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 IEEE Std 1142™-2009
(Revision of
IEEE Std 1142-1995)

IEEE Guide for the Selection, Testing,

Application, and Installation of
Cables having Radial-Moisture
Barriers and/or Longitudinal Water
Blocking

Sponsor

Insulated Conductors Committee

of the
IEEE Power & Energy Society
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Approved 9 December 2009

IEEE-SA Standards Board

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 Grateful acknowledgment is made to Kable Consult LLC for the permission to use Figure 1,
Figure 3, Figure 6, and Figure 8.

Grateful acknowledgment is made to Nordlys SAS, a subsidiary of Polymer Group, Inc. for
permission to use Figure 2, Figure 4, Figure 5, and Figure 7.

Abstract: Detailed information relating to the design, testing, application and installation of
various types of electrical cables in order to prevent the deleterious effect of moisture and
chemical ingress and resultant failures in service is provided in this guide. This includes single
and multi-conductor cables over a complete range of voltage ratings. Testing criteria and
installation methods covered along with many technical references.
Keywords: laminate sheaths, longitudinal water blocking, moisture impervious, powders, radial-
moisture barriers, sealed overlap, water-swellable tapes, yarns

The Institute of Electrical and Electronics Engineers, Inc.

3 Park Avenue, New York, NY 10016-5997, USA

Copyright © 2010 by the Institute of Electrical and Electronics Engineers, Inc.

All rights reserved. Published 26 March 2010. Printed in the United States of America.
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 IEEE Standards documents are developed within the IEEE Societies and the Standards Coordinating Committees of
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 Introduction

This introduction is not part of IEEE Std 1142-2009, IEEE Guide for the Selection, Testing, Application, and
Installation of Cables having Radial-Moisture Barriers and/or Longitudinal Water Blocking.

This guide is an update of previously published IEEE Guide 1142-1995. When that guide was circulated for
a renewal ballot it was found that many revisions were needed to reflect changes in technology and to
incorporate additional types of cables along with other means of preventing moisture/chemical ingress into
cable cores. The objective still remains to supply complete information for utility and industrial cable users
on ways and means to protect cables from the deleterious effects of moisture and chemical ingress to cable
insulation as well as protection from unfavorable environmental and installation conditions. Much
information has been derived from reported global experience as well as the many technical papers that
have been presented in recent years on these topics. The bibliography has been updated to cover many new
informative references.

This guide will be most useful to those users who wish to maximize cable life and minimize cable faults
that cause interruptions in critical circuits.

Notice to users

Laws and regulations

Users of these documents should consult all applicable laws and regulations. Compliance with the
provisions of this standard does not imply compliance to any applicable regulatory requirements.
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For more information about the IEEE Standards Association or the IEEE standards development process,
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iv
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 Errata
Errata, if any, for this and all other standards can be accessed at the following URL:
http://standards.ieee.org/reading/ieee/updates/errata/index.html. Users are encouraged to check this URL
for errata periodically.

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Current interpretations can be accessed at the following URL: http://standards.ieee.org/reading/ieee/interp/
index.html.

Patents
Attention is called to the possibility that implementation of this guide may require use of subject matter
covered by patent rights. By publication of this guide, no position is taken with respect to the existence or
validity of any patent rights in connection therewith. The IEEE is not responsible for identifying Essential
Patent Claims for which a license may be required, for conducting inquiries into the legal validity or scope
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rights, and the risk of infringement of such rights, is entirely their own responsibility. Further information
may be obtained from the IEEE Standards Association.

Participants
At the time this guide was submitted to the IEEE-SA Standards Board for approval, the Moisture
Impervious Cables Working Group had the following membership:

Joseph Snow, Chair

Ajit Hiranandani, Vice Chair

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Kenneth Bow, Technical Editor

Michael Bayer David Cavassa Pierre Mirebeau

Kent Brown Mo Dawud Kenneth Prier
Luanne Cantrell John Hans Candelario Saldivar
Paul Caronia Frank Kuchta Hon Suen
Daniel Mainstruck Thomas Wilki

At the time this draft guide was completed, the following individuals contributed information of use in the
preparation of this guide:

Victor Banks Steve Czupryna Donald Voltz

Armando Rios

v
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 The following members of the invidual balloting committee voted on this guide. Balloters may have voted
for approval, disapproval, or abstention.

John R. Barker Randall Groves Serge Pelissou

Michael Bayer Jeffrey Hartenberger Resuali Robert
William Bloethe Lee Herron Michael Roberts
Kenneth Bow Lauri Hiivala Bartien Sayogo
James A. Braun A. S. Jones Gil Shultz
Chris Brooks Tanuj Khandelwal James E. Smith
Kent Brown Chad Kiger Jerry Smith
Thomas Campbell Robert Konnik Joseph Snow
John Cancelosi Jim Kulchisky Gregory Stano
Weijen Chen Chung-Yiu Lam Gary Stoedter
Robert Christman Benjamin Lenz David Tepen
F. Denbrock Gerald Liskom John Vergis
John Densley G. Luri Martin Von Herrmann
Gary L. Donner Arturo Maldonado Waldemar Von Miller
Gary Engmann John Merando Carl Wall
Todd Goyette Gary Michel Thomas Wilki
Steven Graham Daleep Mohla Dawn Zhao
Michael S. Newman

When the IEEE-SA Standards Board approved this guide on 10 December 2009, it had the following
membership:

Robert M. Grow, Chair

Thomas Prevost, Vice Chair
Steve M. Mills, Past Chair
Judith Gorman, Secretary

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John Barr Alexander Gelman David J. Law
Karen Bartleson Jim Hughes Ted Olsen
Victor Berman Richard H. Hulett Glenn Parsons
Ted Burse Young Kyun Kim Ronald C. Petersen
Richard Deblasio Joseph L. Koepfinger* Narayanan Ramachandran
Andy Drozd John Kulick Jon Walter Rosdahl
Mark Epstein Sam Sciacca

*Member Emeritus

Also included are the following nonvoting IEEE-SA Standards Board liaisons:

Satish Aggarwal, NRC Representative

Richard DeBlasio, DOE Representative
Michael Janezic, NIST Representative

Michelle Turner
IEEE Standards Program Manager, Document Development

Soo H. Kim
IEEE Standards Program Manager, Technical Program Development

vi
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 Contents

1. Overview .................................................................................................................................................... 1
1.1 Scope ................................................................................................................................................... 1
1.2 Purpose ................................................................................................................................................ 2
1.3 Development history............................................................................................................................ 2
1.4 Utilization and trends........................................................................................................................... 2

2. Normative references.................................................................................................................................. 3

3. Definitions .................................................................................................................................................. 3

4. Description of cable designs utilizing radial-moisture barriers and longitudinal water blocking............... 5
4.1 Description of cables with radial-moisture barriers............................................................................. 5
4.2 Description of power cables with longitudinal water blocking ........................................................... 6

5. Materials for moisture barrier and water-blocking functions ..................................................................... 8

5.1 Description .......................................................................................................................................... 8
5.2 Plastic-coated metals for radial designs for all voltage classes............................................................ 8
5.3 Adhesives for sealing the overlap...................................................................................................... 11
5.4 Properties and testing of coated metals.............................................................................................. 11
5.5 Synthetic water blocking tapes, yarns and powders for longitudinal water blocking for all voltage
classes ...................................................................................................................................................... 12
5.6 Selection of jacketing materials......................................................................................................... 15

6. Application of radial-moisture barriers and longitudinal water blocking to low-voltage cables .............. 16
6.1 General .............................................................................................................................................. 16
6.2 Bonded and metallic sheaths as radial-moisture barriers for low-voltage power, control and
instrument cable....................................................................................................................................... 16
6.3 Metallic sheaths as moisture barriers for low-voltage cable.............................................................. 18
6.4 Longitudinal water blocking low-voltage cable................................................................................. 18
6.5 Mechanical tests for low-voltage cables ............................................................................................ 19
6.6 Developmental tests for low-voltage cable with a bonded sheath ..................................................... 20
6.7 Life testing of low-voltage cables with a bonded sheath ................................................................... 21

7. Application of radial-moisture barriers and longitudinal water blocking to medium-voltage cables....... 21

7.1 General .............................................................................................................................................. 21
7.2 Bonded sheaths as radial-moisture barriers for medium-voltage cable ............................................. 21
7.3 Un-bonded laminate sheath with longitudinally folded metallic tape with sealed overlap................ 23
7.4 Metallic sheaths as radial-moisture barriers ...................................................................................... 23
7.5 Water blocking medium-voltage cable .............................................................................................. 23
7.6 Methods of controlling thermal expansion of bonded sheath medium-voltage cable........................ 24
7.7 Developmental mechanical tests........................................................................................................ 25
7.8 Developmental short-circuit test........................................................................................................ 27
7.9 Developmental test for bonded sheaths on medium-voltage cable .................................................... 28
7.10 Life testing of medium-voltage cable with a bonded sheath............................................................ 28

8. Application of radial-moisture barriers and longitudinal water blocking to high and extra-high voltage
cables............................................................................................................................................................ 29
8.1 Bonded sheaths as radial-moisture barriers for high and extra-high voltage cable............................ 29
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8.2 Metallic sheaths as radial-moisture barriers in high-voltage cable .................................................... 31

8.3 Water blocking high-voltage cable .................................................................................................... 32
8.4 Methods for expansion control of bonded or un-bonded sheaths on high-voltage cable................... 34

vii
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 8.5 Tests for high-voltage cables with bonded sheaths............................................................................ 35
8.6 Developmental and sample test for longitudinal moisture transmission............................................ 39
8.7 Discussion of developmental tests for high-voltage cable................................................................. 41
8.8 Life testing of high-voltage cables with bonded sheaths ................................................................... 42

9. Sample tests for measuring the integrity of bonded sheaths for all voltage classes.................................. 42
9.1 General .............................................................................................................................................. 42
9.2 Sample tests common to all voltage classes for measuring the performance of
the bonded sheath ................................................................................................................................... 42
9.3 Developmental tests for radial-water tightness common to all voltage classes ................................. 44
9.4 Special developmental tests for all voltage classes............................................................................ 45

10. Developmental tests common to MV and EHV power cables with radial-moisture barriers and
longitudinal water blocking .......................................................................................................................... 46
10.1 General ............................................................................................................................................ 46
10.2 Developmental tests for prototype MV, HV, and EHV cables with moisture barrier sheaths......... 47
10.3 Developmental electrical tests of the insulation system .................................................................. 48
10.4 Developmental test for thermo-mechanical performance ................................................................ 49

11. Sample tests common to all voltage classes ........................................................................................... 50

12. Routine tests common to all voltage classes........................................................................................... 51

13. Installation of moisture impervious cables ............................................................................................. 51

13.1 General ............................................................................................................................................ 51
13.2 Terminating and jointing ................................................................................................................. 53
13.3 Grounding........................................................................................................................................ 54

Annex A (informative) Bibliography ........................................................................................................... 56

A.1 Technical papers relating to design of moisture barrier cables......................................................... 56
A.2 Technical papers relating to materials and accessories for moisture barrier cables.......................... 58
A.3 Technical papers relating to testing of moisture barrier cables......................................................... 59
A.4 Technical papers relating to low-voltage moisture barrier cables..................................................... 59
A.5 Technical papers relating to medium-voltage moisture barrier cables.............................................. 59
A.6 Technical papers relating to high-voltage moisture barrier cables.................................................... 59
A.7 Specification references for cable with moisture barriers................................................................. 60

viii
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 IEEE Guide for the Selection, Testing,
Application, and Installation of

--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---
Cables having Radial-Moisture
Barriers and/or Longitudinal Water
Blocking

IMPORTANT NOTICE: This standard is not intended to ensure safety, security, health, or
environmental protection in all circumstances. Implementers of the standard are responsible for
determining appropriate safety, security, environmental, and health practices or regulatory
requirements.

This IEEE document is made available for use subject to important notices and legal disclaimers.
These notices and disclaimers appear in all publications containing this document and may
be found under the heading “Important Notice” or “Important Notices and Disclaimers
Concerning IEEE Documents.” They can also be obtained on request from IEEE or viewed at
http://standards.ieee.org/IPR/disclaimers.html.

1. Overview

1.1 Scope

This guide provides cable manufacturers and users with extensive information on the design, testing,
application, and installation of low, medium, and high-voltage power cables, as well as communication,
control and instrument cables that make use of metal-plastic laminates as radial-moisture barriers. This
guide addresses additional means of protecting cables from the entrance of moisture through the use of
polymeric super absorbent materials for longitudinal water blocking of stranded conductors and other
spaces within cables. The alternate use of extruded metal sheaths or bare, longitudinally applied, metallic
tapes with sealed seams will likewise be addressed.

1
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

1.2 Purpose

While metallic sheaths, such as lead and aluminum, have been effective in past years as barriers to
moisture, their relative cost, environmental concerns along with installation difficulties have led to the
search for alternatives. Alternatively, thin metal-plastic foils are finding application as moisture barriers in
low, medium, high, and extra-high voltage power cables. Aluminum, copper, or lead substrates are coated
with polymeric coatings on one or both sides and adhesively bonded to the cable jacket or over sheath. The
tapes are usually applied longitudinally, with an overlap, or seam, that is adhesively sealed over the core of
the cable and under the jacket. In addition, other measures have been taken to block the longitudinal
movement of moisture through the conductor and the shield interfaces so that water-impervious cables are
now available. This guide will provide information on the use of such coated metals in cable constructions
as well as the use of other materials for longitudinal water blocking. Cable users should find this
information of value in the selection, specification, installation, and testing of cables having radial-moisture
barriers and/or longitudinal water-blocking systems.

There is an extensive amount of information in this guide that refers to IEC Standards, British Standards
and CIGRE study group recommendations. These organizations, and others, have developed
recommendations, standards and specifications that are pertinent to cables with radial-moisture barriers and
longitudinal water blocking. Inclusion of a discussion of these documents presents the user of the guide
with a more complete picture of the degree to which cables with radial and longitudinal moisture protection
have developed. The technology has matured greatly since this guide was first published and inclusion of
all pertinent information not only serves to better inform the user of the guide but also documents how
extensive and prevalent the technology has become globally.

1.3 Development history

Thin plastic-coated metals were first developed for use as radial-moisture barriers for telephone cable in the
early 1960’s. They have been successfully utilized, up to the present time in this application. These coated
metals have also been used for moisture barriers and shielding as well as armoring in many other types of
cables, such as control, coaxial, instrumentation, fiber optic, undersea, etc. Such coated metals have also
found application as moisture barriers for low, medium, and high-voltage power cable, where design
parameters have been more restrictive. These design parameters may require special considerations. The
considerations and their implementation will be covered in this guide.

Longitudinal water-blocking of power cables have a long history starting first with the use of non-
polymeric absorbers and filling compounds. More recently, cable producers have used polymeric water
absorbers in the form of yarns, tapes, fillers and powders for longitudinal water blocking within the
conductors. This method is also employed around the concentric neutrals, under the metallic shield,
screens, and within the interstitial areas between conductors of multi-core cables as well as around the
layers of steel wire armoring and other places within a cable.

1.4 Utilization and trends

Many moisture-impervious power cable designs making use of radial and longitudinal-moisture barriers
have been commercialized. There is an upward trend in their acceptance on a worldwide basis. Various
country and international standards have been initiated or issued covering bonded sheaths and/or
longitudinally water-blocked power cables. The bibliography provides further references to the many
designs and the various countries, industries, and utilities that have selected, specified, and installed cable
with moisture barriers and moisture-blocking materials.

2
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

2. Normative references
The following referenced documents are indispensable for the application of this document (i.e., they must
be understood and used, so each referenced document is cited in text and its relationship to this document is
explained). For dated references, only the edition cited applies. For undated references, the latest edition of
the referenced document (including any amendments or corrigenda) applies.

ASTM B 736-002006, Standard Specification for Aluminum, Aluminum Alloy, and Aluminum-Clad Steel
Cable Shielding Stock.

ICEA T-31-610-2007, Guide for Conducting a Longitudinal Water Penetration Resistance Test on Blocked
Conductor.

ICEA T-34-664-2007, Test Method for Conducting Longitudinal Water Penetration Resistance Tests on
Longitudinal Water Blocked Cables.

IEEE Std 532™-2007, Guide for Selecting and Testing Jackets for Power, Instrumentation and Control
Cable. 1, 2

3. Definitions
For the purposes of this document, the following terms and definitions apply. The IEEE Standards
Dictionary: Glossary of Terms & Definitions should be referenced for terms not defined in this clause. 3

blocked conductor: A stranded conductor whose interstices are filled with water-swellable yarns,
powders, combinations of tapes over the conductor or a gel compound that prevents the migration of
moisture longitudinally through such interstices. Water-blocking tapes and yarns are most commonly used
in compact stranding and segmented conductors. Blocking can also be achieved by the use of a rubber-like
extrudable or pumpable material within the strands. Syn: strand-filled conductor.

bonded sheath: A sheath design in which a plastic-coated metallic tape, either pre or post-coated, is
longitudinally or helically wrapped over the core of a cable with an overlap or seam and the coating on the
tape is bonded to the cable jacket during the jacket extrusion process. This coated metallic component may
be smooth or corrugated. Alternatively an adhesive coating or jacket may be used over a bare metallic
substrate to form a bonded sheath.

cable core: The portion of a cable inside the sheath and for medium and high-voltage cable includes the
conductor, the conductor shield, the insulation, and the extruded insulation shield.

filling compound: A highly viscous material that is injected into conductors, typically under pressure
and high temperature.

laminate sheath: a sheath consisting of various layers such as shield and jacket lying one over another.
These layers may not, per the definition of “laminate,” have to be bonded together. If the layers are adhered
to each other, then the sheath can be called a bonded or laminated sheath.

longitudinal water blocking: Term used to describe a cable design that prevents the longitudinal flow
of water, moisture or contaminates along the cable core. The term can refer to the materials that provide a

1
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USA (http://standards.ieee.org/).
2
The IEEE standards or products referred to in this clause are trademarks of the Institute of electrical and Electronics Engineers, Inc.
3
The IEEE Standards Dictionary: Glossary of Terms & Definitions is available at http://shop.ieee.org/.
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

method for blocking the longitudinal ingress of water, moisture or contaminates along the cable core,
concentric neutral, metallic shield, screen, armoring or other cable interstices, during cable manufacturing
as well as, during cable transport, storage, installation, splicing, termination or from a defect or sheath
damage after installation.

metal-laminate covering: Per the CIGRE WG B1-25 [B86] definition, a metal laminate covering
consisting of several layers of plain or smooth (not corrugated) metal and plastic layers bonded together to
get a special set of properties: bending ability, radial water tightness. For the purpose of this document, the
terminology “bonded sheath” is used.

moisture-impervious cables: These are cable designs that prevent both the radial and longitudinal
entrance of moisture into the cable core.

non-woven water-blocking tapes: Cable tapes consisting of one or more non-woven webs plus other
materials needed to maintain mechanical integrity. Super absorbing powders are locked into the non-woven
tapes to provide water blocking capabilities to the tape. Depending on the location of such tapes within a
cable, they may also provide cushioning to absorb expansion of the cable core. They may provide a way of
binding the cable elements. They may be non-conducting or semi-conducting. Also, the tape may be called
a water-swellable tape.

plastic-coated metallic tape: A plastic-coated metal or coated metal in tape form for use on cable
manufacturing lines that is made of aluminum, copper, lead, or other metal substrate coated on one or both
sides with a tightly adhering polymeric coating. The coating used may consist of either an adhesive
polyolefin copolymer that self-bonds to the metal substrate during the laminating or extrusion coating
process or another polymeric compound that is adhered through the use of a supplemental adhesive.
Solvent-based polymeric coatings may also be used.

radial-moisture barriers: Cable designs that incorporate a metal layer as a component of the sheath that
effectively blocks the transmission of moisture from a radial direction.

strand-blocking: A means for filling the strand interstices with a material that will block the movement
of moisture or contaminates through stranded conductors. Strand blocking can take the form of a filling
compound that occupies the entire space between the stranded wires or be in the form of a swellable water-
blocking material that occupies a fraction of the space between the stranded wires but which expands
rapidly in volume upon contact with water to actively seek out and overfill cable free space to block the
flow of water.

swellable water-blocking material: A water-blocking tape, water-blocking yarn or water-blocking

filler that incorporates a super absorbent powder, fiber and/or UV cured coating that will swell upon
contact with moisture. A jelly-like material is formed to block the longitudinal ingress and movement of
moisture.

under-jacket type: A moisture barrier applied under the jacket and over the metallic shield or concentric
neutral of a medium or high-voltage power cable or a combination moisture barrier and shield as used over
the core in low-voltage instrument or control cable and in medium, high, or extra-high voltage power cable.
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water-blocking yarns: A spun yarn formed with a combination of polymeric fibers, super absorbent
fibers and longitudinal or helical filament reinforcement.

woven water-blocking tapes: A woven synthetic web with a coating of swellable powder on one
side. Woven water-blocking tapes are commonly used as a peripheral wrap over the conductor and
therefore must also function as a barrier against penetration of the extruded conductor screen into the free
space between the stranded conductor wires.

4
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

4. Description of cable designs utilizing radial-moisture barriers and

longitudinal water blocking

4.1 Description of cables with radial-moisture barriers

There are two major types of metallic moisture barriers for providing radial-moisture protection to low,
medium, high, and extra-high voltage cables. One major type uses a longitudinally applied, relatively thin
“foil”, or sheet, type of metallic tape, bare or plastic-coated, folded over the cable core with a single
overlap or seam. The longitudinally formed tape has the overlap sealed with a plastic adhesive in the
overlap. Sealing the overlap with a plastic layer is proven technology as a moisture barrier for all voltage
classes of power cable as demonstrated by the many references listed in the bibliography (see Clause 8).

The second type of metallic moisture barrier uses a relatively thick tube of lead, aluminum, copper or
bronze over the core of the cable to provide a radial-moisture barrier.

4.1.1 Longitudinally-applied metallic tape as a radial-moisture barrier

The longitudinally-applied metallic tape type of bonded-sheath design incorporates a metallic tape as a
moisture barrier directly under the jacket of cable intended for various applications where protection from
radial-moisture entry is needed. The metallic moisture barrier can be a thin foil or sheet type of metallic
substrate that is coated on one or both sides with adhesive coatings (plastic-coated metal) or uncoated
(bare). A plastic-coated tape may not be necessary if the cable jacket has adhesive characteristics and can
bond directly to the bare metallic substrate or tape wrapped over the cable core. Both plastic-coated and
bare metallic tapes are wrapped longitudinally over the cable core with a single overlap or seam. In the case
of the plastic-coated metal tape the outer coating on the tape is bonded to the cable jacket by the heat
transferred during the extrusion of the jacket. Because of the bond of the tape to the jacket, the plastic-
coated metal can be applied smooth, that is, without corrugations. However if desired the metal-plastic tape
can be corrugated in line to provide the cable with a bonded sheath with increased flexibility. In the case
when the tape is the plastic-coated metal, the extrusion process can also provide heat to form a seal of the
coating or coatings in the overlap. In the case of the uncoated (bare) tape, where bonding to the jacket is not
desired, the tape cannot be longitudinally applied in a smooth configuration and is therefore corrugated in
line by means of a corrugating machine. The corrugations provide the finished cable with flexibility. In the
case where an adhesive jacket is used, the bare tape may be applied smooth. The overlap of the bare tape is
sealed with a hot melt adhesive that, when applied into the overlap, completes the radial-moisture barrier.
The overlap of a cable using the bonded sheath design with plastic-coated metal is also frequently sealed
using a hot melt adhesive. Overlap sealing methods are covered in 5.3.

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To obtain the principal advantage of the longitudinally-applied tape as a moisture barrier, a key design
consideration should be given to the thickness of the metallic layer. The metallic tape, either plastic coated
or bare should be thick enough so that there are no pinholes present. It should be mechanically strong to
withstand cable manufacture, installation and use without rupture or tearing. Such damage could mean that
the primary moisture barrier has been violated. With optimal combinations of jacket thickness, plastic-
coated metals have typical metal thicknesses in the range of 0.1 mm (0.004 inches or 4 mils) to 0.38 mm
(0.015 inches or 15 mils). For designs using corrugated bare metals, the metal thicknesses are in the range
of 0.15 mm (0.006 inches or 6 mils) to 0.3 mm (0.012 inches or 12 mils). A thicker minimum tape
thickness is generally used with the bare tape option because, versus the bonded sheath, the supplemental
effect of the bond to the jacket is absent for providing mechanical strength to the sheath. So a thicker
metallic tape is used to increase the strength of the sheath. In the bonded sheath design, the adhesion
between the plastic-coated metal and the jacket combines the flexibility of the plastic jacket with the
strength of the metallic component of the tape. The mechanical properties of the bonded sheath cable are
improved versus those of a cable without adhesive bonding, that is, un-bonded. The bond in the bonded

5
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

sheath design provides for increased bend radius and greater hoop strength which could facilitate the
installation process for the cable. However, for the cable without a bond to the jacket, the termination and
splicing process for the metallic tape can be approached in a conventional manner using clamps or
soldering without the need for special grounding devices. The grounding process for cable with a bonded
sheath is covered in 13.3.

Either bare or plastic-coated metal tape is generally corrugated perpendicular to the axis of the cable (i.e.,
laterally or axially), to provide the cable increased flexibility. The profile of the corrugations is sinusoidal
and the number of corrugations per unit length can vary according to cable diameter. The depth of the
corrugations is typically a minimum of 0.8 mm (0.032 inch or 32 mils).

In the case of the bonded sheath, the bond between the jacket and tape provided by the coating on the
plastic-coated metal provides a longitudinal water block in the jacket-tape interface and the sealed
coating(s) in the overlap and/or a hot melt adhesive provides a radial and longitudinal water block at the
overlap. When the bare corrugated tape is used, there is no bond to the jacket so water can flow in the
jacket moisture barrier interface. Likewise, with the bare tape, as with the plastic-coated metal tape, the
sealed overlap provides a longitudinal and radial-moisture barrier. To deal with the potential presence of
water along the overlap of the bare metal option, a water-swellable tape can be placed over the overlapped
seam. If (when) water gets under the jacket, it can encounter the water-swellable tape which may impede
the water from penetrating around or into the hot melt adhesive in the overlap of the bare tape. There could,
however, be an increased propensity for corrosion of the bare metallic tape with the potential for water flow
in the tape-jacket interface.

In rare instances, the plastic-coated metal may be wrapped helically around the cable core and bonded to
the cable jacket. The subsequent bonded sheath can provide a radial-moisture barrier through the sealing of
the helical overlap along the length of the cable. However, the mechanical properties of the cable may
suffer due to a lack of flexibility when compared to cables with longitudinally applied plastic-coated tapes
bonded to the cable jacket.

4.1.2 Metallic sheath as a radial-moisture barrier

Metallic moisture barriers use a relatively thick tube of lead, aluminum, copper or bronze. The lead or
aluminum can be applied over the cable core by an extrusion process. Alternatively, a tape of aluminum,
copper or bronze can be applied longitudinally over the cable core with the edges of the tape butting
together. This “seam” is then welded together to form a tube enclosing the cable core. Corrugations can be
applied to the tube after welding to give the metallic moisture barrier added flexibility. A jacket may be
applied over the tube for additional protection from moisture and mechanical abuse.

4.2 Description of power cables with longitudinal water blocking

Longitudinal water blocking of power cables can take one or more of the following forms:

⎯ Longitudinal water blocking of the conductor

⎯ Longitudinal water blocking of the metallic shield/concentric neutral/screen
⎯ Longitudinal water blocking of the interstitial spaces between conductors in multi-core low-voltage
and medium-voltage cables
⎯ Longitudinal water blocking of steel tape or steel wire armoring
⎯ Longitudinal water blocking of the interface between the metallic component of the bonded sheath
and the cable core
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6
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

4.2.1 Longitudinal water blocking of stranded conductors

The presence of water in a stranded conductor could lead to water treeing and subsequent insulation
failures. Many cable users call for blocked strands to prevent water from flowing through the conductor. In
some cases, water blocking materials in the form of swellable tapes, yarns or powders, or a combination of
these materials, are used to provide longitudinal water blocking of the conductor. In some cases, semi-
conducting filling compounds are injected into the free space or extruded between the layers of the
conductor.

When swellable water-blocking material is used, a common practice is to evaluate the ratio between the
free space in the cable and the amount of water blocking gel produced by the swellable-water blocking
material upon contact with water. As the gel forms, it actively seeks out and fills the free space inside the
cable. The free space should be properly overfilled to provide acceptable water blocking of the conductor
strands. Careful consideration should be given to the aging performance of the water blocking material with
the potential for decades of exposure at the rated operating temperature of the power conductor, typically
90° C. Uniform distribution of the swellable-water blocking materials inside the strands of the conductor is
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a requirement for consistent water blocking. The effect of ions in groundwater should also be considered in
that these ions could reduce the swelling capabilities of water-swellable materials.

For conductors blocked with filling compounds, care should be taken to fill all cable spaces during cable
manufacturing because any unfilled areas may result in a path for longitudinal water flow.

4.2.2 Longitudinal water blocking of metallic screen/concentric neutral wires

It is common practice with MV and HV underground cables to water block the copper wires, straps,
metallic screens, and/or concentric neutrals to prevent longitudinal water paths within and along these
shields or strands in the event of sheath damage or joint failure. One method is to use a semi-conducting
water blocking tape below the copper wires and a non-conductive water blocking tape above the copper
wires and under the jacket. Another method is to use two semi-conducting tapes, one over and one under
the wires or straps.

4.2.3 Longitudinal water blocking of space between core elements in multi-core cables

In multi-core LV and MV power cables the free space between the insulated conductors or wires (such as a
neutral wire) is a large volume channel for longitudinal water flow. Where needed, it is possible to water
block the free space with swellable-water blocking materials, typically yarns, tapes or a combination of the
two.

4.2.4 Longitudinal water blocking of wire or strap armoring

The free space around steel wire or steel-strap armoring can be longitudinally water blocked with yarns,
tapes or a combination of the two. This armored cable design is common in coastal areas or in areas with
high-water tables or in industrial plants in Europe.

4.2.5 Longitudinal water blocking of the bonded or un-bonded laminate sheath

Water-swellable tapes can be used to block the longitudinal flow of water in the interface between the
metallic component of the bonded or un-bonded laminate sheath and the cable core for all voltage classes.

7
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

Such tapes may serve as a bedding tape in medium, high, and extra-high voltage cables to absorb lateral
expansion and contraction with temperature fluctuations due to loading on the cable.

Medium and high-voltage power cables, in general, may require semi-conducting tapes that provide
electrical continuity between the metallic moisture barrier, the metallic shield or screen and the semi-
conducting insulation shield.

5. Materials for moisture barrier and water-blocking functions

5.1 Description

A plastic-coated metallic foil or sheet consists of a relatively thin metallic “foil” or sheet layer, usually
0.10 mm to 0.38 mm (4 mils to 15 mils) in thickness, which is coated on one or both sides with a plastic
layer with typical thickness between 0.05 mm to 0.10 mm (2 mils to 4 mils). The plastic layer can be
insulating or conductive. A strong adhesive bond should be formed between the plastic layer and the metal
layer. The bond should not lose its properties after long-term exposure to heat and moisture. In all cases,
the metal layer should be pinhole free as such holes could defeat its purpose as a moisture barrier.

5.2 Plastic-coated metals for radial designs for all voltage classes

5.2.1 General

The type of metal chosen for a plastic-coated metal depends on the cable design and the role the metallic
component plays as a moisture barrier and/or shield. Present choices include lead foil, copper or aluminum
sheet. All of these metals can be coated with suitable plastics to achieve the desired composite structure.
Plastic-coated metal using lead foils are designed primarily for moisture barrier functions. A copper or

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aluminum composite could be used as a moisture barrier or for dual functions as both moisture barrier and
metallic shield.

5.2.2 Coating classes

Two classes of plastic-coated metal currently exist for use in the bonded sheath designs. One class is
adhesively compatible with polyethylene (PE), copolymers of PE, and chlorinated polyethylene (CPE)
jackets. The other class is compatible with polyvinyl chloride (PVC) based jackets. Reference ASTM B
736-002006 4 for shielding stock can be used as a baseline reference for both types of plastic-coated metals.

Plastic coatings or films exist for each class that will satisfactorily adhere to a specific metal substrate. The
resulting plastic-coated metal can then be used as a radial-moisture barrier in various cable constructions.
The coating may be applied to one or both sides of the metallic layer as the cable design dictates. Plastic
layers on both sides of the metal substrate increase the corrosion resistance of the plastic-coated metal and
enhances the cable manufacturing process. Plastic-coated foils coated on one side or coated on both sides
have found application in bonded-sheath cable designs.

Typically low-voltage cables use two-side coated plastic-metal composites while medium and high-voltage
cables use one-side coated plastic-metal composites. One key factor in using two-side coated metals in low-
voltage cables is to provide corrosion protection to the moisture barrier because it may also be acting as an

4
Information on references can be found in Clause 2.

8
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

electrical shield which requires electrical continuity to perform its electrical functions. Since low-voltage
cables do not typically require longitudinal water blocking, the coating on the inside of the moisture barrier
facing the core acts to protect the combination metallic moisture barrier-electrical shield from corrosion in
case water gets inside the cable. Restricting corrosion, in turn, preserves the electrical shielding function of
the cable. In the case of MV and HV cables, there is typically a means for protecting the cable sheath
interfaces from the longitudinal flow of water thereby restricting the potential for corrosion. So a one side
coated metal with the bare side facing the core may be used. Typically there are screen wires under the
bonded sheath so the electrical shielding function of the cable may not be compromised by any incidental
corrosion of the metallic moisture barrier. However, the key factor in using a one-side coated metallic
moisture barrier on MV and HV cable is the fact that the bare side of the metallic moisture barrier provides
electrical continuity with the cable core over the entire length of the cable. This facilitates transfer of shield
currents to the metallic moisture barrier and can reduce the amount of standing voltage that may develop on
the moisture barrier.

There are differences between one and two-side coated-metallic tapes when the overlap sealing process is
considered. A two-side coated tape may be easier to seal because it only requires that the two coatings on
each side of overlap be melted to form a seal. The bond to the metallic substrate for the coatings has been
established in the manufacturing process for the plastic-coated metal and does not need to be reformed.
With a one side coated tape, a new bond must be formed between the coating on the one side of the overlap
and the bare metal on the other side of the overlap. This requires extra heat energy to form the bond and so
preheat by various methods may generally be used. If sufficient heat is applied, the seal at the overlap of a
one side coated metallic tape can equal that of a two-side coated metallic tape. However, from a practical
point of view, equivalent bond levels may be difficult to achieve when using a one-side plastic-coated
metallic tape versus a two-side plastic-coated metallic tape. So, in general, the sealing of the overlap using
a single coating on a one-side coated metallic tape may only be feasible for low-voltage cables of relatively
small diameters. To achieve an overlap seal with medium and high-voltage cables that may use one side
coated metals, a hot melt adhesive may be inserted into the overlap. Additional details of using hot melts
for sealing the overlap are covered later in the guide (see 5.3). It should be pointed out that once the
sufficient amount of seal strength is obtained, the cable properties are essentially the same no matter how
the overlap seal was obtained, whether with a one side coated metal, a two-side coated metal, or by
insertion of a hot melt into the overlap. In the early days of development of bonded sheaths on medium-
voltage cable with plastic-coated metallic tapes, the overlap seal was obtained using both one and two-side
coated tapes. These cables were able to pass the thermal loading tests [B26]. There was the possibility that
the sheath could expand during the heating cycle and not fully recover to its original dimensions during the
cooling cycle because of the strength of the overlap seal using the coatings on the tape. With the use of hot
melt adhesives in the overlap, the sheath could more easily expand and contract due to the elasticity of the
hot melt in the overlap and the original sheath dimensions could be more closely retained [B41].

The coatings used in such plastic-coated metals may also be classed as either insulating or conductive. An
insulating layer is generally used when a plastic-coated metal is coated on only one side so as to be bonded
to an outer nonconductive jacket. Semi-conducting coatings are used on the side of the plastic-coated metal
facing the cable core to provide electrical contact between the semi-conducting layer insulation screen on
the core of a medium or high-voltage cable and the metallic shield of the moisture barrier or to a
semiconducting cable jacket.

The plastic film or coating on a plastic-coated metallic shield typically meets the following requirements:
a) The plastic layer is able to adhere to itself or to bare metal under the specified conditions of
temperature, pressure, and time needed to form a bond at the overlap of the longitudinally formed
tape during the cable manufacturing process. The metal-coating bond should not show a decrease in
bond strength upon exposure to water per the test requirements of ASTM B 736-002006-2007. The
coating should be able to withstand the temperatures normally encountered in operating cables.

b) The coating should exhibit a strong bond to the jacket. This bond should not diminish, to any
appreciable extent, with extended water exposure and temperature cycling.

9
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

5.2.3 Coated aluminum as a moisture barrier

Plastic-coated aluminum is most often chosen as a moisture barrier from an economic standpoint for all
voltage classes. Aluminum can also be utilized as a surge shield in low-voltage cables for instrument and
tray cable applications in areas with substantial lightning activity, but can also be selected for moisture
barrier purposes only. A minimum thickness of 0.15 mm (6 mils) may be needed for proper handling,
forming about the cable core, and to provide mechanical strength in the finished cable. Coated-aluminum
tape is not typically chosen as a combination shield and moisture barrier for medium, high, and extra-high
voltage cables, but is only used as a moisture barrier.

5.2.4 Coated copper as a moisture barrier

Plastic-coated copper tape can be chosen as a moisture barrier for all voltage classes in power cables.
Frequently, low-voltage cables in substations use coated copper for shielding as well as moisture
protection. Most often, coated copper is used as a bonded sheath over a copper wire neutral or wire screen
for medium or high-voltage cable. Coated copper can serve to protect from galvanic corrosion in that it is
of the same composition as the wire neutral or screen versus the type of galvanic cell that could occur when
an aluminum barrier is used in conjunction with a copper wire neutral or screen. See Bow, K.E. et al.
[B37].

Another factor favoring copper is that it is easier to terminate. In splicing and terminating, copper can have
an advantage because it can be soldered or mechanically clamped more readily than other materials. See
Bow, K.E. et al. [B39].

A coated-copper tape can be chosen as a combination shield and moisture barrier for low and certain types
of medium-voltage cables. Copper is chosen when maximum conductivity is required. The coated copper
metallic moisture barrier can be used as an electrical shield to supplement the wire neutrals of a medium-
voltage cable or the wire screen of a high-voltage cable. A minimum thickness of 0.15 mm (6 mils) may be
required with copper tape to provide short circuit capabilities or to supplement the short circuit capability
of the wire screen. A minimum thickness of 0.05 mm (0.002 inches) may be sufficient to prevent pinholes,
but is not sufficient from a mechanical point of view unless reinforced with relatively thicker plastic layers.
From a fatigue and mechanical point of view, the minimum thickness may be sufficient for a moisture
barrier, but possibly not from an electrical point of view.

5.2.5 Coated lead foil as a moisture barrier

In general, when a plastic-coated lead foil is used as moisture barrier in bonded sheath designs, there is a
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need to reinforce the lead foil with adherent polymer layers to provide strength. A minimum lead thickness
of 0.05 mm (2 mils) is usually necessary to reduce the possibility of pinholes and provide fatigue
resistance. The use of lead foil coated with polymer layers is significantly more environmentally acceptable
than the use of lead sheaths in terms of the volume of lead involved. The thin foil of lead is isolated from
the environment by the presence of the plastic layers; in addition, the adhesive bond of the plastic layers to
the lead minimizes contact between the lead and moisture in the environment.

It has been found that the composite construction of lead foil and plastic films can allow the lead to behave
like a plastic material during thermal loading see Uematsu, T. et al [B30]. The bonding is therefore capable
of expanding and contracting with the cable jacket. It has been found that foil-plastic film composites with
metals other than lead, such as copper or aluminum foils, may not exhibit the same type of plastic behavior
as exhibited by the plastic-coated lead. Load cycling at higher temperature limits, or use on large diameter
power cables, has the potential to split or fracture aluminum or copper foils thereby reducing the ability of
these types of moisture barrier composites to radially block moisture. However, they may be suitable for
low-voltage and certain medium-voltage cables.

10
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

5.3 Adhesives for sealing the overlap

There are designs where an additional adhesive is necessary to enhance the bond strength and moisture
barrier integrity of the overlap formed with longitudinally applied plastic-coated metals. Most often a hot
melt adhesive is used to seal the overlap with one side coated metallic tapes. The ability to seal a single
layer of coating in the overlap may be difficult because of the limited amount of temperature and heat
retention available for sealing the overlap during the jacketing process. The occasions where a hot melt
adhesive may be needed can also result from a need to fill the space within a corrugated overlap, as an
example, or by soft or uneven under-lying cable surfaces. Such circumstances can prevent the proper heat-
sealing of the plastic coatings of the coated metal. Hot-melt adhesives, extruded with suitable application
equipment into the overlapped seam before it is fully closed, are commonly used under these
circumstances. Their fast set-up time and their ability to adhere to the plastic film of the plastic-coated
metal, as well as to most bare metals and jacketing materials, contribute to their ability to form a water-
tight seal. Hot melts based on copolymers such as ethylene vinyl acetate (EVA) have been found adequate
for sealing low-voltage and some medium-voltage cables. However, hot melt adhesives based on
thermoplastic elastomers (TPE) have found favor for medium and high-voltage cables because of their
ability to allow the overlap to move and therefore accommodate thermal loading see Butterbach, R. et al.
[B41]. The use of TPE based hot melts as sealants for the overlap has been shown to allow sufficient
thermal expansion and contraction of the cable core to take place such that additional cushioning layers
under the bonding sheath may not be needed or could be reduced in thickness.

Specific types of adhesive coatings are required for adhesive compatibility with the various types of PE or
PE copolymer jackets. Other types are required for compatibility with PVC jackets.

5.4 Properties and testing of coated metals

5.4.1 Coating adhesion to metal substrates

The adhesion between the plastic coating and the metal substrate of a plastic-coated metal can be measured
according to test procedures shown in ASTM B 736-002006. The value of adhesion should not show any
substantial decrease when aged in the presence of moisture, at elevated temperatures or after temperature
and heat cycling. Many factors affect the values obtained from the coating adhesion test including the
following:
a) Metal thickness
b) Coating thickness
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

c) Test speed
d) Temperature

Such factors should be considered when evaluating different coated metals. All peel tests are relative and
can be affected by parameters of the test, sample configuration and the tensile or physical properties of the
layers being separated.

5.4.2 Flexibility

The flexibility of a foil type of plastic-coated metal needed to accommodate thermal cycles can play a key
role in the long-term life of a medium or high-voltage cable. Since this bonding is expanding and
contracting with the cable jacket during thermal cycling in medium or high-voltage cable it should possess
the ability to flex without generating cracks which could compromise the ability of the foil to act as a
moisture barrier.

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Barriers and/or Longitudinal Water Blocking

5.4.3 Fatigue

The metallic foil bonds such as those based on lead foil, as described in 5.2.5 for bonded sheath
constructions, should have the ability to resist fatigue from repetitive cycles of expansion and contraction.
See Furusawa, H. et al. [B48]. Bonding materials chosen for these types of designs can be tested for fatigue
according to a procedure set forth in ASTM E 796-94 [B80].

5.4.4 Bond strength to jacket

For plastic-coated metal used as radial-moisture barriers in all voltage classes of cable, a key performance
criterion is jacket adhesion. This value can be measured with procedures patterned after those set forth in
ASTM D1876-93 [B83] and ASTM 4565-99 [B84]. The metal-to-coating bond as well as the coating-to-
jacket bond should be stable and resistant to water and temperature aging.

5.4.5 Electrical properties of coatings

5.4.5.1 Insulating

In general, most plastic-coated metals are coated with an insulating plastic layer(s) to bond the tape to the
jacket. These coatings do not conduct electricity and therefore should not be used in applications where
conductivity through the jacket to the metallic component of the bond is required. If an insulating layer is
on both sides of the plastic-coated metal, then it could block current flow from the semi-conducting
insulation shield to the metallic component of the moisture barrier or shield.

5.4.5.2 Conducting or semi-conducting layers

Plastic layers that are semi-conducting, in order to conduct electrical currents, are used on plastic-coated
metal when electrical contact between the metallic substrate and other electrically conducting components
of the cable is required.

5.5 Synthetic water blocking tapes, yarns and powders for longitudinal water
blocking for all voltage classes

5.5.1 Water-blocking tapes

5.5.1.1 Description

--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---
Water-blocking tapes are available in a broad range of designs with a range of water blocking capacities
that the cable producer can select based on specified water blocking targets. See De Boer, R., et al. [B44],
Nieuwhof, B. J., et al. [B53], Nieuwhof, B. J., et al. [B54], and Czupryna, S. W., et al. [B42]. Some
general product categories of water blocking tapes are listed as follows:
⎯ Non-conductive water blocking tape with single non-woven web.
⎯ Non-conductive water blocking tape with double non-woven web.
⎯ Non-conductive water blocking tape with multiple non-woven webs and scrim reinforcement
⎯ Semi-conductive water blocking tape with single non-woven web.
⎯ Semi-conductive water blocking tape with double non-woven web.
⎯ Semi-conductive water blocking tape with multiple non-woven webs and scrim reinforcement.

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Barriers and/or Longitudinal Water Blocking

⎯ Non-conductive water blocking tape with single woven web.

⎯ Semi-conductive water blocking tape with single woven web.

Woven and non-woven water-swellable tapes have various functions as follows:

⎯ Upon contact with water, the tape swells thus forming a gel that actively seeks the available free
space in the cable structure to form a longitudinal water-block for all voltage classes of cable.
⎯ The tape may act as a mechanical stress-relief layer for absorption of thermal expansion of the
cable core for medium, high, or extra-high voltage classes.
⎯ The tape may act as cushioning for the metallic moisture barrier and/or as bedding for neutrals in
medium-voltage cables.
⎯ The tape may be semi-conductive to allow charge transfer from the insulation-semi-conducting
shield to the metallic shield or wire neutrals in medium, high and extra-high voltage cables.
⎯ The tape may act as a barrier against penetration of extruded polymers.
⎯ The tape may provide mechanical binding of cable elements.
⎯ The tape may serve as a radial-moisture barrier by absorbing and holding moisture as it permeates
through the cable jacket.

5.5.1.2 Application of water-blocking tape during cable manufacture

The tape may be applied either helically or longitudinally into areas of available space in cables from all
voltage classes, As examples, underneath a corrugated or smooth plastic-coated metal in low-voltage
cables, between the wire layers in a circular or segmented conductor in medium and high-voltage cables,
between conductors in multi-core low or medium-voltage cables, in the neutral wire area of medium-
voltage cables or underneath steel wire armoring in low and medium-voltage cables. Non-woven tapes may
be applied under or over or on both sides of the neutral wires or the wire screen of medium and high-
voltage cables.

The location and design of a water-blocking tape depends on the degree of swelling powder required to fill
the targeted free space. Depending on the requirements for blocking water in a specific cable design, tapes
can be bi-directional, swelling in both directions upon contact with water, or uni-directional, swelling in
one direction only. The factors affecting the ability of the tape to swell sufficiently and fill the targeted free
space with gel are primarily dimensional. The tape used should be matched to the space to be filled so that
sufficient pressure is built up in the gel to block the flow of water.

--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---
5.5.1.3 Tape selection criteria

5.5.1.3.1 Physical properties

The tape should have the following physical properties:

⎯ The tape should have sufficient mechanical strength, elongation, and flexibility to facilitate easy
application and not impair cable flexibility.
⎯ The tape should have adequate thickness to perform well as a mechanical stress-relief layer and for
cushioning/bedding purposes when these properties are required.

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Barriers and/or Longitudinal Water Blocking

5.5.1.3.2 Chemical properties

The tape should exhibit the following chemical properties:

⎯ The yarn should have a balance between swell height, speed, and gel strength to water-block the
cable interfaces according to the preferred cable water penetration test method.
⎯ The materials of construction for both the tape and the powder should be 100% synthetic to
minimize bacterial degradation in the underground environment.
⎯ For power cable applications, the powder should be capable of swelling and shrinking over
repeated wet/dry cycles.
⎯ The tape should be stable over the temperature range associated with cable load cycling or the heat
generated by the environment or by near-by power cables.

5.5.1.3.3 Electrical properties

Depending upon application, the tape could be either semi-conductive or insulating.

5.5.2 Water-blocking yarns

5.5.2.1 Description

Water-blocking yarns may have various functions in power cables as follows:

⎯ Upon contact with water, the yarn swells thus forming a gel that actively fills the available free
space in the cable structure thereby` forming a longitudinal water-block.
⎯ The yarn may provide mechanical binding of cable elements.

5.5.2.2 Water-blocking yarn application

The yarn may be applied either helically or longitudinally around cable elements. Typically yarns are used
to block water within the conductor, for example, around the central strand of the conductor, around a
compacted circular conductor layer or around a compacted layer in a conductor segment. The location and
design of the water-blocking yarn depends on the degree of swelling power required to fill the targeted free
space. The properties affecting the ability of the water-blocking yarn to swell sufficiently and fill the
interface with gel are primarily dimensional. The swelling properties of the yarn(s) used should be matched
to the space to be filled so that sufficient pressure is built up in the gel to block the flow of water.

5.5.2.3 Water-blocking yarn selection criteria

5.5.2.3.1 Physical properties

The water-blocking yarn should have the following physical properties:

⎯ The yarn should have sufficient mechanical strength, elongation, and flexibility to facilitate easy
application and not impair cable flexibility.
⎯ When used in a conductor of a power cable, the yarn should break apart somewhat after
compacting to improve layer-to-layer electrical contact between the wires.

14
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 IEEE Std 1142-2009
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Barriers and/or Longitudinal Water Blocking

5.5.2.3.2 Chemical properties

The yarn should exhibit the following chemical properties:

⎯ The yarn should have a balance of swell capacity, speed, and gel strength to water-block the cable
according to the preferred cable water penetration test method.
⎯ The materials used in the yarn should be 100% synthetic to minimize bacterial degradation in the
underground environment.
⎯ For power cable applications, the yarn should be capable of swelling and shrinking over repeated
wet/dry cycles.
⎯ The yarn should be stable over the temperature range associated with cable load cycling.

5.5.2.3.3 Electrical properties

Water-blocking yarns are typically non-conductive.

5.5.3 Water-blocking powders

Water-blocking powders are available that swell upon contact with water and form a jelly-like material
within a confined area to prevent longitudinal water penetration. Powder is typically used in a fluted semi-
conducting shield of a medium-voltage cable or sometimes applied directly in and/or over the conductor
layers. It should be noted that it is possible for the powder to migrate during cable manufacturing, transport
and handling and thus leave areas within the cable unprotected. It should also be noted that the ability of
swellable powders, as well as tapes and yarns, to swell in seawater may be significantly reduced.

Decades ago when cables were first water blocked with super absorbers, powders were widely used and
continue to be used today. Thereafter, material manufacturers began using other forms of super absorbers
including super absorbent fibers or UV cured super absorbent coatings on cable tapes and yarns as the
“active ingredient.” Therefore, a more general description is given in this guide as shown with related
definitions for tapes and yarns. Note that some water-blocking tapes may have a woven substrate, typically
polyester or polyamide, and are also included in the definition of water-blocking tapes.

The use of loose super absorbent powder in cables may be decreasing because of concerns over the control
of powder distribution, inhalation hazards, in that the powders may become airborne and form a dust that
may become a breathing hazard. There can be a concern over safety as well in that wet powders may create
a slip hazard for the workers in, for example, a manhole or vault environment.

5.6 Selection of jacketing materials

5.6.1 Principles of jacket selection

IEEE Std 532™-2007 [B111] is a useful guide that provides an overview of jacketing materials in common
use. Linear low-density polyethylene (LLDPE) may be chosen for the jacket, but where higher levels of
abrasion resistance and temperature performance are required, either medium-density polyethylene
(MDPE) or high-density polyethylene (HDPE) or polypropylene (PP) may be selected. ICEA S-94-649-
2004 [B98] may be used as a baseline reference for PE jackets. A wide variety of PVC compounds may be
chosen depending on the end-use requirements. PVC and CPE are generally used where ignition
suppression properties are required in a cable application. Jackets that are based on specially compounded
PE or copolymers of PE that do not contain halogen based flame retardants may be used where jackets with
low levels of combustion emissions and/or corrosiveness are required.

15
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Barriers and/or Longitudinal Water Blocking

There may be specific requirements for flame retardant jackets based on their chemistry. In the European
Union there is a requirement known as the RoHS Directive. This directive deals with the types of flame
retardants and other additives that can be used in plastics used in electrical and electronic equipment
including wire and cable see Dubiel, Karen L., [B45]. In general, the directive restricts the levels of lead,
cadmium, mercury, hexavalent chromium, polybrominated biphenyl (PBB) and polybrominated diphenyl
ether (PBDE) flame retardants. The final choice for a cable material should also depend on mechanical and
chemical performance under fire conditions considerations. In general, non-halogen based flame retardant
jackets may meet the requirements of this directive but the user should check for compliance.

5.6.2 Bonded sheath considerations

A key requirement for a jacket to be used with a bonded sheath moisture barrier for all voltage classes is
that the jacket should be adhesively compatible with the adhesive system used as a coating on the metallic
moisture barrier. For longitudinally folded moisture barriers in medium and high-voltage power cables, the
jacket should have good elongation in order to survive movement of the tape overlap during thermal
cycling. Some jacket materials may require a narrow bedding tape on top of the overlap to prevent jacket
damage at the overlap during thermal cycling.

6. Application of radial-moisture barriers and longitudinal water-blocking to

low-voltage cables

6.1 General
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

Low-voltage cables may benefit from the use of radial-moisture barriers in both above ground and below
ground applications. In general, the moisture barrier can protect the insulation system in above ground
installations from adverse electrical changes due to moisture and humidity. This is particularly true for
foam insulation systems used in, for example, coaxial cables operating at high frequencies. In the
underground environment, the radial-moisture barrier may protect the insulation system from both moisture
and chemicals that may be in the soil due to contamination from the manufacturing process in which the
cables are being used. Quite often the radial barrier is referred to as a chemical/moisture barrier for these
applications. Longitudinal water-blocking may be useful in cables in underground applications to keep
water from flowing within the cable and reaching splices, junction boxes and other system components
where it could cause corrosion of terminals and other electrical connections leading to potential
malfunctions within the cable system.

In general, longitudinally applied and corrugated bare metallic tapes with sealed overlaps are not frequently
used as radial-moisture barriers for low-voltage cable, so detailed information will not be provided on such
constructions for this voltage class (see 4.1.1).

6.2 Bonded and metallic sheaths as radial-moisture barriers for low-voltage

power, control and instrument cable

Bonded sheaths and metallic sheaths (see 4.1.2) provide radial-moisture barriers on low-voltage cables
which can provide protection of the operating core of the cable from moisture and chemicals. In addition,
the metallic component of the plastic-coated metal or metallic sheaths, either acting as the
moisture/chemical barrier, usually serves another purpose such as providing shielding from lightning and
other electrical or magnetic interference. In one application at a refinery, coaxial cable with foam dielectric
was used as a signal and instrument cable. The cable core was protected with a bonded sheath consisting of
a chlorinated polyethylene jacket and a 0.2 mm (8 mils) coated aluminum as the radial chemical/moisture

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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

barrier. A test cable was energized to 600 V AC and 1000 Hz and continuously immersed in 75°C water for
several months see Bow, K.E., et al. [B56]. The insulation resistance was periodically determined. As
shown in Table 1, a coaxial cable with a foam dielectric, and only an outer jacket for moisture protection,
developed a sudden decrease in insulation resistance after 5 weeks of aging indicating deterioration of the
insulating properties of the dielectric due to the presence of moisture. The cable with the radial-moisture
barrier did not change in insulation resistance throughout the duration of the test. The metallic moisture
barrier, integrated into the bonded sheath, effectively blocked the penetration of moisture into the cable
core. A metallic sheath should be at least as effective as the bonded sheath in providing resistance to
moisture penetration into the cable core.
Table 1 —Effects of radial-moisture barrier in maintaining the insulation
resistance of a low-voltage coaxial cable

Time Insulation resistance (MΩ—1000 ft.)

Jacketed Moisture barrier

Initial 80 000 80 000

--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

1 week 80 000 80 000

5 weeks 5700 80 000
10 weeks 5000 80 000

A second application for the metallic moisture barrier, in the form of a bonded sheath, is for low-voltage
instrument or communication cables that make use of twisted pair conductors for signal transmission.
Typically the presence of moisture can increase conductance, which can have an adverse effect on signal
transmission in the steady state. In the case of transients such as those caused by lightning, the metallic
component of the moisture barrier serves to provide both electrostatic and electromagnetic shielding
protection to the cable. The overall shield/moisture barrier functions as an electromagnetic shield by
generating a counter current to the induced currents from the event causing the interference. This current in
the shield effectively cancels the interfering currents on the signal conductors see Bow, K.E. et al. [B57].

A typical low-voltage instrument cable is illustrated by Figure 1. The cable components are the jacket, the
longitudinally formed shield/moisture barrier and the cable core. The plastic-coated metal is typically
coated aluminum with thicknesses of 0.2 mm (8mils) for the aluminum and 0.05 mm (2mils) for the
coating(s) on the aluminum. The figure illustrates the functions of the various components as a composite
structure. The overlap forms a seam that is sealed to form a barrier to the radial penetration of moisture.
The coatings also serve to protect the aluminum from corrosion in addition to their role in bonding the
cable components together. The bond between the jacket and the coated aluminum blocks the longitudinal
flow of moisture and chemicals in the shield-jacket interface. The bond also improves the mechanical
properties, such as bend performance, of the cable because the shield and jacket now form a composite
structure.

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Barriers and/or Longitudinal Water Blocking

“This figure has been provide courtesy of Kable Consult LLC.”

Figure 1 —Multi-conductor instrument cable with coated

aluminum in a bonded sheath
A third application for moisture barriers is for 600 V power and control cables that may be installed
underground in refineries or chemical processing plants or otherwise exposed to adverse environmental
conditions. This construction serves not only as a moisture barrier but also as a chemical barrier. Chemicals
can have an adverse effect on the properties of the insulation on the conductors leading to potential
electrical failure of the cable. The bonded sheath with the 0.2 mm (8 mils) coated aluminum also serves as
mechanical protection by significantly improving the crush and impact resistance of the cable see Bayer,
M. G., Bow, K. E., Snow, J. H., and Voltz, D. A., et al. [B1].

6.3 Metallic sheaths as moisture barriers for low-voltage cable

Extruded aluminum or seam welded aluminum tube has been used as a moisture barrier for low-voltage
cables. These cables have been given the designation “Metal-Clad” (MC) in various standards in the USA
UL 13, [B117]and UL 1569, [B120]. These sheaths require special fittings to seal the ends.

6.4 Longitudinal water-blocking low-voltage cable

Very few, if any, single core low-voltage power cables have longitudinal water blocking. However, multi-
core low-voltage cable designs with longitudinal water blocking are used in Europe. For example, France
requires the use of water-blocking yarns in their 3 conductor × 95 mm2 conductor size, 3 × 150 + 70 mm2
and 3 × 240 + 95 mm2 low-voltage cables to prevent longitudinal water ingress between the conductors.
The cables contain a steel tape armoring layer which is water blocked with swellable-water blocking
material. The conductors themselves are not water blocked. Figure 2 shows the general arrangement of the
water-blocking materials.

Although this is not a widely used design, it does illustrate the role that water-blocking materials can play
in low-voltage cables.

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IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

“Illustration is reprinted with permission of Nordlys SAS, which is a subsidiary of Polymer Group, Inc.”

Figure 2 —Low-voltage cable with longitudinally-water

blocked multi-conductor core

6.5 Mechanical tests for low-voltage cables

Cables with radial-moisture barriers and/or longitudinal water blocking, as with other cables, should be
able to withstand the mechanical stresses imposed during manufacture, shipping, and installation. The cable
and moisture barrier should retain their electrical and physical integrity after being subjected to bending,
twisting, and pulling through conduit systems or directly buried. Visible mechanical damage is usually
apparent before there is any compromise to electrical integrity.

The following sample tests may be used for characterization of low-voltage cables:

a) Bend test
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

b) Twisting test
c) Heat shock test

After each test, the cable should be dissected and visually examined for signs of cracking, wrinkling, or
separation of the metallic bonding, or for damage to other portions of the cable.

6.5.1 Sample bend test

Sample bend test: A bend test is conducted by bending a cable around a mandrel having a diameter that is
determined as a multiple of the diameter of the cable core (DOC) or outside diameter of the cable (OD).
Bending cycles or number of bends can be used to specify the number of turns around the mandrel. A
bending cycle consists of a 180 degree bend in one direction and a reverse 180 degree bend in the other
direction around the mandrel. The cable may be rotated 90 degrees before each bend to allow the bend
stress to be applied to a different quadrant of the cable. After a specified number of bends, the moisture
barrier should be examined for its integrity. The procedure is described in bibliographical reference ASTM
D4565-99 [B84]. Mandrel diameters given in this reference are for communication cable and may not be
suitable for power cable. However, some bend requirements for low-voltage power cable are given in
various UL 13, et al. [B117], UL 1277 PLTC Cable et al., [B119] and UL 1569 et al., [B120].

There are many different choices for the diameter of the mandrel as calculated from the DOC or OD
depending on the cable type, voltage class and a particular specification. Some representative bend test

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Barriers and/or Longitudinal Water Blocking

requirements for shielded power cable are shown in Table 2 and described in bibliographical reference UL
1277 [B119] for tray cable.

Table 2 —Bending mandrel diameters for low-voltage cable

Reference Cable Type Cable OD, mm (in) Mandrel Diameter No. of Bends

UL1277 [B202] LV (Tray) 0–17.78 (0–0.70) 12 × OD 4

UL1277 [B202] LV (Tray) >17.78 (>0.70) 12 × OD 1×180 Bend

NOTE—These parameters are for a cold bend test at –20 °C. No bend test at ambient temperature is
required. 5

6.5.2 Sample twist test for bonded sheath cables

Sample twist test: During installation in conduit, cables may twist as they are pulled. The cable size and
design may play a role in the degree of twisting per unit length. When this consideration is important, a
twisting test can be performed prior to the bend test. A given length of cable is merely twisted 90 degrees
per desired unit length. It is unlikely that a cable will experience both twisting and reverse twisting.
Therefore, twisting in only one direction is normal in this test ASTM 4565-99 [B84]. The twist test is
generally a requirement when corrugated coated metals are used as the radial-moisture barrier. The
corrugations at the overlap can act as stress concentration points and can cause the jacket to “zipper”, i.e.,
tear the jacket, along the length of the overlap.

6.5.3 Sample heat shock test for bonded sheath cable

Sample heat shock test: The heat shock test may be used to measure the integrity of the cable jacket after
exposure to elevated temperatures. It is only conducted for cables whose jackets may be subject to the
formation of cracks because they may be thermally unstable at elevated temperatures or because they may
have inadequate elongation or tensile strength to withstand thermal cycling. The test procedure for cables
having a jacket over a metallic component is described in bibliographical reference UL Standard 2250
[B122] for instrumentation tray cable. The cable is wrapped around a circular metallic mandrel that is 5
times the cable diameter. The specimen is wrapped for ½ bend, basically in the configuration of a U bend.
The ends of the cable are clamped to the mandrel. The specimen is placed in a circulating air oven by
suspending the specimen in the oven thereby allowing it to be exposed to the full draft of the oven. The
oven is set at a temperature consistent with the thermal properties of the particular jacket under test. For
example, for 60 ºC, 75 ºC, or 90 ºC rated PVC, the oven is set at 121 ºC. The specimen is heated for one
hour in the oven. At the end of the heating time, the assembly of specimen and mandrel is removed from
the oven. Immediately after cooling to room temperature in still air, the specimen is removed from around
the mandrel and examined for cracks along the inside surface of the cable. Cracks can be detected by visual
examination as circumferential depressions in the surface of the jacket of the specimen.

6.6 Developmental tests for low-voltage cable with a bonded sheath

The bonded sheath should maintain its mechanical integrity after bending and twisting. There is no need for
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

a thermal cycling test. Longitudinal water blocking is not a common requirement. Typically development

5
Notes in text, tables, and figures of a standard are given for information only and do not contain requirements needed to implement
this standard.

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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

tests for low-voltage cable require the bend test to be conducted at elevated temperatures (60 ºC) and low
temperatures (–20 ºC) to evaluate the bend performance at high and low ambient temperatures.

6.7 Life testing of low-voltage cables with a bonded sheath

A bonded sheath cable with a coated aluminum moisture barrier was removed from service after 25 years
and tested for electrical and mechanical properties. These cables were installed in a chemical producing
facility on the Gulf Coast of the USA. The cable was installed in an open trench and continuously exposed
to water over a 25-year period. The tests showed that the electrical properties of the cable were equal to the
originals and the mechanical properties of the insulation on the conductors were at their original values.
These test data indicate that the moisture barrier can protect a cable core from moisture and chemical
penetration.

7. Application of radial-moisture barriers and longitudinal water blocking to

medium-voltage cables

7.1 General

Starting in the 1970’s failures of high molecular weight polyethylene-insulated, medium-voltage cables in
underground applications due to the water treeing phenomenon and other undesirable effects of water
kindled a strong interest in measures to prevent radial and longitudinal water intrusion into the core of a
medium-voltage cable. Longitudinally formed plastic-coated or bare corrugated tape with a sealed overlap
has been used extensively as a radial-moisture barrier for medium-voltage cable in Europe. Metallic sheaths
have also been used to provide radial-moisture protection. In general, medium-voltage cables have been
installed without radial or longitudinal moisture barriers due to the lower levels of electrical stress
experienced by these cables. In the last 20 years, measures such as the use of tree retardant cross-linked
polyethylene or ethylene propylene rubber versus cross-linked polyethylene as the insulation system and
the use of overall jackets versus open neutral (unjacketed) cables have been used to control the effects of
moisture in the environment surrounding medium-voltage cables.

7.2 Bonded sheaths as radial-moisture barriers for medium-voltage cable

The bonded sheath design as illustrated in Figure 3 utilizes a tape of coated copper to combine the moisture
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

barrier and the electrical shield or neutral into one common metallic layer. Depending on the magnitude of
the fault current, it may be possible to size the thickness of the copper tape to a sufficient thickness to carry
the desired fault or neutral currents. The tape is applied longitudinally with an overlap that is sealed with
the aid of a hot melt adhesive. The outer side of the tape is coated with an adhesive film that bonds the
metallic component of the plastic-coated metal to the outer jacket of the cable. This provides improved
mechanical properties and corrosion resistance. Semi-conducting water-blocking tapes can be used under
the shield/moisture barrier to block longitudinal moisture ingress, to provide electrical continuity between
the metallic shield and the semi-conducting insulation shield, and to provide a cushioning layer for
expansion control.

21
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

“This figure has been provided courtesy of Cable Consult LLC.”

Figure 3 —Single conductor medium-voltage cable, bonded sheath
with coated-copper tape

Probably the most successful and widespread use of medium-voltage cable with a bonded sheath having a
radial-moisture barriers by a utility can be attributed to Electricite de France (EDF), the power company
serving France and other European countries. Starting in 1979, EDF changed their standard 20 kV cable
design to cross-linked polyethylene insulation with a bonded sheath. See Bourjot, P., et al., [B59]. The
design is described in bibliographical reference EDF Standard C33-223 [B145]. The radial-moisture barrier
consists of a 0.2 mm (8 mil) longitudinally applied coated aluminum tape. The tape is bonded to a
relatively thick PVC jacket, 2.6 to 3.0 mm (102 to 118 mils) or 2.8 to 3.0 mm (112 to 120 mils). The

--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---
minimum jacket thickness depends on the conductor cross-section. The overlap is sealed with a hot melt
adhesive. To handle thermal expansion, the semi-conducting insulation screen is grooved or fluted on the
outer surface of the screen in contact with the bonded sheath. These grooves are filled with a water-
swellable powder to provide longitudinal water tightness. Terminations, splices, separable connectors and
ground connectors have been developed for this moisture barrier design.

A similar medium-voltage cable design with a bonded sheath covered by a low-density polyethylene jacket
has been utilized in Sweden starting in the early 1980’s. See Dellby, B., et al., [B13]. In Germany, several
utilities have used medium-voltage cable with a bonded sheath containing a radial-moisture barrier that
consist of coated copper 0.15 mm (6 mils) thick bonded to a polyethylene jacket. A design based on 0.30
mm (12 mils) coated copper was developed to provide additional short circuit capability. See Bertier, D., et
al., [B3]. A corrugated 0.15 mm (6 mils) coated copper tape as the metallic component of the bonded
sheath with a polyethylene jacket has been used in industrial applications as a chemical/moisture barrier for
underground cable installed in petrochemical plants. Both the 5 kV with EPR insulation and the 15 kV
cable with XLPE insulation used in this petrochemical plant had a bonded sheath to not only protect the
cable from moisture, but also to protect the insulation system from possible chemical contamination. See
bibliographical reference Bayer, M. G., et al. [B1] and Bow, K.E. et al. [B37]. A radial-moisture barrier
can also be accomplished with the use of a metallic sheath in lieu of the thin polymer coated copper tape.

22
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

7.3 Un-bonded laminate sheath with longitudinally folded metallic tape with sealed
overlap

For certain applications, especially three phase medium-voltage feeder cables, corrugated, longitudinally
folded bare metal tapes, usually copper, and with a sealed overlap have been used as radial-moisture
barriers. The copper can act as both a shield and moisture barrier. The overlap is sealed with a hot melt
adhesive. In some designs, a water-swellable tape is placed over the overlap to preclude water, which may
potentially enter the interface between the jacket and metallic moisture barrier, from penetrating the
overlap. The advantages and disadvantages of this type of moisture barrier sheath construction are
described in more detail in 4.1.1.

7.4 Metallic sheaths as radial-moisture barriers

Both lead tube, IEC 60840 4/1/04, [B102] and welded or extruded aluminum tube IEEE Std 635™-2003
[B112] have been used as metallic moisture barriers for medium-voltage cable. See 8.2.2 and 8.2.3 for
additional details. Lead sheath designs are covered in bibliographical reference IEC 60502-2 Ed. 2.0,
[B101]. The sheath consists of a seamless tube formed of lead or lead alloy. The minimum nominal wall
thickness of the lead is 1.2 mm (47 mils).

7.5 Water-blocking medium-voltage cable

Medium-voltage cables for buried applications with a jacket that has been applied as a tube or sleeve during
the extrusion process can utilize a water-swellable tape over and/or under the neutral wires to provide a
longitudinal block to water flow. The jacket can provide corrosion protection for the wire neutrals and the
tube or sleeved jacket can provide space for easy access to the neutral wires for termination. The water-
swellable tape fills the space surrounding the neutrals that could become a longitudinal water path. Water
flow along the neutrals could be a potential source of corrosion. See Czupryna, S. W., [B42]. Medium-
voltage cables may also have longitudinal water blocking of the conductor. Figure 4 illustrates a typical
single core medium-voltage cable construction with longitudinal moisture protection.

“Illustration is reprinted with permission of Nordlys, SAS, which is a subsidiary of Polymer Group, Inc.”

Figure 4 —Medium-voltage cable with concentric neutrals

and longitudinal water blocking

23
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

Figure 5 illustrates a multi-core, medium-voltage power cable that has steel wire armor over the three
power conductors. Each individual conductor is protected by a bonded sheath for radial-moisture protection
and water-blocking tapes for longitudinal moisture protection. Water-blocking tapes and fillers are used
between the triplexed conductors to block water flow between the conductors and the inner jacket or
sheath. Water-blocking tape is used to block water flow around the steel wire armor in the interface
between the inner and outer jacket or over-sheath. Larger quantities or more efficient super-absorbing
materials are generally required to fill the large amount of free space in multi-conductor medium-voltage
cables. Therefore, water-blocking of multi-conductor cables may present unique technical and economic
challenges for the cable manufacturer.

“Illustration is reprinted with permission of Nordlys, SAS, which is a subsidiary of Polymer Group, Inc.”

Figure 5 —Longitudinally-water blocked steel wire armored and triplexed

medium-voltage cables with bonded sheaths on the individual conductors

7.6 Methods of controlling thermal expansion of bonded sheath medium-voltage

cable

7.6.1 General

A design consideration for medium-voltage cable with a bonded sheath is that a means for mechanical
stress relief may be required to accommodate the expansion and contraction of the core during thermal
cycling. Early work with bonded sheaths on medium-voltage power cables indicated that, with sufficient
adhesion at the overlap, the bonded sheath could accommodate the thermal expansion of the core. There
was an indication that the bonded sheath would not fully shrink back to its original diameter after the
conductor and cable sheath returned to a lower operating temperature. This could create spaces within the
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

shield-core interface. Although these spaces were not harmful to the operation of the cable, they could form
longitudinal water paths. Depending on the cable design, there could be a need for a specific layer of
material to fill this space and to compensate for thermal expansion. Primarily for the bonded sheath

24
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

moisture barrier cable, there may be a need for some type of cushion that will absorb the change in outer
diameter of the core during load cycling.

7.6.2 Grooved or fluted insulation screen

As described in 7.2, a medium-voltage design has been developed that utilizes a special fluted semi-
conducting insulation screen. The flutes are in the outer surface of the screen facing the metallic moisture
barrier. The screen flattens during thermal loading to absorb the expansion and contraction of the cable
core. The flutes resemble axial groves in the semi-conducting insulation screen and contain water-swellable
powder to longitudinally block the flow of water in the flutes of the insulation screen. See Pinet, A. [B61].

7.6.3 Water-swellable bedding tapes

The use of water-swellable bedding tapes is well established as a means of controlling the thermal
expansion and contraction of the cable core that the bonded sheath encounters due to thermal loading of the
cable. See 8.4.1 for more details.

7.6.4 Elastomeric adhesives for sealing the overlap

The use of elastomeric hot melt adhesives to seal the overlap of the coated metal forming the radial-
moisture barrier in the bonded sheath can allow the overlap to expand and contract to accommodate
thermal expansion (see 5.3 and 8.4.4 for more details).

7.6.5 Axial corrugations

For certain under-sea power cable designs, thermal expansion and contraction can be accommodated by
inserting axial corrugations into the plastic-coated metallic tape during the forming of the coated metal
around the cable core during manufacture of the bonded sheath. These corrugations can allow the tape to
absorb expansion and contraction in the radial direction by allowing the circumference of the cable to
increase or decrease in length.

7.7 Developmental mechanical tests

Cables with radial-moisture barriers and/or longitudinal water blocking, as with other cables, should be
able to withstand the mechanical stresses imposed during manufacture, shipping, and installation. The cable
and moisture barrier should retain their electrical and physical integrity after being subjected to bending,
twisting, and pulling through conduit or tray systems as well as directly buried. Visible mechanical damage
may usually be apparent before there is any compromise to electrical integrity.

The following mechanical tests may be used as development test of medium-voltage cables with bonded
sheaths during the design phase of the cable:

a) Bend test
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

b) Sidewall bearing pressure (SWBP) test

After each test, the cable should be dissected and visually examined for signs of cracking, wrinkling, or
separation of the metallic bonding, or for damage to other portions of the cable.

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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

7.7.1 Developmental or sample bend test for medium-voltage cable

The bend test is normally a developmental test for setting the design of a medium-voltage cable. It may also
be used at a defined frequency to check a manufactured cable against design requirements. The guide
referenced in Clause 2 for conducting a longitudinal water penetration resistance test of a 600 V or
medium-voltage cable rated 5 kV–46 kV that has a sealed conductor or is otherwise water blocked provides
information on mandrel diameters for bend tests. The guide provides information on bend conditioning a
cable prior to conducting the water penetration test. This information is useful for determining a mandrel
size for bend testing a cable because the mandrel size for the bend test is chosen according to thickness of
the conductor insulation and the diameter over the extruded semi-conducting insulation shield over the
insulated core (DOC). The parameters for the choice of cable mandrel diameter are shown in Table 3 as
follows:
Table 3 —Bending mandrel diameters (mm, inch) for water blocked cable per
ICEA T-31-610

Insulation Thickness, mm (inch) DOC < 25.4 mm DOC= 25.43 mm–50.8 mm DOC> 50.83 mm
(< 1.000 inch) (1.001-2.000 inch) (>2.001 inch)

< 4.30 (<0.169) 8× 10× 12×

4.32-7.87 (0.170-0.310) 10× 12× 14×

>7.90 ( >0.0311) N/A 14× 16×

NOTE 1—DOC = diameter over the extruded insulation shield.

NOTE 2—This table only applies to single conductor cable.

The referenced test procedure requires 3 bend cycles (6 reverse bends) around the specific mandrel at
ambient temperature. A cycle is defined as 2 × 180 degree bends in the opposite direction. Specimen length
is not specified, but needs to be longer than 1 m.

BS 7970:2005, [B85] calls for a 10–15 m long specimen that is bent around a mandrel whose diameter that
is 25 × (d + D) +/– 5% where d is the actual diameter of the conductor and D is the external diameter of the
cable.

Bibliographical reference The Underwriters Laboratory Standard UL 1072 [B118] calls for a cold bend test
for all sizes of medium-voltage cable. The test requirement is 1 (one) 180 degree bend around a 14 × OD
mandrel.

7.7.2 Developmental sidewall pressure test for medium-voltage cable

The sidewall pressure test is described in 8.5.7. The test is a developmental test that is not done on a routine
basis. It may be used if there are unusual circumstances during installation that may exceed the
recommended levels of SWBP.

Side wall bearing pressures have been measured for a bonding sheath MV cable with a smooth copper
bonded sheath, a low density polyethylene jacket over a wire neutral (see Bow, K.E. [B37]). The cable
passed through a 90 degree bend in conduit under tension. The SWBP was calculated by dividing the
tension on the cable exiting the bend by the inside radius of the bend.

26
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

The test results indicated that the cable with the bonded sheath moisture barrier withstood sidewall
pressures in excess of what would be expected in a normal installation. The bonded sheath withstood 2000
lb/ft radius or about 1300 kg/m, well above comparable cable designs with conventional sheaths.
Limitations on the test apparatus prevented tests at higher levels of SWBP.

7.8 Developmental short-circuit test

The short circuit capabilities of bonded sheaths and longitudinally folded tape shields have been
extensively investigated. Tests are performed during the developmental or design stage to set such
parameters as shield thickness and do not need to be repeated on a routine basis once the desired short
circuit requirements have been determined. Such tests have shown that thin foil or sheet type of tape shields
in a bonded sheath may have enhanced short circuit capabilities due to the increased heat dissipation
derived from the intimate contact created by the bond between the jacket and metallic shielding tape. See
Mildner, R. C., [B23]. Heat energy can be transferred to the cable components and to the environment more
efficiently leading to higher levels of short circuit current than that which would be calculated from the
standard methods that assume that the shield is in air (that is, no heat dissipation). As a result thinner
shields can be used for handling short circuit currents with the bonded sheath than what would be expected
from standard calculations. Table 4 shows calculated short circuit current values that were obtained by
taking heat dissipation into consideration. See Bow, K.E. [B37].

Table 4 —Calculated fault currents in amperes for bonded sheaths

with coated copper tape shields
Shield Thickness Calculated Fault Current (Amperes) at 6 Cycles
Mm (mils) Based on Following Diameters Over Shield, mm(inch)
25 (1.0) 37 (1.5) 55 (2.0)
0.15 (6.0) 6,500 amps 9,200 amps 12,000 amps

0.30 (12.0) 16,500 amps 23,600 amps 29,700 amps

NOTE—Calculations take heat dissipation into account. Assumed fault duration is 6 cycles.
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

Research work using actual fault tests and comparison of the field results to calculations that took heat
dissipation into account confirmed that longitudinally formed tape shields may have spiking voltages lower
than an equivalent wire shield and equivalent or better short circuit capabilities Martin, M., Silver, D., et al.
[B21]. Test data and calculated values confirmed that a copper tape shield 0.25 mm (10 mils) thick had the
ability to handle a short circuit current of 12,000 amperes for 30 cycles. Use of calculation that takes heat
dissipation into consideration can be the first alternative in determining the short circuit capability of a
bonded sheath unless some specific test is required.

There are several short circuit tests that have been proposed for testing the metallic component of a bonded
sheath on high-voltage cable that could be used for medium-voltage cable. One test is the spiking test
which is called out in bibliographical reference BS 7970 [B85]. The other is a 2 s maximum current test as
called out in bibliographical reference IEC 61901 [B105]. These tests are described further in 8.5.5. These
tests are not routine or sample tests because they may require special test equipment that may only be run
by a few specialized laboratories. Specifying one of these tests for other than development purposes or
prequalification purposes could require extra time and expense for certification of a manufactured cable by
a cable manufacturer.

27
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

7.9 Developmental test for bonded sheaths on medium-voltage cable

There are no recommended industry test protocols for development test to set the design parameters for the
entire voltage class of medium-voltage cable. Bibliographical reference IEC 61901 [B105] covers bonded
sheaths starting at 30 kV. In general, the test protocols in this reference follow the CIGRE
recommendations for high-voltage cable in French Standard C 33-051, [B94]. Most often, these
recommendations have been used as the model test protocol for medium-voltage cable. The key property
requirements are the same as for high-voltage cable, i.e., the moisture barrier sheath needs to maintain its
mechanical integrity after bending and thermal loading. Longitudinal water-blocking tests should be
conducted during or after these tests if the cable is required to block the longitudinal flow of water.

In the case where the metallic moisture barrier serves as both a moisture barrier and shield, there may be a
need to do a calculation for a specific short circuit capability using a program that takes heat dissipation
into consideration. A special short circuit test, done after the developmental phase, such as a high-current
application for 2 s, etc., may need to be conducted to measure whether the bonded sheath maintains its
integrity under unusual short circuit conditions predicated on relay opening times or other factors (see
8.5.5).

7.10 Life testing of medium-voltage cable with a bonded sheath

One utility tested actual bonded sheath medium-voltage cables that had been put in service by periodically
removing a section of the cable from service and testing for AC breakdown strength. The study was
conducted with a control by placing two types of MV cables in service, one with a bonded sheath and one
with only a jacket. See Mercado, K.M. [B22]. The bonded sheath cable had a coated aluminum tape applied
over longitudinally over a wire neutral and a core insulated with XLPE. The second cable had a wire
neutral and overlying jacket, but no radial-moisture barrier. The results of the study are shown in Table 5.

Table 5 —Breakdown strength versus time of services for medium-voltage cable

with a bonded sheath versus jacketed cable
AC Breakdown Strength, kV/mm
Years: Initial 0.3 0.5 1.0 3.0 5.0

Bonded Sheath 47 46 47 45 47 46
Jacketed Cable 38 32 30 23 16 15
NOTE— Medium-voltage cable installed in ducts which were continually filled with water.

It can be seen from Table 5 that the bonded sheath is providing protection from moisture as indicated by the
retention of AC breakdown strength after 5 years of service. Tests of the insulation in the cable with the
bonded sheath for trees indicated no trees were present in the insulation. The jacketed cable is showing
deterioration of AC breakdown strength in the same installation. These data indicate that it may be more
important to do tests that measure the mechanical integrity of the bonded sheath than to test for AC
breakdown strength or treeing in an accelerated test. As long as the bonded sheath maintains its integrity
during service, the properties of the insulation system should be preserved.

28
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

8. Application of radial-moisture barriers and longitudinal water blocking to

high and extra-high voltage cables
For purposes of this guide, the term high-voltage cable includes all the sub-class of high, extra-high, and
ultra-high voltages. Typically bonded sheath cables are used most frequently on high-voltage cables and
extra-high voltage cables up to 400 kV. Radial-moisture barriers are most frequently used on high and
extra-high voltage cables because these cables operate at high levels of electrical stress. The presence of
moisture in the insulation system could lead to rapid deterioration of the insulation system. The use of the
bonded sheath over a metallic wire screen has emerged as an efficient way to protect the cable insulation of
high-voltage cable from moisture. However, the use of metallic sheaths, especially lead and extruded or
welded aluminum tube, continue to be an important way to protect high-voltage and especially extra-high
voltage cable from moisture. These metallic sheaths have the ability to be sized to also provide the cable
with shielding. The use of corrugated, longitudinally formed metallic tapes with a sealed overlap has had
only limited use in high-voltage cable.

8.1 Bonded sheaths as radial-moisture barriers for high and extra-high voltage
cable

The bonded sheath with plastic-coated aluminum or coated copper is finding increased use in high-voltage
cable. Because such cables operate at increased levels of electrical stress versus medium-voltage cables, it
is recognized that extra measures may be required to protect the insulated conductor of the cable from
moisture. The bonded sheath is one of the measures that can provide the core of the cable with radial
protection from chemicals and moisture. Also, the metallic component can be used to supplement the short
circuit capability of the wire screen. The bonded sheath could replace lead and pipe-type sheaths for high-
voltage cable applications. Over the last 2 decades, many kilometers of high-voltage cables with bonded
sheaths containing coated aluminum have been manufactured and installed in Europe, the Middle East and
other locations around the world. Typically, bonded sheaths are used for 69 kV and the 115 kV–138 kV
voltage classes. Use at 225 kV is frequent and recently 345 kV as well as 380 kV and 500 kV cables have
been developed. User reports confirm that the installed cables have performed satisfactorily.

CIGRE WG B1-25 document [B86] defines the bonded sheath as a Separate Design (SD) because the
mechanical and electrical properties are separated from each other. The wire screen provides the short
circuit protection and the bonded (laminated) sheath provides mechanical protection.

A 138 kV high-voltage cable with bonded sheath is illustrated in Figure 6. The construction of this cable is
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

similar to all voltage classes, including 69 kV, 90 kV, 115 kV–138 kV, 225 kV, and 380 kV. The high-
voltage cable generally requires a wire screen to provide the desired levels of short circuit current. The wire
screen is surrounded by 2 layers of semi-conducting water-swellable tapes to block water flow in the wires
of the screen and the core-sheath interface. The bonded sheath with a coated copper or coated-aluminum
moisture barrier is applied over the outer water-swellable tape to provide the cable with a radial-moisture
barrier.

29
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

“This figure has been provided courtesy of Kable Consult LLC.”

Figure 6 —138 kV bonded sheath power cable with a radial-moisture

barrier of coated copper and longitudinal water blocking with
semi-conducting water-blocking tapes
A 132/76 kV cable design utilizing a bonded sheath with one side plastic-coated copper tape has undergone
extensive testing. This design consists of a layer of wires or flat copper straps covered by swelling tapes
and a bonded sheath with a longitudinally folded and overlapped copper tape. A semi-conductive bedding
tape provides the electrical, mechanical and thermal contact between the cable core and the bonded sheath
while allowing for different rates of thermal expansion for the materials. A high-density polyethylene
jacket provides the outer protection and is bonded to the coated metal. A 64 kV version of this cable has
been tested for 2500 hours with a 10-hour-on/14-hour-off load cycle with no breakdown. See H.
Zimmerman. [B32].

Bonded sheaths with coated copper have been used to replace 69 kV, 138 kV and 345 kV LPFF and pipe
cables by a major urban utility in the USA. See Frentzas, F. [B73]. The replacement cable had to fit into an
existing 100 mm (4 inch) diameter duct. The bonded sheath design for this application is similar to Figure 6
and has a 0.15 mm (0.006 inch) one side coated copper tape. The copper is bonded to the cable jacket and
the overlap is sealed with a hot melt adhesive. The copper tape is applied smooth (i.e. without corrugations)
over a copper wire screen. The cable has a fault capability of 63 kA at 15 cycles. Fiber optics may be used
within the sheath to monitor sheath condition, temperatures and operating performance. The cable
accessories consist of pre-molded joints and composite terminations. Pulling tensions are considerably
reduced over that for lead sheaths thus facilitating installation of the cable in existing ducts.

Table 6 compares the usage of high-voltage cables with bonded sheaths to usage of cable with lead, or
other metallic sheaths as moisture barriers. Typically the lead sheath consists of metallic lead or lead alloy
applied over the cable core as a seamless tube having a minimum thickness of approximately 2.2 mm
(90 mils). The bonded sheath consists of a coated aluminum tape with the aluminum component having a
thickness of 0.20 mm (8 mils). The tape is bonded to a polyethylene jacket approximately 2.75 mm
(110 mils) thick. (The thickness of the jacket will vary according to cable diameter). These data were
gathered by CIGRE WG B1-25 in 2009 [B86]. The data represents feedback from 13 countries from around
the world. The global trend is an increase in the share of the bonded sheaths and a decrease in the
consumption of cables with the traditional metallic moisture barriers. The use of the bonded sheath
represents about 27.5% of the installed cable, with the usage starting in the late 1980’s and increasing
steadily to levels estimated to be 400 km per year in some countries.

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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

Table 6 —Usagea comparison in kilometers for lead and bonded sheaths

on high-voltage cableb
Area Bonded Metallic Bonded Sheath Lead and Metallic
Voltage Class, kV Sheath Sheaths
50–109 Global 355 76 7194
110–219 Global 286 2498 605
220–314 Global 109 38 1206
315–500 Global 33 48 59

Total 783 2660 9064

a
Usage as reported by CIGRE WG [B86]
b
High-voltage cable includes 69 kV, 115 kV, 132 kV, 154 kV and 225 kV classes

8.2 Metallic sheaths as radial-moisture barriers in high-voltage cable

8.2.1 Corrugated, longitudinally-folded metallic tapes with sealed overlap

Relatively thin bare copper tapes, usually about 0.20 mm (8 mils) thick, without plastic coatings, have been
utilized as a combination moisture barrier and shield. Their use in high-voltage cable is usually limited to
the lower range of high-voltage due to short circuit limitations. Such copper tapes are corrugated and then
applied longitudinally under the jacket, with an overlap or seam. The overlap is sealed with an adhesive to
block the entrance of moisture. A jacket is then extruded over the corrugated tape. One variation of this
design is to place a water-swellable tape over the overlap. The water-swellable tape, if activated by the
presence of water, can serve as a second line of protection to prevent water from entering the overlap. See
4.1.1 for additional details on this type of construction.

8.2.2 Aluminum sheath moisture barriers

8.2.2.1 Un-bonded design

Extruded or seam welded aluminum tubes with or without a jacket can be used as moisture barriers for high
and extra-high voltage cables. In France and other countries the aluminum sheath has been used extensively
for high-voltage cable rated 90 kV. The aluminum typically has a minimum thickness of 0.56 mm (22.0
mils) and use of this thickness is typical for cable diameters up to 55.37 mm (2.180 inches) for corrugated,
welded aluminum sheaths [B74]. The aluminum can be used as the metallic screen and for mechanical
protection in all voltage classes. Disadvantages of aluminum sheaths may be corrosion protection, bend
performance, jointing and terminating considerations, and sheath losses in high-voltage cables.

8.2.2.2 Bonded metallic sheath or combined design

The bonded metallic sheath or combined design (CD), per CIGRE WG B1-25 document [B86] combines
the electrical and mechanical properties by using tandem extrusion to apply a copolymer adhesive over the
aluminum tube prior to the extrusion of the jacket. This allows the tube to be bonded to the jacket. A
relatively thicker metallic tape longitudinally folded and glued at the overlap may be used versus a welded
or extruded tube to form the metallic sheath. Accordingly, the advantages of the bonded metallic sheath
that is obtained are mechanical strength, moisture resistance and corrosion protection for the aluminum

31
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

tube. See Aucourt, C. [B67]. The thickness of the metallic shield can be chosen to carry the full short
circuit current, or additional wires can be added to match the short circuit requirement. Copper may also be
used as the metallic sheath.

8.2.3 Lead sheath moisture barriers

Lead sheaths have historically been used with oil filled paper insulated power cables but are also used for
cables with solid dielectric insulation. These types of sheaths are specified in bibliographical reference
ICEA S-94-639 [B97].

The use of lead sheaths appears to be the subject of regulatory concern around the world as expressed by
the US Department of Labor OSHA Publications dated 1993 [B33]. The main regulatory concern seems to
surround the potential effect on ground water contamination that lead salts may have if leached from the
sheath of the cable as in bibliographical reference Snow, J. H. [B27]. These salts may have an adverse
effect on the environment, and in particular, drinking water. The splicing of lead sheath cables by soldering
methods creates another potential regulatory concern about worker health as in the Lead Industries
Association [B34]. Exposure to breathable levels of airborne lead may result in the accumulation of lead in
the body and potentially dangerous levels in the blood. Medical monitoring of workers exposed to lead
cable splicing may be required as well as specific plans for compliance that specify and control the degree
of exposure.

In contrast to lead sheaths, the bonded sheath can be environmentally friendly since it may not contain lead
metal or other heavy metals. The sheath can be recycled. There may be other potential economic
advantages with the bonded sheath. Transportation costs are reduced due both to lower weight and the
ability to achieve longer lengths on a reel. The lower weight may increase the ease of installation which can
also play a potential role in reducing costs. Elimination of the lead may also mean reduced worker hazards
during splicing as well as increased efficiency in the splicing operation. This in turn could lower costs.
Future costs of recovery and salvage may also be minimized.

Lead sheathed, paper insulated fluid filled (LPFF) cables also have the potential of being replaced with
XLPE insulated cables having a bonded sheath. One concern with LPFF cable can be that it may have high
maintenance costs after being in service for a number of years. The major issues with LPFF usually appear
to be the potential environmental concerns with both the lead sheath and the fluid dielectric.

8.2.4 Welded copper sheath

Seam welded copper or bronze sheaths are also used for moisture barriers over HV cables in much the
same fashion as welded aluminum sheaths. See Guo, J. [B74]. The sheath is generally copper, but bronze
has been used as well. The minimum thickness of the copper is 0.38 mm (15 mils). Corrugations are
applied after welding. A jacket can then be applied over the welded tube.

8.3 Water-blocking high-voltage cable

Many high-voltage cables may include swellable water-blocking materials to provide longitudinal water
blocking of the circular or segmented conductor, concentric neutral, metallic screen, metallic shield and
other cable free space. Figure 7 shows a typical high-voltage power cable with a full radial-moisture
barrier provided by a bonded sheath and full longitudinal water blocking of the sheath and conductor
interfaces. There are several ways to use water-blocking tapes and yarns to block the strands of the
conductor as follows:

32
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IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

a) One method is to use a combination of yarns and a special water-swellable tape that is non-
conducting, very thin and friable. See Czupryna, S. W. et al. [B42] and Czupryna, S. W., [B43].
This tape breaks apart (fractures) during the wire compacting process and that allows the tape to be
inserted without increasing the diameter of the conductor. The thinner thickness and friability of
these types of tapes provide the cable manufacturer with the ability to insert the tape without a lot
of resistance during the process of closing the conductor strands. The types of tapes based on
woven or non-woven fiber that are used to block sheath interfaces would not be suitable for use in
the conductor because they may have a significantly increased level of resistance to being inserted
into the strands of the conductor. The standard tapes could also increase the conductor diameter due
to their bulk. The reason the option of thin tapes plus yarns may be chosen is that, as larger
conductor sizes are being formed, an increasing number of yarns are needed to provide sufficient
water blocking. At a certain point, typically once the +12 layer of strands is added, the number of
yarns required to be handled becomes unwieldy. A thin, friable tape can be used to simplify the

--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---
manufacturing process for water blocking the conductor. In Figure 7 this tape would be inserted
between the +6 and +12 layer of the conductor strands, between the +12 and +18 layers and any
subsequent layers. Figure 7 shows the tapes (unnumbered) between these conductor layers, but the
illustration is not to scale. The layer is much thinner and the layer actually breaks apart to fill the
spaces in the strands in the finished conductor. A semi-conducting water-swellable tape
(Component 5 in Figure 7) is typically wrapped over the finished conductor and the conductor
screen is extruded over the tape to complete the water-blocking process of the conductor.

b) Another method is to use water-blocking yarn with a diameter of approximately 1.3 mm to block a
conductor having small diameter wires with a high degree of compacting. See Czupryna, S. W., et
al. [B42]. For conductors with larger diameter wires and moderate degrees of compression, yarns
with a higher ability to absorb water are used since the conductor contains a relatively large amount
of free space. In Figure 7 these yarns would be inserted between the +6 and +12 layers and the +12
and +18 layers of the strands in place of the tape layers (unnumbered) in a manner similar to the
yarn illustrated as Component 1 in Figure 7. As was the case above, a semi-conducting water-
swellable tape is wrapped over the periphery of the conductor to complete the water blocking of the
conductor strands.

c) In the case where water-blocking filling compounds are used to block the conductor, a semi-
conducting water-swellable tape is typically wrapped over the periphery of the conductor as
previously described above. The water-swellable tape allows the spaces around the outer layer of
wires to be blocked and forms a relatively smooth and clean surface for the extrusion of the
conductor screen.

33
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

“Illustration is reprinted with permission of Nordlys SAS, which is a subsidiary of Polymer Group, Inc.”

Figure 7 —Longitudinally water-blocked high-voltage cable

with bonded sheath and metallic wire screen

8.4 Methods for expansion control of bonded or un-bonded sheaths on

high-voltage cable

8.4.1 Water-swellable bedding tapes

The water-swellable bedding tapes described in 5.5.1 may be suitable as a cushion layer in the cable sheath
for accommodating the thermal expansion and contraction of the core. Semi-conducting foam-bonded
water-blocking tapes or water-blocking tapes with a relatively thick, 1.5–2.0 mm, non-woven top layer are
commercially available. They have a long history of use as cushion layers in bonded sheath cable designs.
The key to expansion control is to accommodate the thermal-mechanical load cycling so as to be able to
maintain the integrity of the moisture barrier during and after thermal cycling. The combination of
elastomeric adhesives to seal the overlap and bedding tapes are usually used to accomplish this purpose in
high-voltage cables.

8.4.2 Thin lead foils

Certain under jacket designs use a lead foil coated with plastic layers to accommodate thermal expansion.
The plastic-coated lead foil is bonded to the jacket. The lead foil has the ability to elongate and contract
with the jacket during cyclic loading to accommodate the thermal-mechanical forces. See Nakagawa, H., et
al., [B76].

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Barriers and/or Longitudinal Water Blocking

The CIGRE WG B1-25 document [B86] defines the bonded sheaths with coated lead foils as the Separated
semi-conductive Design (SscD) because the cable has separated electrical and water tightness properties
with a semi-conductive plastic-coated lead foil. The jacket is usually PVC.

8.4.3 Synthetic materials

In some prototype cable designs, semi-conducting foams or crepe paper have been used as cushion layers.
These materials may not provide longitudinal water blocking.

8.4.4 Elastomeric adhesives for sealing the overlap

An elastomeric adhesive may be used to seal the overlap as previously described in 5.3. The elastomer
based adhesive can have the ability to absorb the expansion and contraction of the cable core at the overlap
without losing its bond to the components of the coated metal forming the overlap. The use of this type of
adhesive in addition to water-swellable cushioning layers may provide sufficient expansion control for
high-voltage cable.

8.5 Tests for high-voltage cables with bonded sheaths

8.5.1 General

The tests for cable are divided into classes which cover the stage of development, commercial acceptance
and user needs. Tests conducted during the design and prototype stages of development are generally not
repeated in the commercial phase because these tests are conducted to set parameters such as thicknesses of
the components, mechanical and electrical properties and related design criteria for the cable. Sample and
routine tests generally cover the commercial phase. These tests, in general, are used to measure the integrity
of the sheath. These are tests done during the development of the cable design. The classes of tests are as
follows:

a) Developmental tests:
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

⎯ Prequalification tests: These tests are conducted on a prototype cable before supplying the cable on
a commercial basis.

b) Type tests: These tests are conducted on the cable design along with accessories before they are
supplied on a commercial basis for a design that meets the requirements of the cable user. These
tests verify the properties of the cable as part of a system.
c) Sample tests: These are tests conducted on complete cable or component, at a specified frequency,
to verify that the specific product meets the design and manufacturing specifications.
d) Routine tests: These are tests made on every manufactured length of cable or every component to
demonstrate the integrity of the cable or component.
e) After-laying tests: These tests are conducted on the completed cable system after installation, and
prior to use, to demonstrate that the cable system has retained its integrity and to assess if any
damage or workmanship errors might have occurred.

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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

A working group of CIGRE, Study Committee 21, prepared recommendations on developmental tests for
high-voltage cables with synthetic insulation and bonded protective coverings as moisture barriers. The
recommendations were published in the Electra Journal in 1992 [B87]. (Note: CIGRE WG B1-25 is in the
process of revising the recommendations and has completed the initial draft of their report [B86]. This
guide covers the new test recommendations. The original recommendations have been updated with the
preliminary recommendations from CIGRE WG B1-25). However, only parts of the original guidelines
from 1992 were included in the bibliographical reference IEC 60840 4/1/04 [B102] which is an IEC
standard for HV cable for rated voltages above 30 kV to 150 kV. However, the developmental tests have
been published as an IEC technical report IEC Technical Report 61901 TR 7/1/05 [B105]. Also a British
Standard has been published with similar tests for cables with metallic wire and foil sheath constructions
for cables rated 66kV to 132 kV as given in bibliographical reference British Standard, BS 7970-2005
[B85]. The test procedures parallel the procedures in the IEC Technical Report with a few exceptions as
noted in the following sub-clauses. These test procedures recognize that maintaining the mechanical
integrity of the bonded sheath is the key to maintaining the integrity of the moisture barrier properties of
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

the cable. The various tests recommended in these documents are summarized in 8.5.2 through 8.5.2.

8.5.2 Developmental impact test for cable

Note again, for the most part, that the following tests are development tests used to determine the design of
the cable and the performance of prototype cables and, as such, are not used as routine factory tests.

CIGRE WG B1-25 [B86] recommends that the impact test use a 27 kg (59.5 lbs) weight to test the bonded
metallic sheath. The concern is that damage to the metallic component could alter the electrical integrity of
the metallic sheath. The weight represents the case where very heavy object, such as a manhole cover, may
fall on the cable. The weight is dropped 4 times at the same spot on the bonded metallic sheath. For the
bonded sheath cable with a plastic-coated metal tape, the test protocol has been modified with the major
change being that the impact test weight has been changed to a 5 kg (11 lbs) weight dropped from 1 m to
reflect the incidence of potential damage from, for example, dropped worker tools. The weight is dropped 5
times on 5 different spots about 100 mm (4 inches) apart. There is not a concern about the electrical
integrity of the metallic component of the bonded sheath because the short circuit capability is provided by
the screen wires. However, the impact resistance of the bonded sheath should be high enough to preserve
the radial-moisture barrier.

8.5.3 Developmental abrasion test for cable

The jacket of the cable has the function of preventing abrasion which could expose the metal component
and lead to corrosion of the metallic moisture barrier. Per the CIGRE WG B1-25 [B86] recommendations
the abrasion test is carried out when the jacket material is not PVC, MDPE or HDPE. No test is required of
these materials because they have a proven history of resistance to abrasion. When a new material with
unknown resistance to abrasion is used, a test consisting of a conical shaped weight weighing 48 kg (105.8
pounds) is rubbed on the surface of the cable back and forth 4 times over a 50 cm (19.7 inches). Visual
inspection is used to observe if the metallic moisture barrier has been exposed.

8.5.4 Developmental cable test of the adhesive bonds of the bonded sheath in long term
aging

Per the CIGRE WG B1-25 [B86] recommendations, the long term aging test is conducted by immersing a 1
m (39.4 inches) cable specimen with ends sealed in a 1% sodium chloride and 1% sodium sulfate salt
solution for 3000 hours at 80 °C. After aging the metallic component is examined for corrosion and the
adhesion is measured between the jacket and coated metallic moisture barrier and at the sealed overlap.

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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

8.5.5 Developmental cable system test for short circuit capability

Per the CIGRE WG B1-25 [B86] recommendations, the short circuit test is conducted for no longer than 5 s
on a 5 m long specimen that includes the metallic moisture barrier, metal screen, connection at the
accessory, the grounding connection and the grounding wires. The test simultaneously tests the system
components. The short circuit is applied so that it flows through the cable conductor and returns through
the metallic moisture barrier/shield, the metallic screen and the connectors. The joint is positioned so that
there is at least 2 m (78.8 inches) of cable on each side of the joint and earth and ground connections. The
test is carried out at the short circuit level calculated for the application. The maximum recommended
temperature by CIGRE WG B1-25 [B86] for the bonded sheath is 180 °C with a 250 °C temperature at the
wire screen.

Bibliographical reference BS 7970-2005 [B85] calls for a spiking test in which a metallic spike, 4 to 6 mm
in diameter, is driven in the cable to contact the phase conductor and a designated fault current is required
to flow through the metal conductor and return through the metallic screen for a required time. This test has
been dropped as a recommended test by CIGRE WG B1-25 [B86].

Bibliographical reference IEC 61443 [B103] sets the temperature limit for a polyethylene over sheath or
jacket bonded to coated aluminum or copper foil as 150 °C, the same as that of the polyethylene by itself.
Likewise, for a PVC jacket bonded to aluminum or copper, the temperature limit is 160 °C. There is
evidence that the polyethylene bonding may be equal to the PVC and capable of 160 °C as well.

8.5.6 Developmental cable system test for corrosion of cable accessories

Per the CIGRE WG B1-25 [B86] recommendations, the cable system test is conducted by immersing a
cable and attached accessory into a tank filled with tap water to a depth of 1 m (39.4 inches). A total of 20
heating and cooling cycles are applied by raising the water temperature within 15 °C or 20 °C below the
maximum operating temperature of the conductor in normal operation. The minimum duration of the
heating cycle is 12 hours. After the test, there should be no corrosion of any metallic component of the
accessory, connection of the cable to the accessory, accessory screen or bonding leads

8.5.7 Developmental sidewall pressure test for cable

Per the CIGRE WG B1-25 [B86] recommendations, the sidewall pressure test may be conducted if the
anticipated sidewall pressures are higher than expected for a jacket of PVC, MDPE or HDPE or if there are
optical fibers included in the cable design. The sidewall pressure test may require special equipment. The
sidewall pressure test per IEC 61901 TR 7/1/05 [B105] uses a 15 m (50-foot) length of cable, which is
pulled around a fixed wheel to achieve a sidewall pressure of 750 kg/m (500 lb/ft) T/R. The side wall
bearing pressure (SWBP) is calculated from the tension (T) in the steel wire pulling the cable and the wheel
radius (R). The radius of the wheel should not be greater than that used for the bend test. The cable should
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be in contact with the wheel for at least 90 degrees. Other methods to do the test could be accomplished by
pulling the cable around a fixed wheel, or small diameter rollers, through a bend of 180 degrees.

A SWBP test determines cable performance if a cable is to be pulled through duct with bends and elbows.
This information is used in determining maximum permissible pulling tensions during installation. Various
reports and guides describe, in detail, test parameters and recommended maximum SWBP limits for
various constructions, also see 8.5.8.

The test to determine maximum SWBP is performed by applying tension and back tension to the cable as it
is pulled through an elbow. A pulling lubricant is applied to the cable prior to the test. The moisture barrier
should be examined before and after pulling. Tests for adhesion can be used to establish the degree to
which the integrity of the moisture barrier has been maintained. Since various cable designs with metallic

37
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

moisture barriers may respond to this test differently, such qualification testing should be accomplished at
several levels of SWBP. Limits of SWBP should be established by the cable manufacturer and the user.
Maximum recommended limits for SWBP are generally at least 10% lower than the damage threshold
level.

8.5.8 Developmental system test for thermal cycling and thermal mechanical performance

CIGRE WG B1-25 [B86] points out that the thermal cycling or thermal mechanical tests are already
covered in relevant cable standards. If these tests are needed, then these standards can be used to cover all
the developmental requirements for the bonded sheath. For example, British Standard, BS 7970-2005 [B85]
and IEC 60840 4/1/04 [B102] provide test procedures and requirements.

8.5.9 Type tests for bend performance for high-voltage cable

The bend test may be considered a type test because it is a lead test for other tests such as long term aging,
water blocking and electrical tests. The test sample, 3 m (118.2 inches) long is bent 3 times around a
mandrel having a diameter of 25 times the diameter of the cable. The metallic component of the bonded
sheath can be visually inspected for delamination, folding, buckling or crossing of the shield wires.

A bend test similar BS 7970-2005 [B85] is called for in the IEC 62067 [B106] for high-voltage cable. The
bend test calls for 6 bends around a 25 × (d + D) mandrel. The test specimen can be up to 30 m long and
the test is done at ambient temperature.

Visual criteria are universally used for assessing the results of the bend test. The metallic shield is
examined, without magnification, for cracking, splitting, wrinkling or voids in the jacket-shield interface. A
jacket bond test can be used to quantify the effects of bending by comparing the bond strength between the
jacket and metallic shield before and after the bend test.

The choice of bend test parameters is the choice of the cable owner and can be chosen from any of the
above standards or from specific end-use requirements. The bonded sheath has bend properties that may be
superior to the types of cable where the shield is not adhesively bonded to the jacket. Such behavior has
been documented in reference Bow, K.E. [B6]. Typically to show the performance of the bonded sheath in
comparison to un-bonded sheaths with shields, smaller mandrel diameter to cable diameter (D/d) ratios are
chosen, such as 6x for smaller diameter low-voltage cable, 10× for medium-voltage cable and 12x for high-
voltage cable. A survey of the above bend test parameters would indicate that the parameters from ICEA-
31-610-2007 might be the most appropriate for bonded sheath HV cable (7.6.1). This observation is based
on the following considerations: (1) bend test parameters in Table 3 are based on a standard designated for
the testing of water blocked cable at ambient temperature; (2) they take into consideration both the wall
thickness of the insulation and the diameter over the core of the cable; and (3) they can be applied to any
voltage class. The use of BS or IEC criteria, for example, may be appropriate from a specification point of
view, but a 25 × (d+D) mandrel ratio may not be representative of the bend performance that can be
achieved with a bonded sheath.

8.5.10 Sample test for measuring adhesion in bonded sheaths

After each test procedure, the jacket bond strength, and overlap seal strength tests may be used to
quantitatively measure the effect of each test procedure on the bonded sheath. A peel test specimen 200
mm (7.9 inches) long and 10 mm wide (0.4 inches) is cut from the sheath and the overlap. The specimen is
tested for adhesive strength at 50 mm (2 inches) per minute with a peel angle of 180 degrees. Per CIGRE
WG B1-25 [B86] recommendations, minimum peel strength of 1.0 N/mm (5.7 pounds per inch) is
expected.

38
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

8.6 Developmental and sample test for longitudinal moisture transmission

8.6.1 General

The longitudinal water penetration test may be used as a developmental test, prequalification test, type test,
sample test, and routine test. Certain additional qualification test considerations may be necessary to fully
characterize a moisture barrier cable. The user should first delineate cable with only a radial-moisture
barrier (water from the outside) from a moisture-impervious cable (water from outside and/or
longitudinally through the conductor or other free space within the cable). It has been shown that water in
the conductor of a MV/HV power cable can initiate the treeing phenomenon more quickly than water from
the outside. Therefore, separate tests may be required to properly distinguish between the effects of water
in the conductor versus water from the outside. Also, since under-jacket moisture barrier cables usually
have a water-blocking layer under the moisture barrier to prevent longitudinal flow of water, additional
consideration should be given to a test for this property. Jackets may also affect results and their presence
should be taken into consideration as a control. It follows that appropriate tests should be designed to
provide an accurate comparison of the performance of these water-blocking measures in preventing
moisture from reaching insulation surfaces within the cable.

8.6.2 Longitudinal water transmission in sheath interfaces

Longitudinal water migration under the jacket of cables may have an adverse effect on the insulation, the
insulation shield and cause corrosion of the metallic shield. Cable terminations and splices may also
degrade. Longitudinal water migration should therefore be minimized. This may be accomplished through
the use of water-swellable materials in the free space of the cable.

The two basic types of longitudinal water propagation tests are:

⎯ Testing the full cross-sectional area of the cable.

⎯ Testing the interface between the sheath/shield and the jacket (T-type).

8.6.3 Testing for longitudinal water blockage

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Longitudinal water blockage testing can reference any of the following industry specifications:

⎯ ICEA T-31-610-2007, Water Penetration Resistance Test for Sealed Conductor (with
modifications).
⎯ ICEA T-34-664-2007, Conducting Longitudinal Water Penetration Resistance Tests on Cable.
⎯ IEC 60502-2 [B101], Power cables with extruded insulation and their accessories for rated voltages
from 1 kV up to 30 kV.
⎯ IEC 60840-4/1/04 [B102],Power cables with extruded insulation and their accessories for rated
voltages above 30 kV up to 150 kV.
⎯ IEC 62067 [B106], Power cables with extruded insulation and their accessories for rated voltages
above 150 kV up to 500 kV.

39
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IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

The ICEA T-31-610-2007 test subjects the entire cable cross-sectional area to water pressure and may be
suitable as a production test or a qualification test. One of the above tests can be used to qualify a new
cable design ICEA T-31-610-2007 test may also be considered for production testing for cables that have
both sealed conductors and the sheath interfaces blocked to the flow water.

Note that this test is intended to evaluate sealed conductors for longitudinal water penetration. As such, it is
necessary that the testing procedure be modified before an evaluation of water blocking in the sheath/shield
to jacket interface can be made. The following changes should be considered by those responsible for using
this standard to test for longitudinal water penetration around the sheath interfaces:

a) The preconditioning air oven temperature of cables with thermoplastic jackets should be
40 °C lower than the rated overload temperature of the cable.

b) The test should be conducted with the jacket or bonded sheath in place.
c) The test pressure should be 0.35 bar (5 psi).
The IEC standards listed in the first paragraph of this subclause are most often used globally for
longitudinal tests of water blocking in the sheath interfaces of MV and HV cables with radial and
longitudinal water blocking. To handle testing for the longitudinal penetration of water in cable, the ICEA
T-34-664-2007 test has been developed. This test is similar to the longitudinal water penetration test called
out in the IEC specifications. The test is designed to test the sheath interfaces for moisture resistance.

8.6.4 Longitudinal water transmission in the conductor

A cable with an outer moisture barrier may sometimes employ a means for blocking water ingress through
the conductor. This may be accomplished through either:

a) The use of a solid conductor where conductor size permits.

b) In the case of stranded conductors, the use of a filled/blocked strand.
c) The use of a lead-foil bonding around the conductor.
d) The use of water-swellable yarns woven into the stranded conductor during the stranding process.
The literature reflects that water in the strands of test cables may contribute substantially to insulation
degradation. Thus, comparisons to cables tested with water in the strand should be avoided with radial-
moisture barriers unless appropriate control samples are utilized to separate the effects of water in the
conductor from the effects of water entering from the radial direction. Testing for water-blocking
performance of the conductor involves placing a reservoir of water at the upper end of a vertical 0.91 m
section of cable and applying pressure. Typically, the application of 0.02 to 0.11 Pa for 1 hour has been
used. ICEA T-31-610 covers this test. Cable that does not have a filled and blocked strand should be
manufactured in such a manner as to prevent water entrapment in the conductor.

8.6.5 Longitudinal water transmission from moisture barrier damage

The possibility exists that the moisture barrier could be damaged, thus allowing water to contact the
insulation screen. It is possible for damage to be simulated by using a controlled experiment to examine
water penetration due to moisture barrier faults. However, no industry standards or guides are known to
exist at this time with regard to the defect type, size, or frequency.

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IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

8.7 Discussion of developmental tests for high-voltage cable

Not all the developmental tests and test sequences described in this clause may be required to characterize a
bonded sheath cable for high or extra-high voltage applications. The key tests to measure whether the
sheath is providing a radial-moisture barrier suitable to the application can be narrowed down to the bend
test, the thermal cycling test, and, in the case that the cable is designed to block the longitudinal flow of
water, the longitudinal water penetration test. The bend test and cycling tests measure the ability of the
metallic component of the bonded sheath to maintain its mechanical integrity. If the mechanical integrity is
maintained, then the moisture barrier properties of the cable should be maintained. Typically the thermal
cycling test is run for 14 or 20 cycles. This number of cycles is consistent with other cable designs or
specifications and represents a number of cycles after which little additional changes in cable dimensions
are to be expected. The water penetration test is normally run after a bend test to measure whether the
handling of the cable may compromise the longitudinal water resistance of the cable.

There are 2 levels of performance in the impact test procedures, one with a 27 kg (59.5 pound) weight and
one with a 5 kg (11 lbs). The higher weight is used for the bonded sheath design where the cable jacket is
bonded to a metallic tube of extruded or seam welded aluminum or copper. For this design the metallic
component serves as both the electrical shield and the moisture barrier. This combined design is described
in 8.2.2.2. There is a concern that mechanical damage may alter the electrical performance of the shield so
a heavier weight is used in the impact test. In the case of the bonded sheath using coated aluminum, coated
copper or coated lead for the moisture barrier, there is a wire screen that is sized to meet the anticipated
electrical requirements. The effect of mechanical damage to the sheath is of lesser concern so a lighter
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weight is used. However, the impact resistance of the bonded sheath should be high enough to preserve the
moisture barrier properties of the coated metal tape. The user and cable designer should decide what the
end use requirements for impact should be because there is a disadvantage in requiring higher than needed
levels of impact resistance. This can lead to designs that are not optimized from a cost-performance
standpoint, i.e., higher levels of impact resistance generally require an increased thickness for the metallic
moisture barrier. This may lead to increased material requirements to achieve higher levels of impact
performance that may not be needed with respect to the degree of mechanical and radial-moisture
resistance that may be required. Thus the use of thicker metallic moisture barriers/shields than required to
achieve impact resistance may not be cost effective. Once the impact requirement for the end use
application is met during the development phase of the cable, it becomes a parameter of the cable design
and no longer needs to be tested on a sample or routine basis.

The long term aging test is used to determine the stability of the adhesion between the plastic and metallic
components in the bonded sheath. The test may also be used as a corrosion test to assess, for example, the
effect that physical damage may have if that damage leads to penetration of the metallic moisture barrier
which, in turn, could allow water into the cable. In that case the key may be to prevent longitudinal water
penetration. Running the water penetration test may allow the cable designer to assess the degree to which
longitudinal penetration of moisture is controlled. Then corrosion can be limited to the area where a break
in the sheath occurred. The long term aging test, as described in 8.5.4, has the ability to measure whether
the coated metal bonding is permanently bonded to the jacket and if the overlap maintains its integrity. The
long term aging test is meaningful to assess whether the permeation of the corrosive agent can cause the
bond between the radial-moisture barrier and the jacket to be compromised. If the bond shows a decrease in
adhesion or fails through delamination, then the bonded sheath may not prevent the radial ingress of
moisture over the expected lifetime of the cable. In the case of high-voltage cables this bond failure could
lead to rapid degradation of the insulation system due to the higher levels of voltage stress at which these
cables operate.

The short circuit test allows the cable designer to assess the components needed to effectively ground the
metallic moisture barrier. It can also assess whether the metallic moisture barrier is meeting the calculated
short circuit current when the metallic moisture barrier is also acting as an electrical shield or screen as in
the combined design. When a wire screen is included under the metallic moisture barrier for short circuit
capability in the bonded sheath, then it will be sized to meet the perceived needs for fault protection
without relying on the capabilities of the metallic moisture barrier. Short circuit capability of the bonded
sheath should be determined from calculations that take heat dissipation into consideration. Work described

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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

for bonded sheaths in bibliographical reference by Mildner, R. C., [B23] with coated copper and reference
Martin, M., [B21] for longitudinally applied copper shields showed that the measured and calculated short
circuit capabilities of these sheaths greatly exceeded the values that would be calculated from the standard
method where heat dissipation was not considered. Again, the short circuit test is a developmental system
test. Once the parameters of the metallic components are determined, the test is not repeated on a sample or
routine basis.

The sidewall pressure test is also a parameter of the cable design, and once the design is set, it may not
need to be repeated as a sample or a routine test requirement. The test could be rerun if there are
circumstances during installation where potentially excess levels of sidewall pressure may be encountered.

The bend test may be used to measure the mechanical integrity on the sheath. Since the cable jacket is
integral with the metallic moisture barrier, the sidewall pressure is increased by the composite structure of
the bonded sheath. The bend test criteria for water blocked medium-voltage cable in Table 3, may be the
best developmental test to use for developing the design parameters for a bonded sheath on a high-voltage
cable since it takes cable diameter and insulation thickness into consideration when choosing the mandrel
diameter for use in the bend test.

8.8 Life testing of high-voltage cables with bonded sheaths

An accelerated aging study of a HV cable with a bonded sheath showed no degradation of the AC
breakdown strength after more than 10,000 hours of aging. A conventional cable with no moisture barrier
degraded rapidly in AC breakdown strength after the first 3000 hours of testing. See Bow, K.E. [B37].

9. Sample tests for measuring the integrity of bonded sheaths for all
voltage classes

9.1 General

Subclause 8.7 has outlined the considerations when applying developmental test procedures to design
moisture-blocked cables. Some previous sub-clauses have introduced research test methods specific to
evaluating the radial-moisture penetration in water-blocked cables. Other developmental tests can be based
on the relevant industry standards. The following sub-clauses will provide suggestions on the sample test
procedures to follow for evaluating the bonded sheath as applied to low, medium, and high-voltage cables.
These tests may be applicable to all classes of tests related to the developmental phases, production and
acceptance phases associated with moisture blocked cables.

9.2 Sample tests common to all voltage classes for measuring the performance of
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

the bonded sheath

9.2.1 Visual tests

After each test sequence or phase of a test, the bonded sheath can be examined in a qualitative manner
using visual observation to look for defects such as splitting, seam opening or bond separation.

9.2.2 Adhesion tests

Adhesion tests are most often used to measure the integrity of the moisture barrier provided by the bonded
sheath. The assumption is made that if the bond strength of the metallic moisture barrier at the overlap and

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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

between the metallic component and the jacket is maintained after the various cable tests (such as bending,
thermal loading, etc.,) then the moisture resistance of the sheath is being retained. After each test sequence
or phase of a test, the bonded sheath can be examined for performance in a quantitative manner by use of
adhesion tests. These tests can be used to measure the bond strength within the overlap and /or between the
metallic component and the cable jacket.

9.2.2.1 Overlap adhesion test

The test for adhesion within the overlap is conducted by cutting a longitudinal (along the cable axis) strip
12.5 mm (0.5 inch) from the center of the overlap. The strip contains the overlap and the jacket bonded to
the overlap. To prepare the overlap for testing, the layer of the overlap nearest to the core is separated from
the layer bonded to the jacket. This layer is bent back 180 degrees on itself to form a tab that can be
mounted in one jaw of a tensile machine. The portion of the overlap bonded to the jacket is mounted in the
other jaw of the tensile machine. A steel backing plate is placed next to the specimen to keep the peel angle
at 180 degrees. The layers of the overlap are then separated at a test speed of 50 mm (2 inches) per minute.
The bond strength is recorded in force per a normalized width.

9.2.2.2 Jacket adherence test

There are two possible test scenarios for testing the adhesion between the metallic moisture barrier and the
jacket. The specimens can be cut longitudinally (along the cable axis) or circumferentially from the cable
sheath. There are advantages and disadvantages to both types of specimens. The longitudinal specimen
allows for more accurate measurement of bond strength because the peel angle during testing can be
maintained at 180 degrees. The circumferential specimen has a natural curve that causes the peel angle to
vary continuously during the bond strength test. This results in a peel record that shows a constantly
changing value of bond strength as the test progresses. The circumferential specimen has the advantage of
allowing the continuity of the bond to be observed by using one specimen. Multiple longitudinally-cut
specimens must be used to check for continuity of the bond along the length of the cable.

The choice of specimen type also depends on whether the metallic moisture barrier is applied smooth or
corrugated.
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

9.2.2.3 Smooth plastic-coated metallic moisture barrier

If the plastic-coated metal is applied smooth, adhesion test specimens most often are cut longitudinally. The
procedure is the same as described for the overlap in 9.2.2.1 with the exception that the specimens could
alternatively be cut with a width of 25.4 mm (1 inch) if the sheath has a large diameter. The metallic
moisture barrier is separated from the jacket to form a tab, which is placed in one jaw of the tensile
machine. The jacket is placed in the other jaw with a steel backing plate to keep the peel angle at 180
degrees.

9.2.2.4 Corrugated plastic-coated metallic moisture barrier

If the plastic-coated metallic moisture barrier is applied corrugated, the specimen most often is cut
circumferentially. The circumferentially cut specimen will allow the record of the bond strength to be a
smooth curve. The circumferentially cut specimen does have an issue in that the peel line is not straight due
to the corrugations that may be captured when the specimen is cut. Also, as noted previously, the natural
curl in the specimen also causes the peel angle to vary continuously as the metallic moisture barrier is
separated from the jacket.

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Barriers and/or Longitudinal Water Blocking

If a longitudinal specimen is cut from the sheath with a corrugated moisture barrier, the peel angle varies
continually as the corrugations are separated from the jacket. This results in a peel record that has wide
fluctuations in bond strength. It is therefore necessary to make an estimate between the highs and lows in
the peel record to obtain an average value of bond strength.

9.2.2.5 Choice of test samples

Jacket bond tests are relative. The choice of configuration for the specimen, whether the specimen has a
smooth or corrugated metallic moisture barrier, the peel angle, the test speed, and other factors, such as
jacket thickness, can affect test results. The choice of sample configuration and test conditions need to be
consistent in order to make comparisons between samples from the same cable or between different cables.

9.3 Developmental tests for radial-water tightness common to all voltage classes

9.3.1 General

These tests are developmental tests and are used to set the design parameters for a moisture barrier cable.
They are complicated and time consuming and should be used only as research tools.

One direct method of determining moisture diffused into the insulation is accomplished by performing an
analysis to measure insulation water content before and after exposure to wet aging tests. Another method
utilizes tritiated water to measure the permeation rate of the sheath or the materials comprising the sheath.

9.3.2 Moisture content of insulation before and after aging

The presence of water in cable insulation can be analytically determined by several techniques including
coulometric titration, Karl-Fisher titration, infrared spectroscopy, and differential scanning calorimetry.

Caution should be exercised when interpreting results as they can be significantly affected by the
following:

a) Water that is not homogeneously distributed in the cable insulation.

--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---
b) Moisture measurement results, using commercial instruments, may be erroneous due to the
competing effects of various curing by-products that may be liberated during the test.
c) Sampling effects that can exceed the magnitude of the actual measurement.

9.3.3 Moisture penetration at the overlap

A test method based on the use of water containing a small amount of the hydrogen isotope tritium has
been found useful for evaluating radial-moisture barriers for cable. See Poulsen S. H., [B55]. This isotope
can be detected with a high degree of accuracy and selectivity by liquid scintillation analysis. A length of
the bonded sheath or other type of cable sheath with the core removed and about 250 mm long is placed in
a test cell made of stainless steel. The cell is designed for operation between +1º and 50 °C. The challenge
chamber is filled with tritiated water, which surrounds the exterior of the cable sheath. A sample of the
atmosphere taken from inside the cable sheath can be used for the scintillation analysis. This trace method
is well suited for determining the water permeation rate of both the materials used for conventional cable
sheaths as well as for the bonded sheath.

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IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

9.3.4 Permeation rate of jackets

An overall outer jacket should be an integral part of any moisture-impervious cable design. The jacket is
also the first line of defense against radial permeation of moisture and will usually contribute to the
moisture barrier performance of a cable in a wet environment. Different jacket materials can vary in their
moisture vapor transmission rate. For example, the higher the density of polyethylene jackets, the lower the
transmission rate.

9.4 Special developmental tests for all voltage classes

Moisture-impervious power cables may be exposed to unusual environmental conditions that require
special material or design considerations. The following comments should be considered in such instances.
These conditions may include chemical and corrosive environments or exposure to fire.

9.4.1 Chemical resistance

The chemical resistance of any cable is a function of many parameters. The first line of defense against
chemical attack can be the overall outer jacket. The selection of a jacketing compound should be made to
suit the chemical environment in which the cable will be required to operate. In special cases an additional
chemical barrier or sheath may be required.

9.4.2 Corrosion protection

One side plastic-coated metals, when used as moisture barriers on the cables described in this guide, are not
necessarily intended to provide corrosion protection. Generally, plastic-coated metals bonded to the cable
jacket remove the moisture path in the shield jacket interface and thereby stabilize the bonded sheath and
core from the ingress of groundwater and chemicals that may exist around buried cable installations. Thus,
the bonded sheath forms a corrosion barrier that protects the outer surface of the metallic moisture
barrier/shield against corrosion. In the bonded sheath design, the plastic-coated metal also serves to protect
the wire screen or the underlying neutral wires. A combination of special jacket material and plastic-coated
metallic moisture barriers may be necessary to control corrosion in certain environments. If water enters the
cable from a sheath defect or from the cable ends, and the cable design contains water-swellable tapes or
powders, then there is the possibility of corrosion to the inner surface of the metallic moisture barrier/shield
in the areas under the sheath where the water-swellable material swelled and retained water. Here a
moisture barrier/shield based on copper may be superior to an aluminum moisture barrier. However,
extensive research has shown that the water swollen super-absorbents in water-swellable materials may not
appreciably accelerate the corrosion of metallic moisture barrier/shields. References to applicable technical
papers on this subject are listed in A.1.

A corrosion test can be conducted after the longitudinal water propagation test (see 8.5.4) by opening up
the sheath and examining the inner surface of the metallic moisture barrier for corrosion in the area where
water penetrated into the metallic moisture barrier-core interface.

Another developmental corrosion test is based on the procedure described for the long term aging test. This
test is conducted by immersing a 1 m specimen of cable in a salt solution at 80 °C. After 3000 hours, the
specimen is removed and the metallic moisture barrier/shield is examined for corrosion. This test measures
the ability of the salt solution to permeate the jacket and the ability of the adhesive coating on the bonding
to retain its bond to the metal and jacket in a hot, moist environment. If the adhesive bond decreases or
fails, there may be potential for corrosion and for moisture to penetrate the insulation system and cause
premature failure of the cable.
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,

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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

9.4.3 Fire propagation and emissions

Fire propagation and gaseous emissions may be a concern where cables are installed indoors. The user may
wish to specify limits on propagation and emission properties.

9.4.3.1 Fire propagation testing

The degree of fire retardant properties required for a cable should be determined by the user. The test
method most often specified is the vertical tray flame test based on IEEE Std 1202™-2006 [B114]or CSA
FT4 [B88] or IEC 60332 [B100].

9.4.3.2 Smoke and gaseous emission testing

Smoke and gaseous emissions that occur during burning are a function of the cable insulation, shielding,
and jacketing materials. The amount and types of these emissions may be controlled by compound
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

formulation. UL 1685 [B121] is a commonly conducted emission test.

9.4.4 Pre-conditioning

Thermal and/or mechanical preconditioning of cables prior to a water-treeing test may serve several
purposes. In cables without moisture barriers, the intent of thermal treatment is to remove any volatiles that
may, in the short term, provide some resistance to treeing during an accelerated test. In cables with radial-
moisture barriers, preconditioning may change the moisture resistance characteristics of the plastic-coated
metal. This could result in fatigue cracking of the bond, opening of the overlap seam, and/or bond
deterioration of the bond between the metallic component of the plastic-coated metal and other cable
components. The selection of a preconditioning treatment will vary with cable size, design, and intended
use of the cable.

10. Developmental tests common to MV and EHV power cables with

radial-moisture barriers and longitudinal water blocking

10.1 General

Moisture-impervious cables may be superior to other cable designs by virtue of their control over the flow
of water and moisture which may play a key role in fostering the deterioration mechanisms within the
insulation that are associated with water.

Moisture may enter cables from the radial direction during service through the permeation process.
Moisture may enter longitudinally at unsealed cable ends, at sheath faults or defects or by undetected jacket
damage during installation. The continued presence of moisture at either the inner or outer surface of the
insulation may initiate and propagate water treeing which is a known mechanism of insulation degradation.

Moisture transmission into cables can be measured directly or indirectly with complicated and somewhat
difficult research test procedures. These test procedures could be used in the design and developmental
phases for establishing the parameters and performance of a moisture barrier cable. They should not be
used as sample or routine tests. Some consideration needs to be given to the purposes of the radial-moisture
barrier and longitudinal water blocking. For example, it would not be appropriate to expose the insulation
or conductor of the core of the cable directly to water if the purpose of the test is to measure the
effectiveness of a radial-moisture barrier.

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IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

Indirect methods take into account the deterioration mechanisms of power cables associated with water in
the presence of an electrical field. In some cases, energized cables subjected to water contaminated with
various ions may lose dielectric strength as measured by an AC or impulse breakdown test or experience a
fault under the test conditions. Increasing voltage tends to accelerate deterioration in the presence of water
and ions. Cables with radial-moisture barriers and/or longitudinal water blocking, after such tests, normally
demonstrate higher retained dielectric strength and increased life when compared to non-protected designs
using similar insulation materials.

Temperature ratings as described in various relevant specifications can apply equally to cables with radial-
moisture barriers and/or longitudinal water blocking. Consideration needs to be given to the temperature
rating of the cable jacket in setting the temperature rating of the bonded sheath, just like any other cable
construction. In addition to the maximum critical temperatures for operation in normal, emergency, and

--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---
short-circuit modes, a cumulative number of thermal cycles should be considered at various temperature
ratings to characterize the design in terms of causing potential fatigue failure of the radial-moisture barrier.
Such thermal cycles can also show whether the design prevents accumulated set or deformation of the
bonded sheath due to thermal expansion and contraction of the core.

Other benefits of the use of moisture barriers may include preservation of the integrity of the cable core
from moisture/ chemical penetration, enhanced fire performance, and/or enhanced corrosion resistance
relative to other cable designs.

The cable core consisting of semi-conducting shields, insulation and conductor should meet the electrical
tests as required by various industry standards. In conducting such tests, the test parameters for moisture
barrier only versus moisture-impervious cables should be determined. When the standard test procedure
requires water in the conductor, then the performance of a radial-moisture barrier may not be adequately
measured. The tests for radial-moisture protection should be conducted without water in the conductor.

Again this clause describes developmental tests for determining the design parameters for a cable with a
radial-moisture barrier and/or longitudinal water blocking. Once the design parameters are determined,
these tests are not repeated on a sample or routine basis during the manufacturing and commercial phases.

10.2 Developmental tests for prototype MV, HV, and EHV cables with moisture
barrier sheaths

The following sub-clauses describe various tests that may be used to determine the effectiveness of a
developmental or prototype cable with a radial-moisture barrier and/or longitudinal water blocking in order
to establish the operating parameters of moisture-barrier or moisture-impervious cable designs. Not all of
these tests are required for radial and/or longitudinally water blocked cable constructions. Since the
insulated conductor(s) in the cable core reflect standard practices, the cores should be qualified according
to the appropriate industry specifications for qualification and production testing. The suggested changes to
existing standards to accommodate the testing needs for moisture-impervious cable designs should not be
interpreted as the initiation of changes in those standards. Rather, the manufacturer and user of cable
having radial-moisture barriers and/or longitudinal water blocking should agree on such changes as
supplemental to existing standards. The changes can then be incorporated into a supplemental customer
specification as jointly determined.

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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

10.3 Developmental electrical tests of the insulation system

10.3.1 Developmental test comparing of dielectric strength before and after aging

In this test, coils of cable are placed in a tank of water and energized at two or three times their rated
voltage for a period of six months, one year or two years. After aging a section of the cable specimen is
removed and tested for retention of dielectric strength.

The AEIC accelerated water treeing test may not be suitable for use on the water-impervious cable designs
due to the moisture barrier over the cable core and the longitudinal blocking measures utilized in this type
of construction. If there is doubt about the suitability of the cable core, then the outer moisture barrier, in
the case of the bonded sheath design, should be removed from the cable and only the core should be
subjected to the accelerated water treeing tests.

One school of thought is to assume that the moisture-impervious designs are an effective means for
preventing moisture intrusion to the insulation surfaces. If this assumption is accepted, then conducting an
accelerated water-treeing test is meaningless.

Another school of thought holds that the standard water treeing test procedure could be performed on
completed moisture-impervious cables as a means of evaluating the performance of various designs. In this
instance, cable samples should be subjected to thermo-mechanical test procedures in order to stress the
moisture barriers prior to subjecting the cable to the accelerated water-treeing test. Based on this
hypothesis, the following modifications to test procedures are suggested.

The effectiveness of a moisture barrier can be determined by comparing the dielectric strength before and
after aging a sample of the cable. An accelerated water treeing can be performed and the results compared
to AC and impulse breakdown tests performed on samples of new or un-aged cables or cables that have
been dry-aged. If truly moisture-impervious, then cables with moisture barriers should experience little or
no decline in properties when tested after aging. The following modifications should be made to the
accelerated water-treeing test:

a) Because the preconditioning test is a comparative test, it is important to have samples of cable with
identical insulated conductors. In the cable sample without the moisture barrier, preconditioning
may remove volatiles that provide some resistance to treeing. However, these volatiles would be
unable to migrate past plastic-coated metal or other metallic barrier in a moisture-impervious
design. If the samples are preconditioned, consideration should be given to this effect.
b) An additional effect of preconditioning is that thermal/mechanical stress is placed on the plastic-
coated metal during preconditioning. Care should be taken to factor out the effect that
preconditioning may have on the integrity of the plastic-coated metal.
c) Many industry standards call for a specific cable size for testing. The test results from this specific
size can be extrapolated to cover other sizes. Cable samples other than the standard size may be
used if their sizes are comparable. It is recommended that a standard cable size be used, if possible,
since cross-comparisons can then be made to data generated in other tests. If the user has a desired
cable size outside the range covered by the minimum size, then that cable should be tested in lieu of
the recommended cable size.
d) The effect of moisture within the conductor strands can have a detrimental effect on cable life.
Testing a moisture-impervious cable in this manner may counteract any positive effect the radial-
moisture barrier might have on cable life. It is prudent that the treeing test be conducted without
water in the strand.
e) Removal of the jacket before testing may be detrimental to the thermal operation of the moisture
barrier in a moisture-impervious design. It is prudent that the jacket or bonded sheath not be
removed when making these tests.

48
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

10.3.2 Developmental test for cable life

A cable life test is similar to the test comparing dielectric strength before and after a period of aging. Rather
than removing cables periodically and performing destructive tests, cables undergoing this type of test
should remain energized until the test voltage produces failures. Typically, 5 to 20 specimens are used of
each cable design to be compared. Cables tested in this manner usually fail according to one of the extreme

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value distributions and are often plotted as Weibull or log normal graphs.

10.4 Developmental test for thermo-mechanical performance

Tests involving thermal cycling simulate the effect of load cycling on the bonded sheath with a plastic-
coated metal when used as a radial-moisture barrier. The consequential effect on the physical and electrical
integrity of the cable can then be determined. Consideration should be given to the fact that both ethylene
propylene rubber (EPR) and XLPE insulation materials expand and contract during load cycling. However,
XLPE requires special consideration due to its higher coefficient of thermal expansion. In order to obtain a
130 °C (264 °F) emergency rating, a thermal expansion-absorbing layer or other sheath design
modifications may be required. Note: Industrial users often do not require a 130 °C emergency rating as
industrial loads tend to be more consistent.

As with other types of power cables, there should be stable and acceptable measurements of partial
discharge, dissipation factor, and conductivity of the semi-conducting components throughout the operating
range of temperature for the cable. In addition to these considerations, plastic-coated metals as radial-
moisture barriers may be subject to fatigue cracking, bond separation, seam opening, and distortion or
permanent set for the metallic component of the bonded sheath. Tests and visual inspections to determine if
any such deficiencies exist can be conducted without voltage applied to the cable sample during
temperature load cycling.

10.4.1 Developmental test for electrical properties during and after thermal cycling

The cyclic aging test is suitable for determining electrical property stability of cables with plastic-coated
metals in a bonded sheath, except that the jacket should not to be removed as required by the standard test
procedure.

10.4.2 Developmental test for the determination of operating temperatures

The ability to withstand the temperature load cycles that a power cable may endure is one of the most
critical performance requirements of a cable when a plastic-coated metal is used as a radial-moisture
barrier. The degree to which a plastic-coated metal can be stressed during thermal cycling is dependent on
the cable design. Such factors as the conductor size, the insulation and shield wall thickness, the provision
for a thermal expansion-absorbing layer and the insulation and shield material types may have an impact on
the temperature rating and the response to load cycling. Users and manufacturers may wish to analyze
proposed cable designs to determine the conditions under which the physical limitations of the bonded
sheath will be exceeded from a thermal point of view. While a plastic-coated metal rupture may not result
in a catastrophic cable fault, the effectiveness of the moisture barrier could be compromised.

10.4.3 Developmental thermal cycling test to end of sheath life

This developmental test measures the number of load cycles to the highest conductor temperature to which
the cable may be subjected during operation. The test is continued (with or without voltage) until a rupture
of the radial-moisture barrier or other failure occurs. Dissection and visual examination should be
performed at intervals or until sufficient cycles have been performed to satisfy the user that the design life

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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

can be obtained. This may require cycling under several time and temperature conditions. A curve showing
the number of cycles to failure versus cable temperature can then be established. Failure of the bonded
sheath is defined as splitting, seam opening, or bond separation of the sheath components as determined by
visual or microscopic examination.

A similar test should be applied to determine the short circuit (current-time) performance of the bonded
sheath with the plastic-coated metal. If the cable construction does not allow the 250 °C (482 °F) rating or
the user doesn’t require it, the cable may be rated at an appropriate temperature as determined by the user
and the manufacturer.

10.4.4 Developmental thermo-mechanical test prior to accelerated water treeing test

⎯ As an option for increasing the severity of the test, the number of test cycles can be increased from
a minimum of 14 to 30.
⎯ As an option, it may be possible to decrease the cycle duration to 2 h on and 4 h off, or as
appropriate, for the size of the cable under test, as long as there is enough time for the cable to
achieve steady-state conditions.
⎯ The bonded sheath should experience a time and temperature on the surface of the jacket of at least
0.5 h at 90 °C during the on period and 0.5 h at 35 °C during the off period.
⎯ Tests for adhesion can be used to establish the integrity of the moisture barrier during and after the
thermo-mechanical testing.

10.4.5 Developmental accelerated water treeing test

⎯ Considerations such as using thermal loading or cable life testing should be taken into account to
accelerate the growth of water trees. The use of microscopic examination for water trees during or
after the aging cycle can be employed when applying a treeing test to completed moisture-
impervious cables.
⎯ The conductor size and insulation thickness of a complete cable should be as required by industry
standards for the thermo-mechanical procedure.
⎯ The duration of the aging test should be sufficiently increased to allow sufficient progress in the
growth of water trees in a cable whose radial-moisture barrier may have been intentionally
damaged during the mechanical and or thermo-mechanical tests.
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

Attempts should be made to run at least one set of samples until failure in order to develop aging data or in
the absence of failure tests for adhesion can be used to establish the integrity of the radial-moisture barriers.

11. Sample tests common to all voltage classes

Once the design parameters are set by the developmental tests, there may be a need to test the finished
cable with tests suitable for the end use. The cable manufacturer may need to measure all dimensions to
confirm that they comply with the design parameters. The eccentricity of the sheath and the jacket
thickness should be in accordance with design parameters. The overlap seal should be measured for bond
strength. After testing for bond strength, the overlap seal can be visually inspected for consistency and
continuity in the application of the hot melt. A circumferential jacket bond strength test should be
conducted to make sure there are no skips in the bond between the jacket and the metallic moisture barrier.
Either a longitudinal or circumferential bond strength value should be obtained to meet the specified
minimum level of bond strength as agreed upon by the seller and the purchaser. Typically a value of 1750

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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

Newtons/meter (10 pounds/inch of width) has historically been the minimum bond strength for a specimen
cut longitudinally from a bonded sheath by USA practice. The BS Standard 7970 [B130] requires that the
peel strength of the metallic tape at the overlap and to the jacket be a minimum of 1.5 N/mm (8.6 lbs per
inch of width). The CIGRE WG B1-25 [B86] set the minimum peel strength at 1.0 N/mm (5.7 pounds/inch)
as noted in 8.5.10. As noted in 9.2.2.5, bond strength tests are relative and identical test specimens should
be used to obtain comparable test values. Finally, if longitudinal water blocking is a requirement, then a 1
hour or 24 hour water blocking test should be conducted on each production lot of cable to make sure that
the water blocking-feature functions properly.

If in the course of the production of the moisture blocked cable, significant changes may be required in the
materials or process conditions, then appropriate developmental tests should be redone to measure whether
any of these changes have an adverse effect on the performance of the moisture blocking attributes of the
cable.

12. Routine tests common to all voltage classes

The cable user and the cable manufacturer need to agree on the test parameters and test values for the level
of adhesion within the components of the bonded sheath. The cable manufacturer may need to supply
certified test results for the values of jacket bond strength and overlap bond strength as a way to measure
the integrity of the sheath. Certified test results for longitudinal water blocking may also need to be
provided if this is a cable performance requirement. The manufacturer should rely on visual inspection to
observe if the sheath is free of dimensional and other defects.

13. Installation of moisture impervious cables

13.1 General

Moisture-impervious cable designs incorporate longitudinally water blocked and radial-moisture barriers.
In general, handling and installation procedures for such cables should not be different from those used on
cables that are not moisture-impervious or without some form of moisture barrier. Likewise, most standard
pre-molded and shrinkable accessories should be readily adaptable.

13.1.1 Minimum bending radius

The mechanical reinforcement bonding the cable jacket to a plastic-coated component as the radial-
moisture barrier can improve the bend performance of cables with a bonded sheath versus cables where the
jacket is not bonded to the metallic moisture barrier. The minimum recommended pulling and training
radius for cables with moisture barriers depends on cable diameter and insulation thickness in the case of
MV or HV cables. The range of minimum bend radius for these cables may be 8 to 16 times cable diameter
as discussed in 7.7.1.
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

13.1.2 Attachment of pulling devices

Compression-type pulling eyes can be employed with aluminum and copper conductor cables for the
bonded sheath design. Some reports indicate that compression pulling eyes on aluminum conductors may
fail before maximum allowable pulling tensions are reached. Epoxy-filled pulling eyes may overcome this

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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

limitation. Other pulling eyes may be installed over the jacket and compressed in concentric bands to
maximize pulling strength.

Bonded sheath cables with plastic-coated metal tapes as radial metallic moisture barriers that have been
applied corrugated should not be pulled using a basket weave grip due to the potential for stretching
(elongating) the bonded sheath because the corrugations may be pulled out by the force of pulling on the
cable sheath.

Basket-weave pulling grips may also be used with bonded sheaths with plastic-coated metal tapes as the
metallic moisture barriers that have been applied smooth depending on the cable diameter and subsequent
cable weight. However, jacket or sheath damage may result if the cable weight is too high because the
pulling tension is usually applied to the outer surface of the jacket. Smooth moisture barriers may be
stretched with this type of pulling device, especially if there is a loose fit of the sheath over the cable core.

13.1.3 Pulling tension

Maximum allowable pulling tension on the conductor should be commensurate with the diameter of the
wires in the conductor, the number of wires and the material and the sheath design. Procedures for
calculating pulling tension are available from IEEE Std 1185™ [B113]. If a basket weave grip is to be
used, the cable manufacturer should be consulted on the maximum allowable tension the sheath can handle.

13.1.4 Side wall bearing pressure (SWBP)

The expected SWBP is the radial force exerted on the core and sheath of a cable at a bend point when the
cable is under tension. The SWBP acting upon a cable at any bend may be calculated from the procedures
outlined in other IEEE guides [B186]. The SWBP of the cable sheath is a property of the cable. It can be
determined from developmental tests or calculation. The cable vendor should be consulted on the value for
the specific moisture barrier cable under consideration. If the sidewall pressures are judged to be excessive
for the required installation, then the cable may need to be tested for the procedures outlined in 8.5.3.

13.1.5 Other considerations

13.1.5.1 Cable pulling lubricants

Moisture barrier cables may use the same pulling lubricants as other types of cables. Pulling lubricants
should be compatible with cable jackets, insulations, and the environment. They should not set- up or
harden during the installation period. The coefficient of friction can vary from 0.15 (for well lubricated
cables pulled into new smooth wall conduits) to 0.85 (for lubricated cables pulled into rough or dirty
conduit or ducts). Typical values for the coefficient of friction for cables range from 0.3 to 0.5.
--``,,``,,```,`,```,,``,,,`,``-`-`,,`,,`,`,,`---

13.1.5.2 Protection of cable

Moisture barrier cables require the same protection from pulling obstacles as other types of cable. Before
pulling cables, the raceways, conduit, or ducts should be thoroughly inspected and cleaned. Pulling
mandrels are recommended for pulling through raceways. Any abrasions or sharp edges that might cause
damage to cable sheaths or jackets during the pulling operations should be removed. Once cable pulling
operations have started, a determination should be made as to which cable pulls are susceptible to damage,
and adequate precautions should be taken to protect the cables. After cable installation has started, cable
raceways should be periodically cleaned as necessary to prevent the accumulation of debris. Cables being

52
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

installed in cable trays, conduit, ducts, or trenches should not be pulled around corners or obstructions
without the use of cable sheaves of the proper radius.

13.1.5.3 End seals

Moisture barrier cables can benefit from the use of end seals as other types of cable. Cables with
longitudinal water blocking have an advantage over other types of unblocked cables in that the water-
blocking materials limit the penetration of moisture from unsealed ends. However, the use of end seals
should be considered necessary for any medium or high-voltage cable during storage and pulling, and while
awaiting accessory installation. However, with moisture-impervious cable, utilizing solid or strand-blocked
conductor, and water-blocking materials in the sheath interfaces, the inherent longitudinal blockage of
moisture may diminish the need for end caps. Nevertheless, the use of end caps during storage and
installation should be considered as essential for any moisture barrier or moisture impervious medium or
high-voltage cable. The cable manufacturer and the cable user should determine procedures relative to the
use of end caps.

13.2 Terminating and jointing

A joint or termination for a cable with a metallic-moisture barrier should provide adequate provision for
grounding the moisture barrier plus provide for continuity of the moisture barrier over the joint. The
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technique to accomplish this will vary, depending on the cable design. With some designs, the metallic
radial-moisture barrier may also function as the system neutral or the metallic shield. In such instances,
grounds may be connected at terminations in a conventional manner.

13.2.1 Terminations

In order to terminate cables with moisture barriers, the outer jacket and bonded sheath should be removed
to expose the insulation shield and insulation of the cable. Standard techniques may then be used to provide
a non-tracking outdoor insulation over the area where the sheath has been removed. As with any cable
construction, the termination should be designed and installed so as to reduce and/or eliminate air spaces or
voids within the termination. Low-moisture vapor transmission rate materials should be used where
possible. Environmental conditions of the cable installation should be considered when selecting
appropriate termination practices.

The termination kit should accommodate the requirement to ground the metallic component of the moisture
barrier sheath. The termination should provide an outer insulation surface that is fully sealed to the
conductor terminal lug and to the cable jacket, thereby meeting the requirements of a Class I termination
according to IEEE Std 532-2007.

Termination designs should incorporate positive sealant components using non-tracking adhesives and
sealants plus moisture-blocked or solid-ground leads.

13.2.2 Joints and splices

Joints for moisture-impervious cable should meet the performance requirements of relevant industry
standard IEEE Std 404™-1993 [B109]. The joint should accommodate the various constructions of a
moisture barrier or moisture-impervious cable that manufacturers may provide.

The sealant system should accommodate conditions where neutral wires or tape-shield layers may have
formed indentations in an extruded insulation shield layer.

The moisture-barrier layer may be reconstructed across the joint using any technique that provides a
moisture/vapor-proof barrier. Heat shrinkable or cold shrink components with an integral metal foil,
aluminum foil with polymer bonded components, or devices combining the moisture/vapor barrier and the

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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

outer jacket may be used. It is desirable to construct the joint so as to reduce abrupt changes in geometry
and minimize internal air spaces or voids. Use of a low-moisture/vapor transmission rate material for the
joint should be considered where possible. These procedures should help eliminate the ingress and
migration of moisture, both longitudinally and in the radial direction.

The joint should be provided with a one-piece outer jacket component that is positively sealed onto the
cable jacket. A heat or cold shrinkable sleeve uniformly coated with an adhesive or mastic may meet this
need.

In addition to certified test evidence that the joint designs meet the requirements of appropriate standards,
manufacturers should provide test data demonstrating the efficacy of their moisture barrier joint.

13.3 Grounding

Provision should always be made to ground the metallic component of the radial-moisture barrier.

With bonded sheath constructions, there may be other considerations with respect to grounding the metallic
moisture barrier. If a copper metallic tape coated on only one side is used as both shield and barrier, then
the moisture barrier may be terminated by soldering or clamping techniques similar to those used with bare
(uncoated) spirally wrapped or longitudinally folded copper tapes. If neutrals are under the barrier, then
barrier-to-neutral contact through the semi-conducting cushion tape may preclude grounding of the barrier
when the neutrals are grounded by standard procedures. Use of a semi-conducting coating on the side of the
moisture barrier facing the insulation screen/neutrals may also preclude grounding of the screen. If an
insulating coating is used on the side of the barrier tape facing the core, the tape may then be terminated
using standard mechanical connectors developed for medium-voltage cables. An appropriately sized
grounding wire and a sufficient number of connectors should be utilized to provide the ground connection
with sufficient current-carrying capacity.

The most common method for terminating (grounding) the metallic component of the bonded sheath on
medium-voltage cable is to use mechanical connectors. These connectors have teeth on one side of the
connector to bite into the metallic shield and a clamping mechanism on the opposite side to lock it to the
jacket. Tests have confirmed that these connectors have the ability to carry appropriate levels of short
circuit current for a given size of cable. See Hervig, H. C., [B50]. They are covered by EDF specification
HN 33-S-23 [B90] and EDF specification HN 33-S-52, [B95]. They have been extensively tested against
appropriate EDF specifications for their performance in finished terminations and splices and have met all
requirements for short circuit performance. A photo of the connector is shown in Figure 8.

“This figure has been provided courtesy of Kable Consult LLC.”

Figure 8 —Typical connecter

54
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

For high-voltage cables the preferred method of terminating the metallic moisture barrier is to use soldering
or welding techniques. It is normally very difficult to strip the jacket from the metallic foil that forms the
radial-moisture barrier. Care must be taken to strip the jacket without damaging the metallic tape. Usually
the application of heat to soften, but not melt the jacket, has been found effective to separate the jacket
from the metallic foil. A softened jacket has a reduced bond to the metallic component but enough integrity
to be easily stripped. There is an “art” to this technique which can be developed with experience and
training.

13.4 After-laying test

In the case of high-voltage cable, a semi-conducting graphite layer is frequently applied over the outer
surface of the jacket. This allows the sheath to be tested in the field for its integrity by applying a voltage
between the metallic shield or moisture barrier and ground. Testing for the sheath integrity is important to
measure whether installation damage has occurred that could allow moisture to penetrate through the
radial- moisture barrier and enter the insulation-sheath interface.

The cable, joints and terminations should be thoroughly tested in the factory using a 50 Hz or 60 Hz,
elevated voltage partial discharge test to determine if each cable component meets specific ICEA, IEEE or
IEC partial discharge requirements. However after shipping, handling and installation, the components as
part of a cable system may no longer meet these requirements. Thus, an after-laying test is recommended.
Ideally, a partial discharge test may be repeated on the installed system to determine if the factory
requirements were again met. If such a test is not feasible, then refer to IEEE Std 400™-2001 [B108] for a
list of test types and application recommendations.

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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

Annex A

(informative)

Bibliography

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A.1 Technical papers relating to design of moisture barrier cables

[B1] Bayer, M. G., Bow, K. E., Snow, J. H., and Voltz, D. A., “Chemical-moisture barrier cable, concept
and practice,” 1994 IEEE Industry Applications Society Petroleum and Chemical Industry Conference,
Vancouver, B.C., Canada, pp. 183-190, Sept. 1994.
[B2] Bayer, M. G., Bow, K. E., Snow, J. H., and Voltz, D. A., “Wire and cable update 1990,” 1990 IEEE
Industry Applications Society Petroleum and Chemical Industry Conference, Houston, TX., pp. 19-29,
Sept. 1990.
[B3] Bertier, D., et al., “Cable with new structure including semiconducting material and allowing
simultaneously continuous earthing of the screens and protection against moisture and corrosion,”
Proceedings of Jicable 84, May 1984.
[B4] Bow, K. E., “The development of underjacket moisture barrier cable as a counter measure against
treeing,” IEEE Transactions on Power Delivery, vol. 5, no. 1, pp. 47-53, Jan. 1990.
[B5] Bow, K. E., Grosser, B.K., Smith, J. W. and B. J. Nieuwhof, “Water impervious on-jacket moisture
barrier cable,”, Second International Conference on Polymer Insulated Power Cables, pp. 324-331
Proceedings of Jicable 87.
[B6] Bow, K. E. and Smith, J. W. “Laminated Sheathed Cable for Replacement of Lead Sheathed cable
in Medium-Voltage Applications”, Forth International Conference on Polymer Insulated Power Cables,
pp. 270-275, Proceedings of Jicable 95.
[B7] Bow, K. E., and Snow, J. H., “Chemical/moisture barrier cable for underground systems,” IEEE
Transactions on Power Apparatus and Systems, vol. PAS-101, no. 7, pp. 1942,1949, 1982.
[B8] Bow, K. E., and Snow, J. H., “Design, testing and application of moisture impervious cable,” 1991
IEEE T&D Conference, Dallas, TX., September, 1991.
[B9] Bow, K. E., and Snow, J. H., “Moisture-barrier power cable with a plastic-metal laminate sheath,”
Proceedings of Jicable 84, May 1984.
[B10] Bow, K. E., and Voltz, D. “Chemical and moisture resistant medium and low-voltage cables,”
Fourth International Conference on Polymer Insulated Power Cables, pp. 276-281, Proceedings of Jicable
9, June, 1995.
[B11] Cinquemani, P. L., “Longitudinal water blocked cables,” IEEE-ICC, St. Petersburg, FL., November,
1991.
[B12] Couneson, P., et al., “Development of a lightweight XLPE cable through the use of a composite
copper/aluminum screen,” CIGRE 1990 Session, pp 21-104, 1990.

[B13] Dellby, B., et al., “Water tight XLPE cables,” International Conference on Large High-Voltage
Electric Systems (CIGRE),Paris, France, pp 21-11, Sept. 1982.
[B14] Gauthier, P., et al., “Distribution cable practice and prospects in Electricite de France,” International
Conference on Power Cables, A.E.I., Milano, 1981.

56
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

[B15] Groeger, J., et al., “Experimental difficulties and significance of water content measurements in
cable insulations,” Proceedings of Jicable 87 Second, International Conference on Polymer Insulated
Power Cables, Versailles, France, Sept. 1987.
[B16] Groeger, J. H. and Mashikian, M. S. “Aging phenomena at cable-shield interfaces affecting the
propensity of the insulation to develop water trees,” Proceedings of Jicable ’9 Third International
Conference on Polymer Insulated Power Cables, pp. 206-213 Paper A.8.3, 1991.
[B17] Jacobson, C., “Designing polymeric cables,” Electrical Review International, vol. 204, no. 6, Feb.
1979.
[B18] Kimura, C., et al., “Newly developed meta-seal SP underground cable,” IEEE Transactions on
Power Apparatus and Systems, vol. PAS-101, no. 7, pp. 2340-2347, 1982.
[B19] Luzzi, G. J., “Gas pressure build-up in aluminum conductor cables,” IEEE Transactions on Power
Apparatus and Systems, vol. PAS-101 (6), pp. 1697-1699, 1982.
[B20] Marciano, F., et al., “Longitudinally water resistant cables,” Proceedings of Jicable 91, Versailles,
France, June 1991.
[B21] Martin, M., Silver, D., Lukac, R. and Suarez, R., “Normal and short circuit operating characteristics
of metallic shielded, solid dielectric power cable,” Proceedings of the IEEE/PES Summer Power Meeting,
EXV/UHV Conference, Vancouver, Canada, July 1973.
[B22] Mercado, K. M. and Walker M. L. “A comparison of the in service performance of URD primary
cables with or without water block construction,” Transmission and Distribution Conference and
Exhibition, Chicago, IL. Panel No. 11, Apr. 1994.
[B23] Mildner, R. C., Arends, C. B., and Woodland, P.C., “The Short Circuit Rating of Thin Tape Cable
Shields,” IEEE Transactions on Power Apparatus and Systems, vol. PAS-87, no. 3, pp 749-759, March
1968.
[B24] Mildner, R. C.; Ropp, W. E.; and Snow, J. H.; “A note on the sensitivity of bonded jackets to flaws
in construction,” The Dow Chemical Company.
[B25] Nicholls, A. W., and Steennis, E. F., “Water treeing, state of the art,” CIGRE 1990 Session, pp.
15/21-02, 1990.
[B26] Robbins, B., “Evaluation of power cables with moisture barriers,” 77th Insulated Conductors
Committee Meeting, Appendix III-C-1, Nov. 1985.
[B27] Snow, J. H., “Lead Issues and Cable Alternatives”, Open Forum, Panel Session, Moderator, Minutes
of the Insulated Conductors Meeting, Houston, TX, Pages 66-82, April 16, 1996.
[B28] Uchiyama, T., et al., “Development of CV cable with water proof layer on the cable core,” 14th
Symposium on Electrical Insulating Materials of the IEE of Japan, 1981.
[B29] Uchiyama, T., et al., “Development of waterproof cross linked polyethylene cable,” Wire Journal
International, vol. 16, no. 9, pp. 178-189, 1983.
[B30] Uematsu, T., et al., “Development and use of water impervious cable,” Korea-Japan Joint
Symposium on Electrical Material and Discharge, pp. 31-35, July 1986.
[B31] Vartanion, S., and Sandler, A. N., “Cable pulling for practical application in modern refineries,”
IEEE Power Engineering Society Petroleum and Chemical Industry Conference, pp no. PCI-73-6, Houston,
TX.., Sept. 1973.
[B32] Zimmerman, H., M. Schwarz, M., and Mathis, W.f., “Results for long term performance. Test on
polymer insulated cables up to 230kV.” Proceedings of the 1991 Transmission and Distribution
Conference, pp. 176-179, 1991.
[B33] “Lead in Construction”, US Department of Labor, Occupational Safety and Health Administration,
OSHA 3142, OSHA Publications Office, 200 Constitution Avenue, N.W., Washington, DC 20210, 1993.

57
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

[B34] “Voluntary Industry Program to Increase Worker Protection”, Lead Industries Association, Inc., 295
Madison Avenue, New York, NY 10017, September 27, 1996.

A.2 Technical papers relating to materials and accessories for moisture barrier
cables

[B35] Ball, E. H., et al., “Extruded cable insulation for wet locations,” Second International Conference on
Power and Accessories 10 kV to 180 kV, IEEE Conference Publication no. 270, pp. 156-161, 1986.
[B36] Bekki, K., et al., “Longitudinal water blocking in solid dielectric insulated power cables,” Sixth
Conference on Electric Power Supply Industry (6th. CEPSI), no. 3.06, Jakarta, Nov. 1986.
[B37] Bow, K. E. “Medium and high-voltage cables having laminate sheathes with coated copper,” Fifth
International Conference on Insulated Power Cable, vol. 2/2, pp. 649-654, Proceedings of Jicable ’99.
[B38] Bow, K. E., et al., “Semi-conductive plastic-coated metallic shielding and armoring materials for
power cables,” Proceedings of Jicable ‘ 91, Versailles, France, June 1991.
[B39] Bow, K. E., Grosser, B.K. and Pikula, D.G. “Coated copper shielding tapes for the wire and cable
industry,” International Wire and Cable Proceedings, pp. 51-60, 1985.
[B40] Bow, K. E. “Laminate Sheath Power Cable Insulated with XLPE for Flame Retardant Applications,”
6th International Conference on Insulated Power Cables, pp. 357-362, June 2003.
[B41] Butterbach, R. and Heucher, R. “Advantages of hot melt adhesives for overlap bonding and sealing
in power cables,” Fourth International Conference on Polymer Insulated Power Cables, pp. 411-413,
1991.
[B42] Czupryna, S. W., Everaere, J., Delattre, M., “Improvements in superabsorbent water-blocking
materials for new power cable applications,” 7th International Conference on Insulated Power Cable
Jicable 2007, Paris-Versailles, France, pp. 24-28, June 2007.
[B43] Czupryna, S. W., Everaere, J., “Power conductor water blocking with tapes and yarns containing
superabsorbent polymers,” 55th IWCS/FOCUS, pp. 208-212, 2006.
[B44] De Boer, R., “The use of water-swellable materials in the design of power cables,” Proceedings of
Jicable ‘ 91, Versailles, France, June 1991.
[B45] Dubiel, Karen L., MacLeod, Scott C., “Determining Compliance to the RoHS Directive for Wire and
Cable Products,” Wire and Cable Technology International, March 2006, Pages 74 -77.
[B46] Duchateau, F., et al., “Quality evaluation of accessories for MV polymeric cables,” Proceedings of
Jicable ‘84, May 1984.
[B47] Fukuda, T., et al., “Development of lead foil plastic composite tape for water impervious cable,”
presented at Ninth International Lead Conference, Goslar, Germany, Oct. 1986.
[B48] Furusawa, H., et al., “Water impervious URD cable having lead foil on conductor and on core,”
IEEE Transactions on Power Delivery, vol. PWRD-1, no. 1, pp. 51-57, 1986.
[B49] Hane, Y., et al., “Water impervious splices for 6.6 kV XLPE cables,” IEEE Transaction on Power
Apparatus and Systems, vol. PAS-103, pp. 3165-3171, 1984.
[B50] Hervig, H. C., “Water impervious cable terminations and splices,” IEEE/PES Transmission and
Distribution Conference and Exposition, Panel # 11, Chicago, IL, April 1994.
[B51] Matsumoto, T., et al., “The long service performance of Pb-laminated plastic layer for water
impervious XLPE cable,” Proceedings of Second International Conference on Properties and Applications
of Dielectric Materials, (ICPA DM-88), vol. 2, pp. 447-450, 1988.
[B52] Mombellet, H., “Carboxymethylcellulous and water tightness of cables,” Jicable, May 1984.
[B53] Nieuwhof, B. J., “Conductive and non-conductive water-swellable non-wovens for longitudinal
water-blocking,” Jicable, May 1984.

58
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

[B54] Nieuwhof, B. J., and deVrieze, R. “Longitudinal waterblocking performance of conductive and non-
conductive water-swellable non-wovens,” International Wire and Cable Symposium, pp. 83-87, 1983.

A.3 Technical papers relating to testing of moisture barrier cables

[B55] Poulsen S. H., Ursin, C., Weldingh H. “Sensitive testing of XLPE cable watertightness,” Power
Technology International, 1993.

A.4 Technical papers relating to low-voltage moisture barrier cables

[B56] Bow, K. E., Grosser, B. K., Donner, G. and Russel. T. “An overview of the use of installation of
electrical database cable in an industrial process plant,” Paper No. PCIC 85-52, pp. 269-280, 1985.
[B57] Bow, K. E. and Voltz, D. A., “Cable with overall shield for protection from lightning and faults.”
1991 Transmission and Distribution Conference, pp. 155-160, 1991.

A.5 Technical papers relating to medium-voltage moisture barrier cables

[B58] Bayard, C., et al., “Watertight medium-voltage submarine cables,” Proceedings of Jicable 84, May
1984.
[B59] Bourjot, P., et al., “Thermomechanical behavior and watertightness of MV polymer insulated
cables,” Proceedings of Jicable 84, May 1984.
[B60] Deschamps, L., et al., “Thermal and mechanical behavior of 20 kV cables under overload
conditions,” CIRED, 1983.
[B61] Pinet, A. “French practice for MV cables and accessories,” IEEE PES Transmission and Distribution
Conference, Los Angeles, CA.
[B62] Pinet, A. “The new 20 kV cable of the French MV power system,” IEEE Publication A79 408-6,
1979.
[B63] Pinet, A., and Paris, M., “The new 20 kV cable of the French MV power system,” IEEE
Transactions, Jan/Feb. 1980.
[B64] Schuppe, W. D., “Progress with XLPE insulated medium-voltage cables in the Federal Republic of
Germany,” Proceedings of Jicable ‘84, May 1984.
[B65] Tanabe, T., et al., “Water tree deterioration and counter measure of low and medium-voltage XLPE
cables,” Proceedings of Jicable ‘84, May 1984.
[B66] White, T. M., et al., “11 kV polymeric insulated triplex cable,” Second International Conference on
Power and Accessories 10 kV to 180 kV, pp. 41-45, 1986.

A.6 Technical papers relating to high-voltage moisture barrier cables

[B67] Aucourt C. and Corison, E. “New development for HV cables,” Proceedings of Jicable ‘ 87 Second
International Conference on Polymer Insulated Power Cables, pp. 394-404, 1987.
[B68] Ball, E. H, and Benford, D. F., “The use of 66 and 132 kV XLPE insulated cables for long circuit
connections in London,” Second International Conference on Power and Accessories 10 kV to 180 kV, no.
270, pp. 202-207, 1986.
[B69] Boone, W., et al., “Development and trial of EHV XLPE cables in the Netherlands,” CIGRE 1984,
Paper 21-02, 1984.

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59
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

[B70] Dorison, E., et al. “Changes in the specifications of HV and EHV cables associated with installations
and operating conditions,” CIGRE 1984 Session, Paper 21-03, 1984.
[B71] Fister, V., Hansen, S. A., Krieger, W., Oswald, K and Weinmann, T. “Germany’s first 220 kV
XLPE cable system in Bayernwerk AG’s Network.” Elekuizitaciswirtschaft. Zoitschrift der Voreiniguog
Deutscher Elekuizitaclswerke, Vol. 87, No. 26/88, 1988.
[B72] Fondeur, J. H., et al., “HV cables with corrugated laminate aluminum sheath: construction,
characteristics, laying advantages,” Proceedings of Jicable ‘87, Sept. 1987.
[B73] Frentzas, F. “Commonwealth Edison Co. 138kV Transmission Retrofit Project.” Appendix 10-E-1.
Minutes of the 102nd Meeting of the Insulated Conductors Committee. St. Petersburg. Fl., November 1997.
[B74] Guo, Jim Jun, Zhang, Lili, Xu, Chunchman, Boggs, Steven A., High Frequency Attenuation in
Transmission Class solid Dielectric Cable”, Paper TPWRD 00547-2007, IEEE/PES Proceedings on Power
Delivery.
[B75] Lundgren, T., et al., “Crosslinked polyethylene insulated cables in the voltage range 72-245 kV,”
CIGRE 1974 Session, Paper 21-06, 1974.
[B76] Nakagawa, H., et al., “Development and installation of 154 kV XLPE cables,” Proceedings of
Jicable ‘84, May 1984.
[B77] Schadlich, H., et al., “Field testing of XLPE insulated cable in 220 kV and 380 kV systems,” CIGRE
1990 Session, Paper 21-106, 1990.
[B78] Smee, G. J., and West, R. S. V., “Factors influencing the choice between paper and XLPE insulated
cables in the voltage range 66 kV-132 kV,” Second International Conference on Power and Accessories 10
kV to 180 kV, no. 270, pp. 193-197, 1986.
[B79] Takenouchi, K., et al., “The experience in service for 66 kV XLPE insulated power cables,”
Proceedings of Jicable ‘84, May 1984.

A.7 Specification references for cable with moisture barriers

[B80] ASTM E 796-94 2/15/00, Standard Test Method for Ductility Testing of Metallic Foil. 6
[B81] ASTM D903-93 4/10/04, Standard Test Method for Peel or Stripping Strength of Adhesive Bonds.
[B82] ASTM D1248-84 3/1/05, Standard Specification for Polyethylene Plastics Extrusion Materials for
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Wire and Cable.

[B83] ASTM D1876-93 10/10/01, Standard Test Method for Peel Resistance of Adhesives (T-Peel Test).
[B84] ASTM 4565-99 3/10/99, Standard Test Methods for Physical and Environmental Performance
Properties of Insulations and Jackets for Telecommunications Wire and Cable.
[B85] British Standard, BS 7970-2005, Electric cables-Metallic wire and foil sheath constructions of power
cables having XLPE insulation for rated voltages from 66 kV (Um = 72.5 kV) to 132 kV (Um = 145 kV).
[B86] CIGRE Working Group B1-25, “Advanced design of metal laminated coverings,” Draft Brochure,
May 2009.
[B87] CIGRE Working Group 14 of Study Committee 21, Guidelines for Tests on High-Voltage Cables
with Extruded Insulation and Laminated Protective Coverings, Electra No. 141, April 1992, pp.53-64.
[B88] CSA (Canadian Standards Association) C22.2 No. 0.3-92 Para 4.11.4, Test Methods for Electrical
Wires and Cables: FT4.
[B89] Dutch Standard NEW 3620, Apr. 1989, Cables With Insulation of Cross-linked Polyethylene for
Voltages of 6 kV Up to and Including 30 kV.

6
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60
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

[B90] Electricite de France, France, HN 33-S-23, Cross-Linked Polyethylene (XLPE) insulated cables of
12/20 KV rated voltage for distribution networks.
[B91] Electricite de France, France, HN 33-S-52, Single Core Cables with Polymeric Insulation 36/63
(72.5) KV and 52/90 (100) KV and up to 87/150 (170) KV rated voltage.
[B92] French Standard C 33-001, Accessories for extruded cables from 3 kV to 30 kV.
[B93] French Standard C 33-050, Single-core splices for extruded cables from 10 KV to 30 kV.
[B94] French Standard C 33-051, Screened separable connectors and associated devices for extruded
cables from 10 kV to 30 kV.
[B95] French Standard C 33-052, Single-core terminates for extruded cables from 10 kV to 30 kV.
[B96] French Standard C 33-22, XLPE cables for distribution networks from 10 kV to 30 kV.
[B97] ICEA S-93-639 5-46 kV Shielded Power Cable for Use in the Transmission & Distribution of
Electric Energy.
[B98] ICEA S-94-649-2004, Std for Concentric Neutral cables Rated 5 through 46 kV.
[B99] IEC 840-1988, Tests for power cables with extruded insulation for rated voltages above 30 kV
(Um=36 kV) up to 150 kV (Um=170 kV).
[B100] IEC 60332, Test on Electric and Optical Fibre Cables Under Fire Conditions.
[B101] IEC 60502-2 Ed. 2.0 3/1/05, Power Cables with Extruded Insulations and Their Accessories for
Rated Voltages from 1 kV (UM = 1, 2 kV) up to 30 kV (Um = 36 kV0).
[B102] IEC 60840 4/1/04, Power cables with extruded insulation and their accessories for rated voltages
above 30 kV (Um = 36 kV) up to 150 kV (Um = 17- kV) Test methods and requirements - Third Edition.
[B103] IEC 61443 7/1/99, Short-Circuit Temperature Limits of Electric Cables with Rated Voltages
Above 30 kV (Um = 36 kV) - First Edition.
[B104] IEC 61443 Ed 1.0, Amendment 1, Short-circuit temperature limits of electric cables with rated
voltages above 30 kV (Um = 36 kV), 2008-05-30.
[B105] IEC 61901 TR 7/1/05, Development tests recommended on cables with longitudinally applied
metal foil for rated voltages above 30 kV (Um = 36kV) – First Edition.
[B106] IEC 62067, Power cables with extruded insulation and their accessories for rated voltages above
150 kV up to 500 kV.
[B107] IEEE Std 48™-1990, Standard Test Procedures and Requirements for High-Voltage Alternating-
Current Cable Terminations.
[B108] IEEE Std 400-2001, IEEE Guide for Field Testing and Evaluation of the Insulation of Shielded
Power Cable Systems.
[B109] IEEE Std 404-1993, IEEE Standard for Extruded and Laminated Dielectric Shielded Cable Joints
rated 2500 V to 500 000V.
[B110] IEEE Std 525™-1992, IEEE Guide for the Design and Installation of Cable Systems in
Substations.
[B111] IEEE Std 532-2007, IEEE Guide for Selecting and Testing Jackets for Power, Instruments, and
Control Cables.
[B112] IEEE Std 635-2003, IEEE Guide for Selection and Design of Aluminum Sheaths for Power
Cables.
[B113] IEEE Std 1185, IEEE Guide for Cable for Generating Stations.
[B114] IEEE Std 1202-2006, Standard for Flame-Propagation Testing of Wire and Cable.
[B115] KEMA Specification S10 for 50-220 kV Single Phase Plastic Insulated Cables, 1990.

61
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 IEEE Std 1142-2009
IEEE Guide for the Selection, Testing, Application, and Installation of Cables having Raidal-Moisture
Barriers and/or Longitudinal Water Blocking

[B116] NFPA 70, National Electric Code.

[B117] UL 13, UL Standard, Power limited Circuit Cables.
[B118] UL 1072, UL Standard, Medium-Voltage Cables.
[B119] UL 1277 PLTC Cable, UL Standard 1277, Electrical Power and Control Cables with Optional
Fiber Members.
[B120] UL 1569, UL Standard, Metal Clad Cables.
[B121] UL 1685 UL Standard, Safety Vertical-Tray Fire-Propagation and Smoke-Release Test for
Electrical and Optical-Fiber Cables-Second Edition.
[B122] UL 2250 UL Standard, Safety Instrumentation Tray Cable- First Edition.

A.8 Other references

[B123] EPRI Report RP 1519-01 (From Project EL 3333), “Maximum Safe Pulling Lengths for Solid
Dielectric Insulated Cables,” vol. 1 and 2, Feb. 1984.

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[B124] J.H. Groeger and M.S. Mashikian. “Long-Term Service Degradation of Polyethylene and Rubber
Insulated Power Cables,” International Wire and Cable Symposium Proceedings. pp. 388-396. 1991.

62
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