Customer Installations

Advice No. 1231 20/3/02

Doc. Ref.

TO: Customers, Service Providers and EnergyAustralia Staff.

11kV Polymeric Underground Cable

- Technology Transition Program
The purpose of this Customer Installations Advice (CIA) is to inform Accredited Service
Providers (ASPs) that EnergyAustralia will progressively change from paper-insulated lead-
covered (PILC) cable technology to polymeric (e.g. Ethylene Propylene Rubber (EPR), Cross
Linked PolyEthylene (XLPE)) cable technology for new 11kV underground Network
construction during 2002.
The new polymeric cables will be introduced on the following dates:
Single core substation cables: see below *
Urban / rural feeder cables: 1 July 2002
City feeder cables: 1 October 2002
The following have been chosen as the standard range of polymeric cables:

Item 11kV Polymeric Cable Transition Date

1a 70mm2 Cu Single Core EPR *
2b 185mm2 Cu Single Core EPR *
3b 300mm2 Cu Single Core EPR *
6a 95mm2 Al Three Core EPR 1 July 2002
7a 150mm2 Cu Three Core EPR 1 July 2002
8a 185mm2 Al Three Core EPR 1 July 2002
TBA City feeder cable TBA 1 October 2002
10a 300mm2 Al Three Core XLPE 1 July 2002
11a 400mm2 Al Three Core XLPE 1 July 2002
12 35mm2 Al Single Core EPR 1 July 2002
13 630mm2 Cu Single Core EPR *
* Partial transition by 1 July 2002; Full implementation by 1 October 2002.
Brief technical details of these polymeric cables are given in the Attachment to this CIA.

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Network Standards
The following Network Standards will be updated in time for the above transition dates:
NS 110 Specification for Design Standards for URD (Sydney)
NS 111 Specification for Design and Construction Standards for URD Subdivisions
(Newcastle and Upper Hunter Region)
NS 112 Design Standards for Commercial/Industrial Developments
NS 114 Electrical Design Standards for Chamber Type Substations
NS 129 Construction Standards for HV Cable Joints and Terminations
NS 130 Specification for UG Cable Laying
NS 142 Construction Standards for Kiosk Type Substations (Hunter)
NS 161 Specification for Testing of Cables after Installation
NS 156 Working Near or Around Underground Cables.
Interim Design/Construction Projects
It is recognised that ASPs may have design and/or construction projects planned or in process
during the transition program to polymeric cables.
The following table provides a convenient conversion guide between PILC cables currently in
use and the new polymeric cables.

11kV PILC/XLPE Cable Item New 11 kV Polymeric Cable

currently used
95mm2 Cu Single Core PILC
185mm2 Cu Single Core PILC
300mm2 Cu Single Core PILC
95mm2 Al Three Core PILC
185mm2 Cu Three Core PILC
240mm2 Al Three Core PILC
240mm2 Cu Three Core PILC TBA
300mm2 Cu Three Core PILC
300mm2 Al Three Core PILC
500mm2 Al Three Core PILC
35mm2 Al Single Core XLPE
630mm2 Cu Single Core PILC
630mm2 Cu Single Core XLPE
1000mm2 Cu Single Core PILC
1a 70mm2 Cu Single Core EPR
2b 185mm2 Cu Single Core EPR
3b 300mm2 Cu Single Core EPR
6a 95mm2 Al Three Core EPR
7a 150mm2 Cu Three Core EPR
8a 185mm2 Al Three Core EPR
City feeder cable - TBA
10a 300mm2 Al Three Core XLPE
11a 400mm2 Al Three Core XLPE
12 35mm2 Al Single Core EPR
13 630mm2 Cu Single Core EPR

The conversion guide should be used to substitute polymeric cables for PILC cables where
they can be accommodated in projects.
In particular, note that three core cable, Items 10a and 11a commonly used in Underground
Residential Developments (URDs) will have the cable termination consisting of a trifurcation
point into single core cables outside the kiosk substation in the trench. The termination will
effectively be three single core terminations.
Details of all joint and termination designs will be documented in revised Network Standards.

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Where bending radii and other cable installation parameters for PILC cables have already
been used in the design project and the substituted polymeric cables cannot meet the
requirements of the project, PILC cables should be used for construction.
Cable Supply
Current stocks of PILC cables at EnergyAustralias Warehouse are not expected to last much
beyond July 2002.
In order to assist ASPs in securing PILC cable supply for projects, EnergyAustralia is
prepared to order new stocks of PILC cable for ASPs after July 2002 and until end December
2002 from an overseas cable supplier provided ample notice is provided. These special orders
are expected to cost more than current stocks and ASPs are advised to consider their
immediate needs and place orders early from EnergyAustralia or other suppliers.
Suitably trained ASPs may commence using polymeric cables from the transition date for
each item of cable.
Training
ASPs may need to undergo training in the use of the new polymeric cables and accessories.
Details of the suitability of prior training and the availability of appropriate training will be
advised in a further CIA to be published shortly.
Updates
Regular updates on the transition program will be provided via CIAs, Network Standards and
some presentations.

______________________________
John Mackay
Manager Network Assets.

Attach. /

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 Attachment to CIA 1231
6.35/11kV UNDERGROUND POLYMERIC INSULATED ELECTRIC CABLES
BRIEF SPECIFICATION
Cables generally comply with AS/NZS 1429.1-2000
Item 1a Single core cable consisting of 70mm circular stranded compacted
copper conductor, EPR polymeric insulation, 16mm stranded copper wire
concentric screen, HDPE sheath.
Item 2b Single core cable consisting of 185mm circular stranded compacted
copper conductor, EPR polymeric insulation, 35mm stranded copper wire
concentric screen, HDPE sheath.
Item 3b Single core cable consisting of 300mm circular stranded compacted
copper conductor, EPR polymeric insulation, 35mm stranded copper wire
concentric screen, HDPE sheath.
Item 6a Three core composite sheathed cable, each core consisting of 95mm2
circular stranded compacted aluminium conductor, EPR polymeric
insulation, 16mm stranded copper wire concentric screen (individually
screened cores), composite 5V-90 PVC / HDPE sheath.
Item 7a Three core composite sheathed cable, each core consisting of 150mm2
circular stranded compacted copper conductor, EPR polymeric insulation,
29mm stranded copper wire concentric screen (individually screened
cores), composite 5V-90 PVC / HDPE sheath.
Item 8a Three core composite sheathed cable, each core consisting of 185mm2
circular stranded compacted aluminium conductor, EPR polymeric
insulation, 29mm stranded copper wire concentric screen (individually
screened cores), composite 5V-90 PVC / HDPE sheath.
Item 10a Three core composite sheathed cable, each core consisting of 300mm2
circular stranded compacted aluminium conductor, XLPE polymeric
insulation, water swellable tape, 29mm stranded copper wire concentric
screen (individually screened cores), composite 5V-90 PVC / HDPE
sheath.
Item 11a Three core composite sheathed cable, each core consisting of 400mm2
circular stranded compacted aluminium conductor, XLPE polymeric
insulation, water swellable tape, 29mm stranded copper wire concentric
screen (individually screened cores), composite 5V-90 PVC / HDPE
sheath.
Item 12 Single core cable consisting of 35mm circular stranded compacted
aluminium conductor, EPR polymeric insulation, 16mm stranded copper
wire concentric screen, HDPE sheath.
Item 13 Single core cable consisting of 630mm circular stranded compacted
copper conductor, EPR polymeric insulation, 120mm stranded copper
wire concentric screen, composite 5V-90 PVC / HDPE sheath.

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6.35/11kV UNDERGROUND POLYMERIC INSULATED ELECTRIC CABLES
CABLE CONSTRUCTION
ITEM 1a ITEM 2b ITEM 3b ITEM 6a ITEM 7a ITEM 8a
70 Cu 1 185 Cu 1 300 Cu 1 95 Al 3 150 Cu 3 185 Al 3
EPR EPR EPR EPR ISC EPR ISC EPR ISC
5. CONDUCTORS 70 Cu 185 Cu 300 Cu 95 Al 150 Cu 185 Al
(b) Shape Circular Circular Circular Circular Circular Circular
(d) Maximum allowable continuous
conductor temperature (oC) 90 90 90 90 90 90
(e) Overall dia. (mm) 9.9 16.1 21.0 11.5 14.5 16.1
6. CONDUCTOR SCREEN
7. INSULATION
(a) Type of insulation EPR EPR EPR EPR EPR EPR
(b) Min. average radial thickness 3.4 3.4 3.4 3.4 3.4 3.4
(mm)
(d) Dia. over insulation (mm) 18.3 24.5 29.6 19.9 22.9 24.5
8. NON-METALLIC
INSULATION SCREEN
(c) Dia. over ins. Screen (mm) 20.6 26.8 31.9 21.6 24.6 26.2
9. METALLIC INSULATION
SCREEN
(d) Details of materials applied over Polyester Polyester Polyester Polypropyl Polypropyl Polypropyl
the core screen wires prior to ene fillers ene fillers ene fillers
application of the polymeric sheath and PP and PP and PP
tape tape tape
10. WATER SWELLABLE TAPE N/A N/A N/A N/A N/A N/A
12. NON-METAL INNER SHEATH

(a) Material N/A N/A N/A 5V-90 5V-90 5V-90

PVC PVC PVC
13. POLYMERIC OVERSHEATH

(a) Material HDPE HDPE HDPE HDPE HDPE HDPE

(c) Dia. over oversheath (mm) 27.3 34.3 39.8 61.2 69.3 72.8
14. COMPLETED CABLE

(a) Average overall diameter (mm) 27.3 34.3 39.8 61.2 69.3 72.8
(b) Min. bending radius-(mm)
(i) during installation 675 855 990 1530 1745 1840
(ii) set 405 515 595 920 1050 1105
(c) Mass of cable kg per km 1230 2600 3830 3160 6995 4860
(d) Max. pulling tension, stocking grip 2.6 4.1 5.5 13.1 17.1 18.9
(kN)
(e) Continuous current rating (Amps)-
(i) cable laid direct 240 415 540 220 365 315
(ii) cable laid in duct 240 395 485 185 305 265

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 ITEM 10a ITEM 11a
300 Al 3 WST ISC 400 Al 3 WST ISC
5. CONDUCTORS 3 x 300 Al 3 x 400 Al
(b) Shape Circular Circular
(d) Maximum allowable continuous
conductor temperature (oC) 90 90
(e) Overall dia. (mm) 20.1 23.0
6. CONDUCTOR SCREEN
7. INSULATION
(a) Type of insulation XLPE XLPE
(b) Average radial thickness (mm) 3.4 3.4
(d) Dia. over insulation (mm) 28.7 31.5
8. NON-METALLIC INSULATION
SCREEN
(c) Dia. over ins. Screen (mm) 30.7 33.5
9. METALLIC INSULATION
SCREEN
(d) Details of materials applied over the
core screen wires prior to application 2 interleaved water swellable tapes 2 interleaved water swellable tapes
of the polymeric sheath
10. WATER SWELLABLE TAPE
(b) Conductive / non-conductive Semi-conductive Semi-conductive
(c) Percentage overlap 67 67
(d) Applied under or over metallic Under Under
screens
12. NON-METAL INNER SHEATH

(a) Material PVC PVC

13. POLYMERIC OVERSHEATH

(a) Material HDPE HDPE

(c) Dia. over oversheath (mm) 82.5 89.0
14. COMPLETED CABLE
82.5 89.0
(a) Average overall diameter (mm)
(b) Min. bending radius-(mm)
(i) during installation 2060 2230
(ii) set 1240 1340
(c) Mass of cable kg per km 6189 7253
(d) Max. pulling tension , stocking grip 45 60
(kN)
(e) Continuous current rating (Amps)-
(i) cable laid direct 442 507
(ii) cable laid in duct 372 426

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 ITEM 12 ITEM 13
35 Al 1 EPR 630 Cu 1 EPR
5. CONDUCTORS 35 Al 630 Cu
(b) Shape Circular Circular
(d) Maximum allowable continuous
conductor temperature (oC) 90 90
(e) Overall dia. (mm) 7.0 30.3
6. CONDUCTOR SCREEN
7. INSULATION
(a) Type of insulation EPR EPR
(b) Min. average radial thickness (mm) 3.4 3.4
(d) Dia. over insulation (mm) 15.4 39.4
8. NON-METALLIC INSULATION
SCREEN
(c) Dia. over ins. Screen (mm) 17.7 41.1
9. METALLIC INSULATION
SCREEN
(d) Details of materials applied over the
core screen wires prior to application Polyester Polypropylene
of the polymeric sheath
10. WATER SWELLABLE TAPE
N/A N/A
12. NON-METAL INNER SHEATH

(a) Material N/A 5V-90 PVC

13. POLYMERIC OVERSHEATH

(a) Material HDPE HDPE

(c) Dia. over oversheath (mm) 24.4 50.7
14. COMPLETED CABLE

(a) Average overall diameter (mm) 24.4 50.7

(b) Min. bending radius-(mm)
(i) during installation 605 1275
(ii) set 365 765
(c) Mass of cable kg per km 635 8055
(d) Max. pulling tension , stocking grip 1.7 9.1
(kN)
(e) Continuous current rating (Amps)-
(i) cable laid direct 130 740
(ii) cable laid in duct 130 590

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