Kerite Catalog Introduction - Arthur J Hurley …

1 INTRODUCTIONThe Kerite company 's reputation for manufacturing the highest quality electrical cables is based on testing in the toughest set of environmental conditions that exist - the real world. While others point to unproven short-term tests, at Kerite we draw upon a century of experience in formulating, compounding, manufacturing, and evaluating rubber insulated power cables. The successful track record of our field-proven insulation establishes a unique benchmark for ongoing research and development power cables (5kV thru 138kV) utilize Permashield as a stress control layer over the conductor. Permashield's nonconducting properties allow for 100% electrical inspection during the extrusion process. This assures that there are no voids or breaks which can result in premature cable failure. This layer also reduces the level of electrical stress throughout the insulation system and limits charge injection into the primary power cables utilize a specially formulated ethylene propylene rubber (EP) insulation.

2 Drawing upon our extensive experience in formulating insulations, Kerite achieves those electrical, mechanical, thermal and chemical properties most relevant to long-term field performance. Millions of feet of Kerite insulated cables have been installed in all types of environments with no known failures due to insulation degradation or weakness. This record is unsurpassed in the cable industry. Unique features and benefits which make Kerite superior to other commercially available cable insulations include corona immunity; long-term, over-voltage endurance; long-term moisture resistance; and impulse also has a rigid quality assurance program that, because we formulate and compound our own insulations, allows us the opportunity to inspect all incoming raw materials to ensure compliance with exacting Kerite standards. In addition, a sample of every batch of Kerite insulation is tested and evaluated before it is extruded.

3 Final testing of all finished cables is performed on the actual shipping unique feature of Kerite Power Cable is our easily removable insulation shield. Our semiconducting shield can be removed without the use of heat or special tools. This speeds installations, while greatly reducing the potential for failures caused by cut-throughs and insulation tearing during removal, a common problem with other types of ShieldThe standard shielding system for power cables consists of a 5 mil helically wrapped bare copper tape. At Kerite , this tape is applied with a 20% overlap. Copper tape may be supplemented with concentric neutral wires when additional fault current carrying capabilities are required. Cupro Nickel tape is used for nonjacketed aerial cable applications. Where ultimate resistance to environmental conditions is required, cables can be furnished with an extruded lead sheath and optional jacket.

4 Another shield option is longitudinally applied corrugated copper JacketOverall jackets fall into one of two basic categories: Thermoplastic or thermoset. The most widely used thermoplastic jacket, Polyvinyl Chloride (PVC), offers mechanical protection, flame retardancy, oil resistance and low cost. In underground duct applications Polyethylene (PE) may be used. It offers increased resistance to moisture and mechanical damage but is not flame retardant and can not be used on cables with UL MV 105 jackets offer a wide range of capabilities including, flame retardancy, mechanical toughness, and flexibility, but at a higher cost than most thermoplastic jackets. Available thermosetting jacket options include; Kerite FR - Chlorosulfonated Polyethylene (CSPE) with a long history of utilization in heavy-duty applications such as power plants and process industries. Kerite Low Smoke Zero Halogen jacket (LSZH) for use where there is heightened concern for personnel and equipment in case the cable becomes involved in fire.

5 Mechanical ProtectionAluminum or galvanized steel armor wires, interlocked armor or continuous corrugated weld armor can be provided for mechanical FinishesFor submarine cable applications, aluminum or galvanized steel armor wires can be provided in single or double layers. These wires can be supplied with individual jackets. A bedding layer and flooding compound can be added to maximize the protection. Temperature RatingThe maximum continuous operating conductor temperature for a Kerite insulated power cable is 90 C or 105 C in normal operation, with the emergency operating conductor temperature limit of 130 C or 140 C (See the Catalog pages for the specific Catalog number). The safe short circuit conductor temperature is 250 power cables can be furnished with either copper or aluminum conductors. For most applications, the selection of conductor material is one of economics. As the conductor size increases, the difference in initial cost increasingly favors aluminum.

6 However, because aluminum has a lower conductivity than copper, an aluminum cable of equal ampacity will be larger. This may require larger ducts, conduits, ladder racks or trays, thus offsetting the savings resulting from aluminum conductors. For direct burial or aerial cables preassembled or spun in the field, the additional size would probably be of little Single Permashield (SPS) Cable DesignFor over a century, Kerite power cables have withstood the toughest test of all - the test of time - setting the standard by which cable is judged, through actual field experience not just accelerated laboratory testing. Introduced over 35 years ago, our exclusive Permashield and EP Insulation System achieves the highest level of dependability and the lowest total cost of quality is reflected in every foot of Kerite cable. It is this commitment to superior performance that has established Kerite as the best cable value - for today, tomorrow and Copper-Solid-Stranded Aluminum-Solid-Stranded-FilledPermashiel d Insulation System 5kV - 138kv SinglePermashield(SPS)Metallic Shield Copper Tape-Bare-Tinned Zinc Tape Cupro Nickel Lead Copper Tape plus Concentric Neutrals Wire Braid LongitudinalCorrogatedCopper TapeOverall Jacket Thermoplastic-Insulating or Semi-Conducting-PolyvinylChloride (PVC)- Polyethylene (PE)-Polyurethane(TF)-Polypropylene(PP)- ThermoplasticElastomer (TPE)-Low Smoke Zero Halogen (TSLS) Thermosetting- Kerite FR (CSPE)-Low Smoke Zero Halogen (TSLS)

7 OPTIONSC onductor Copper-Solid-Stranded-Stranded,Filled Aluminum-Solid-Stranded-Stranded,FilledI nsulation 100% Level 133% Level Copper Concentric Neutral Wires Bare or Tinned Round or Flat Full, One-Third or SpecialOverall Jacket Insulating or Semi-Conducting Marker Stripes SequentialFootage PhaseIdentification NESC Direct Buried Idenitfier Polyethylene(PE) Polypropylene(PP) ChlorinatedPolyethylene(CPE)ABC DEF1 = 1/C2 = 2/C3 = 3/C4 = 4/C5 = 5/C6 = 6/C7 = 7/C14 = 14 AWG12 = 12 AWG10 = 10 AWG08 = 8 AWG06 = 6 AWG04 = 4 AWG02 = 2 AWG01 = 1 AWG11 = 1/0 AWG21 = 2/0 AWG31 = 3/0 AWG41 = 4/0 AWG25 = 250 kcmil35 = 350 kcmil50 = 500 kcmil 75 = 750 kcmil90 = 1000 kcmil95 = 1500 kcmil97 = 1750 kcmil99 = 2000 kcmilA = AlumC = CopperF = Filled AlumG = Filled CopperH = Compact Filled AlumS = Solid AlumT = Solid CopperX = Compact CopperY = Compact Filled CopperZ = Compact Alum00 = 600V 02 = 2kV05 = 5kV08 = 8kV15 = 15kV 25 = 25kV35 = 35kV46 = 46kV 69 = 69kV95 = 115kV98 = 138kV PR = PrecipitatorCatalog Number MatrixPrefixNo.

8 Of Condrs Conductor SizeConductor MaterialVoltageISO 9002 registered (Since 1995)SuffixInsulationLevelShieldingIndiv idual JacketAssemblyOuterAssemblyFinishGHIJK0 = No PS1 = 90 C SPS 100%3 = 90 C SPS 133%9 = 90 C SPS 100% SystemA = 105 C SPS 100%C = 105 C SPS 133%I = 105 C SPS 100% System 0 = Nonshielded1 = Full Bare Conc2 = All other Bare Conc3 = 1/3 Bare Conc4 = Cu Tape5 = Wire Braid6 = Cupro Tape7 = Lead8 = Armor Wires9 = All OthersA = 1/3 Tinned ConcB = Full Tinned ConcC = All Other Tinned ConcD = Tinned Cu TapeE = Bare Cu Tape & ConcF = Tinned CU Tape & ConcG = Zinc TapeH = Bare Flat StrapsJ = Tinned Flat StrapsK = 10 mil BCTL = 10 mil TCT0 = None1 = Black LLDPE2 = Black PE & Red Stripes4 = PVC5 = Black PVC & Red Stripes6 = FR (CSPE)7 = Semicon PE8 = Semicon PE & Red Stripes9 = All OthersB = TF Jacket PolyurethaneE = PolyproF= TPRG = TSLS Thermoset Low SmokeH = TPLS Thermoplastic Low SmokeJ = CPE ThermoplasticClorinated PE0 = None1 = Parallel2 = Twist3 = Twist with Neutrals4 = Cabled5 = Cabled with Neutrals6 = Parallel W/Neutrals7 = All others9 = Twist with Messenger0 = None1 = Black PE2 = PVC3 = FR4 = Galv ST Int Arm5 = Galv ST Int Arm, PVC6 = Galv ST Armor Wires7 = Galv St Armor Wires, Sub Finish8 = Galv ST Armor Wires, Individual PE Jackets9 = All OtherA = Al Int ArmB = Al Int Arm, PVCC = Cable in ConduitG = Galv St Arm Wires, Overall PECatalog Number Matrix POWER CABLE - KI-600 TYPEEPR Insulation / CSPE Thermoset Jacket90 C, 600 Volt, NEC TYPE RHH, RHW-2 or USE-2 - UL ListedCONSTRUCTION-Copper Class "B" Conductors per ASTM B-3, B-8 & B-33-Heat and Moisture Resistant Ethylene Polypropylene Rubber Insulation(EPR)

9 -Black Heavy Duty Chlorosulfonated Polyethylene JacketFEATURES-Thermoset insulation and jacket provide excellent thermal stability-Flame Retardant-Flexible for installation easePERFORMANCE STANDARDS-Insulation in accordance with ICEA S-95-658 Class E-1I & E-2-Jacket in accordance with ICEA S 95-658 for heavy-duty CSPE-UL Listed as Types RHH, RHW-2 or USE-2 (size 14 AWG not USE-2)-UL Listed for "CT Use" on sizes 1/0 and larger-Size 1/0 and larger pass ICEA 70,000 BTU and UL 1581 vertical tray flame tests-Cable pases UL VW-1 vertical flame test-Rated 90C for normal operation, wet or dry locations, 130C emergency overload conditions, 250C short circuit conditionsSINGLE CONDUCTORCATALOG NUMBER SUFFIX 00600 Insulation ThicknessJacket Nominal PrefixConductor Size (AWG/kcmil)# of StrandsMils(mm)Thickness Mils(Inch)(mm)Net Weight (lbs/K') MINUTE AC FINAL TEST VOLTAGES ConductorSingleMulti SizeConductorConductor(AWG/ACAC kcmil)(kV)(kV)#6 - # #1 - #4 Conductor to ConductorCATALOG NUMBER EXAMPLE: 106C00-00600 = #6 AWG (7) CU 600V, 45 mil Kerite , 30 mil Kerite FR Jacket.

10 For diameter over the insulation, refer to Three Conductor PVC Jacket table above. POWER CABLES - TYPE MV-905kV NON-SHIELDED (SPS) 90 C RatingCONDUCTOR - Class "B" Copper Strand (Aluminum Conductors Available) CONDUCTOR SHIELD - Unique Permashield SystemINSULATION - Exclusive Corona-Immune InsulationJACKET - Thermosetting Kerite FR (CSPE) SINGLE CONDUCTOR Catalog NUMBER SUFFIX30600 (MV90) Catalog Size No. Insulation JacketCable NO. (AWG/ of Thickness Insul. Thickness Weight PREFIX kcmil) Str. (Mils) (Inches) (Mils) (Inches) ( ) 106C05- 6 7 125 80 269 104C05- 4 7 125 80 339 102C05- 2 7 125 80 442 101C05- 1 19 125 80 512 111C05- 1/0 19 125 80 596 121C05- 2/0 19 125 80 702 131C05- 3/0 19 125 95 863 141C05- 4/0 19 125 95 1026 125C05- 250 37 140 110 1240 135C05- 350 37 140 110 1606 150C05- 500 37 140 110 2141 175C05- 750 61 155 125 3122 190C05- 1000 61 155 125 3979 192C05- 1250 91 170 140 4964 195C05- 1500 91 170 140 5818 197C05- 1750 127 170 155 6745 199C05- 2000 127 170 155 7580 (AWG / kcmil)AC (kV) #6 - #2/0 33 #3/0 - #4/0 35 Single 250 - 500 39 Conductor 750 - 1000 44 1250 - 1500 48 1750 - 2000 50 Multi Conductor ALL 23 Catalog NUMBER EXAMPLE:106C05-30600 = #6 AWG (7) CU 5kV, SPS 125 mil Kerite ,80 mil Kerite FR.