmission and Distribution of
Electrical Energy
 Institute of Electrical and Electronics Engineers (IEEE)

IEEE 1202 - Flame Testing of Cables for Use in Cable Tray in Industrial
and Commercial Occupancies

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 PIP ELSWC01
May 1998 Medium Voltage Power Cable - XLPE

 National Electrical Manufacturers Association (NEMA)

NEMA WC26 - Wire and Cable Packaging
 National Fire Protection Association (NFPA)

NFPA 70 - National Electrical Code (NEC)
 Underwriters Laboratories

UL 1072 - Medium-Voltage Power Cables

UL 1569 - Metal-Clad Cables
2.3 Conflict Resolution
Any conflicts between the referenced documents shall be identified in writing to the
Buyer for resolution. In general, when resolving conflicts, the following order of
precedence shall apply:

 Purchase Order
 Data Sheet(s) PIP ELSWC01D
 This Practice PIP ELSWC01
 Other Referenced Specifications

3. Definitions
For purposes of this practice, the following definitions apply:

Filled Insulation: Cross-linked polyethylene insulation material that contains 10% or more of
carbon black and/or mineral fillers by weight

Tree: Tubular “tree-like” channels in solid organic insulation materials that result from
partial discharge (corona) and molecular decomposition in the region of very high, diverging
electric fields

Unfilled Insulation: Cross-linked polyethylene insulation material that contains up to 2-1/2%

carbon black by weight for cables rated up to and including 5 kV and no carbon black for
cables rated above 5 kV

4. Construction

4.1 Conductors
4.1.1 Conductor material shall be Class B, stranded, soft or annealed copper per
ASTM B3, ASTM B8, or ASTM B496 and configured as specified on the Data
Sheet.
4.1.2 Conductor diameter shall be in accordance with ICEA S-66-524.

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PIP ELSWC01
Medium Voltage Power Cable - XLPE May 1998

4.2 Conductor Strand Shield

4.2.1 Conductors shall be covered with an extruded layer of semiconducting
material compatible with the insulation and the conductor.
4.2.2 The minimum point conductor strand shield thickness and minimum average
insulation thickness shall be in accordance with Table D1 of AEIC CS5,
Section D.
4.2.3 The conductor strand shielding shall be in accordance with AEIC CS5,
Section D.2 and meet the resistivity requirements of AEIC CS5, Section D.4.
4.2.4 The conductor strand shield shall be inseparably bonded to the overlaying
insulation and shall be free stripping from the conductor.

4.3 Insulation
4.3.1 Insulation shall be manufactured from high quality, natural (unfilled) or tree
retardant (filled) cross-linked polyethylene compound, as specified on the
Data Sheet. The insulation shall be triple-tandem extruded with the
conductor and the strand shield to prevent interfacial contamination. It shall
be rated at 90 C for normal operation, 130 C for emergency overload
conditions, and 250 C for short circuit conditions. The insulation shall
conform to the requirements of the NEC 1996 Table 310-64.
4.3.2 Individual conductor phase identification shall be Manufacturer’s standard
unless specified otherwise on the Data Sheet.
4.3.3 Insulation thickness (level) for shielded cables shall be in accordance with
the 133% insulation level requirements of NEC 1996 Table 310-64, unless
otherwise specified on the Data Sheet. Insulation thickness for non-shielded
cables shall be in accordance with NEC 1996 Table 310-63 for wet and dry
locations.

4.4 Insulation Shielding

4.4.1 The cable shall be shielded when specified on the Data Sheet. Unless
otherwise indicated on the Data Sheet, the insulation shield shall consist of
an extruded semiconducting thermosetting compound directly over the
insulation, and a non-magnetic metal tape shield directly over the
semiconducting covering. Substitution of a nonmetallic semiconducting tape
for the extruded covering is not acceptable.
4.4.2 The extruded semiconducting covering shall be in intimate contact with the
insulation, but shall be easily removable without damaging the insulation
and shall leave no residue which cannot be readily removed.
4.4.3 The metal tape shall be minimum 5.0 mil bare, 12.5% minimum lapped
copper, unless otherwise specified on the Data Sheet. The tape shall be
applied helically and shall be continuous.
4.4.4 Grounding wires shall be supplied when specified on the Data Sheet.
Grounding wires shall be bare and shall be in contact with the insulation
shield to increase the short circuit capacity.

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 PIP ELSWC01
May 1998 Medium Voltage Power Cable - XLPE

4.5 Conductor Jacket

When specified on the Data Sheet, an inner jacket shall be provided over the
conductor assembly. Wall thicknesses and tolerances shall be as specified in
ICEA S-66-524, with the minimum wall thickness no less than 80% of the minimum
average thickness. Inner jacket material shall be PVC unless specified otherwise on
the Data Sheet.

4.6 Ground Conductor(s)

For multiple conductor cables, ground conductor(s) shall be supplied and shall be
Class B compressed, concentric stranded bare copper in conformance with ASTM B3
and ASTM B8 sized in accordance with Table 21.1 of UL 1072 - 1995, unless
specified otherwise on the Data Sheet.

4.7 Fillers and Binder Tape

For multiple conductor cables, the insulated single conductors shall be cabled
together with non-hygroscopic filler material and an overall binder tape.

4.8 Armor Assembly

For multiple conductor cables, a protective armor shall be provided when specified
on the Data Sheet. The armor shall meet requirements of UL 1569 for Type MC
cables.

4.9 Outer Jacket

4.9.1 An outer protective PVC jacket shall be applied over the completed cable
assembly unless otherwise specified on the Data Sheet.
4.9.2 Jackets for non-shielded cables shall conform to the discharge-resistant
jacket requirements of the referenced standards.
4.9.3 Wall thickness and tolerances shall be as specified in applicable ICEA and
UL standards, with the minimum wall thickness no less than 80% of the
minimum average thickness.
4.9.4 Cable and outer jacket shall be flame-retardant and shall meet or exceed the
requirements of IEEE 1202.
4.9.5 Outer jacket color shall be Manufacturer’s standard unless otherwise
specified on the Data Sheet.
4.9.6 Outer jacket shall be oil-resistant and UV-resistant according to UL 1072.

4.10 Cable Identification

The cable shall be marked and identified in accordance with NEC 1996 Article 310-
11 and AEIC CS5.

4.11 Cable Length Tolerance

The length of each segment of cable shall be minus 0% to plus 2%, unless otherwise
specified on the Data Sheet.

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PIP ELSWC01
Medium Voltage Power Cable - XLPE May 1998

4.12 Cable Approval

Cables shall be NEC Type MV, marked “Sunlight Resistant”, “For Use In Cable
Tray”, and for “Direct Burial” in accordance with UL 1072.

5. Inspection and Testing

5.1 Inspection and Testing Standards

Factory inspection and testing shall be performed on all cables in accordance with
the following standards:

 UL 1072
 AEIC CS5
 ICEA S-66-524
 IEEE 1202
5.2 Required Testing
5.2.1 All cables shall be free from moisture. Evidence of water within the cable
shall be grounds for rejection.
5.2.2 For shielded cables, each length of completed cable shall pass an AC test for
5 minutes at the test voltages listed in Table 1. Test voltage is to be applied
between conductor and the respective metal shield.

Table 1
Rated Insulation Insulation AC DC
Voltage Level Thickness Test Voltage Test Voltage

5 kV 100% 90 mils 18 kV 35 kV
5 kV 133% 115 mils 23 kV 45 kV
8 kV 100% 115 mils 23 kV 45 kV
8 kV 133% 140 mils 28 kV 55 kV
15 kV 100% 175 mils 35 kV 70 kV
15 kV 133% 220 mils 44 kV 80 kV
25 kV 100% 260 mils 52 kV 100 kV
25 kV 133% 320 mils 64 kV 120 kV
35 kV 100% 345 mils 69 kV 125 kV
35 kV 133% 420 mils 84 kV 155 kV

AC values per AEIC CS5-94, DC values per AEIC CS5-87

5.2.3 Each length of completed shielded cable shall be partial discharge tested per
AEIC CS5. The maximum partial discharge shall not exceed 5 picocoulombs
at a test voltage of up to 4 times rated voltage to ground.
5.2.4 A final dielectric test on the shipping reel shall be performed for all cables.

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 PIP ELSWC01
May 1998 Medium Voltage Power Cable - XLPE

5.3 Optional Testing

5.3.1 When specified on the Data Sheet, a preliminary tank test shall be performed
on all medium voltage, shielded cables. Each individual insulated length of
conductor after extrusion (conductor, conductor shield, insulation, insulation
shield), and prior to any further processing, shall be immersed in a water
tank for a minimum of twenty-four (24) hours. Prior to removal from the
water, each conductor shall be subjected to an AC test for five (5) minutes,
and to a DC test for fifteen (15) minutes at the test voltages specified in the
Table 1 of Section 4.2.
5.3.2 When specified on the Data Sheet, each length of completed shielded cable
shall pass a DC test for 15 minutes at the test voltages listed in Table 1 of
Section 5.2. Test voltage is to be applied between conductor and the
respective metal shield.

6. Shipping

6.1 Cable Reel Identification

6.1.1 Reel Identification Minimum reel identification and marking shall be in
accordance with AEIC CS5.
6.1.2 Additional reel identification shall be provided as indicated on Data Sheet.

6.2 Test Lead

For non-shielded cable, a minimum of two (2) feet of the inner end of the cable shall
be left out of the test hole to facilitate field testing on the reel. For shielded cable, a
minimum of three (3) feet of cable shall be required.

6.3 Pulling Eyes

When specified on Data Sheet, a factory installed pulling eye shall be provided.

6.4 Preparation for Shipment

6.4.1 Cable and cable reels shall be prepared for shipment in accordance with
AEIC CS5.
6.4.2 All cable ends shall be sealed with heat-shrinkable type protective caps
6.4.3 Protective coverings shall be in accordance with NEMA 26. When specified
on the Data Sheet, wood lagging shall be used.

7. Documentation

7.1 Documentation for Quotation

The following information shall be provided by the Seller with quotations:
1. Standard and maximum reel lengths
2. Diameter over inner sheath

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PIP ELSWC01
Medium Voltage Power Cable - XLPE May 1998

3. Diameter under armor or shield

4. Diameter over armor or shield
5. Overall diameter of complete cable assembly
6. Cable weight
7. Individual conductor diameter
8. Conductor DC resistance
9. Conductor AC resistance
10. Conductor inductive reactance *
11. Minimum bending radius
12. Maximum conductor continuous operating temperature
13. Cable current carrying capacity *
14. Cable short-circuit withstand capacity presented in graphical form or by
formula
15. Maximum pulling tension and sidewall loading for each cable assembly
16. Descriptive literature (catalogs, etc.)
17. Short-circuit current capacity of shielding tape for 0.5 second and 1.0 second
fault durations
18. Maximum allowable distance for shield grounding between insulation joints
to limit shield voltage to below 25 volts at full rated load
19. Derating of cable due to circulating currents in shields
20. Power losses in cable at full current carrying capacity
* Seller to provide nominal values for typical installation methods
such as tray, duct bank, individual metallic conduit in air, etc.

7.2 Documentation at Time of Shipping

The following information shall be provided to the Buyer at time of shipment:
1. Certified test reports
2. X-Y plot of the partial discharge test shall be supplied within 2 weeks after
shipment.

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