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AS/NZS 3599.1:2003AS/NZS 3599.1Australian/New Zealand StandardElectric cablesAerial bundled Polymeric insulatedVoltages6.35/11 (12) kV and 12.7/22 (24) kVPart 1: Metallic screenedThe Standard is downloaded from Standard SharingAS/NZS 3599.1:2003This Joint Australian/New Zealand Standard was prepared by Joint Technical Committee EL-003, Electric Wires and Cables. It was approved on behalf of the Council of Standards Australia on 8 August 2003 and on behalf of the Council of Standards New Zealand on 19 August 2003. It was published on 11 September 2003.The following are represented on Committee EL-003:Australasian Railway AssociationAustralian Electrical and Electronic Manufacturers AssociationAustralian Industry GroupCanterbury Manufacturers Association of New ZealandDepartment of Defence, AustraliaDepartment of Mineral Resources, N.S.W.Electrical Contractors Association of New ZealandElectrical Regulatory Authorities CouncilElectricity Supply Association of AustraliaInstitution of Engineers, AustraliaMinistry of Economic Development, New ZealandNational Electrical and Communications AssociationKeeping Standards up-to-dateStandards are living documents which reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Between editions, amendments may be issued. Standards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments which may have been published since the Standard was purchased.Detailed information about joint Australian/New Zealand Standards can be found by visiting the Standards Australia web site at .au or Standards New Zealand web site at www.standards.co.nz and looking up the relevant Standard in the on-line catalogue.Alternatively, both organizations publish an annual printed Catalogue with full details of all current Standards. For more frequent listings or notification of revisions, amendments and withdrawals, Standards Australia and Standards New Zealand offer a number of update options. For information about these services, users should contact their respective national Standards organization.We also welcome suggestions for improvement in our Standards, and especially encourage readers to notify us immediately of any apparent inaccuracies or ambiguities. Please address your comments to the Chief Executive of either Standards Australia International or Standards New Zealand at the address shown on the back cover.This Standard was issued in draft form for comment as DR 03049.AS/NZS 3599.1:2003Australian/New Zealand StandardElectric cablesAerial bundled Polymeric insulatedVoltages6.35/11 (12) kV and 12.7/22 (24) kVPart 1: Metallic screenedOriginated as AS 3599.11988.Jointly revised and designated AS/NZS 3599.1:2003.COPYRIGHT Standards Australia/Standards New ZealandAll rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher.Jointly published by Standards Australia International Ltd, GPO Box 5420, Sydney, NSW 2001 and Standards New Zealand, Private Bag 2439, Wellington 6020ISBN 0 7337 5487 23AS/NZS 3599.1:2003The Standard is downloaded from Standard SharingPREFACEThis Standard was prepared by the Joint Standards Australia/Standards New Zealand Committee EL-003, Electric Wires and Cables, and is based on requirements laid down by theElectricity SupplyAssociation ofAustralia. This Standardsupersedes AS 3599.11988.The objective of the Standard is to specify construction, dimensions and test requirements for cross-linked polyethylene insulated individually metallic screened, three phase, aerial bundled cables (ABCs), steel wire supported, for working voltages 6.35/11 (12) kV and12.7/22 (24) kV.For reasons of standardization and rationalization, this Standard provides for the construction, dimensions, and test requirements of only a limited range of individually screened three-core cables.This Standard is complementary to the range of cables covered in AS/NZS 3599.2, Electric cablesAerial bundledPolymeric insulatedVoltages 6.35/11 (12) kV and 12.7/22 (24) kV, Part 2: Non-metallic screened, and in AS/NZS 1429.1, Electric cablesPolymeric insulated, Part 1: For working voltages 1.9/3.3 (3.6) kV up to and including 19/33 (36) kV. This Standard is generally compatible with the appropriate requirements specified in those Standards.This Standard differs from the previous edition in the following significant ways.(a) The Standard has been published as a Joint Australian/New Zealand Standard.(b) The specifications for the conductor screen, insulation and insulation screen have been referenced to AS/NZS 1429.1.(c) The HDPE sheath material has been referenced to AS/NZS 3808.(d) The word catenary has been deleted from the definition of the support wire.(e) Current carrying capacities have been provided for both a 30C and a 40C ambient air temperature.(f) Recalculated values have been provided for the recommended copper screen wires and the mechanical characteristics of the support wire.The term informative has been used in this Standard to define the application of the appendix to which it applies. An informative appendix is only for information and guidance.CONTENTSPage1SCOPE .4 2REFERENCED DOCUMENTS . 43DEFINITIONS . 54VOLTAGE DESIGNATION . 65MAXIMUM CONDUCTOR TEMPERATURES. 86CONDUCTORS . 87CONDUCTOR SCREEN . 88INSULATION. 89INSULATION SCREEN . 810BEDDING TAPE . 811METALLIC SCREEN. 812WATER-BLOCKING OF SCREENS (OPTIONAL) . 913SEPARATOR TAPE(S) . 914SHEATH. 915PHASE IDENTIFICATION . 1016CABLE IDENTIFICATION . 1017METRE MARKING . 1018SUPPORT WIRE . 1019LAYING UP . 1220PREPARATION FOR DELIVERY . 1221MARKING OF DRUMS . 1222TESTS. 13APPENDICESACABLE DATA AND RECOMMENDATIONS. 16BPURCHASING GUIDELINES . 21CDIAMETER OF DRUM BARRELS AND INSTALLATION BENDINGRADII FOR CABLES. 229AS/NZS 3599.1:2003The Standard is downloaded from Standard SharingSTANDARDS AUSTRALIA/STANDARDS NEW ZEALANDAustralian/New Zealand StandardElectric cablesAerial bundledPolymeric insulatedVoltages6.35/11 (12) kV and 12.7/22 (24) kVPart 1: Metallic screened1 SCOPEThis Standard specifies the construction, dimensions, and test requirements for cross-linked polyethylene (XLPE) insulated, individually metallic screened, high density polyethylene (HDPE) sheathed, steel wire supported, three phase, aerial bundled cable (ABC) (see Figure 1), for electricity supply.NOTES:1Cable data and recommendations to assist in the selection of the appropriate cables are given in Appendix A.2Purchasing guidelines are provided in Appendix B.2 REFERENCED DOCUMENTSThe documents below are referred to in this Standard. AS1222Steel conductors and staysBare overhead1222.1Part 1: Galvanized (SC/GZ)1222.2Part 2: Aluminium clad (SC/AC)3983Metal drums for insulated electric cables and bare conductorsAS/NZS1125Conductors in insulated electric cables and flexible cords1429Electric cablesPolymeric insulated1429.1Part 1: For working voltages 1.9/3.3 (3.6) kV up to and including 19/33 (36) kV1660Test methods for electric cables, cords and conductors1660.2.1Part 2.1: Insulation, extruded semi-conductivescreens andnon-metallic sheathsMethods for general application1660.2.2Part 2.2: Insulation, extruded semi-conductivescreens andnon-metallic sheathsMethodsspecific to elastomeric, XLPEandXLPVC materials1660.3Part 3: Electrical tests2857Timber drums for insulated electric cables and bare conductors3008Electrical installationsSelection of cables3008.1.1Cables for alternating voltages up to and including 0.6/1 kVTypicalAustralian installation conditions3008.1.2Cables for alternating voltages up to and including 0.6/1 kVTypical NewZealand installation conditions3808Insulating and sheathing materials for electric cablesCOPYRIGHTIEC60986Short-circuit temperature limits of electric cables with rated voltages from 6kV (Um = 7,2 kV) up to 30 kV (Um = 36 kV)ESAA(Electricity Supply Association of Australia)HB C(b)1Guidelinesfor designandmaintenanceofoverheaddistribution and transmission lines3 DEFINITIONSFor the purpose of this Standard, the following definitions apply.3.1 Approximate valueA value which is neither guaranteed nor checked; e.g. it is used to calculate dimensions for cable users.3.2 Conductor screenA layer or layers of non-metallic semiconductive material applied directly over the conductor.3.3 Core (of a cable)An assembly comprising a conductor, semiconductive conductor screen, insulation and semiconductive insulation screen.3.4 Direction of layThe slope of the conductor wires, screen wires, phase cable, or the like when the phase cable or, in the case of complete cable, the cable bundle is held vertically.It is right-hand when the slope is in the direction of the central part of the letter Z, and left- hand when the slope is in the direction of the central part of the letter S.3.5 Installation testsTests made on installed cable to demonstrate the integrity of the cable and its accessories.3.6 Insulation screenA layer or layers of non-metallic semiconductive material applied directly over the insulation of each core.3.7 Length of layThe axial distance of one complete turn of the helix formed by a cable component, e.g. a wire of the metallic screen or a phase cable.3.8 Maximum conductor temperatureThe maximum temperature at which the conductor of the cable may be operated and it is the temperature resulting from the combined effect of the ambient conditions and the current loading of the conductor.3.9 Metallic screenA screen of copper wires applied over each core.The Standard is downloaded from Standard Sharing3.10 Non-hygroscopicApplied to a material, means that the material, after being preconditioned in an oven at50 5C for 24 1 h and allowed to cool in a desiccator, does not absorb more than5 percent by weight of moisture during a 48 h treatment in humidity of 95 4 percent at a temperature of 20 5C.3.11 Phase cableAn assembly comprising a core, tapes, metallic screen and sheath, which together form one phase of the bundled cable (see Figure 2).3.12 Routine testsTests made by the manufacturer on each manufactured length of cable to check that each length meets the specified requirements.3.13 Sample testsTests made by the manufacturer on samples of completed cable, or components taken from completed cable, at a specified frequency, so as to verify that the finished product meets the specified requirements.3.14 Support wireA steel member provided to support the three laid-up phase cables.3.15 Type testsTests made before supplying, on a general commercial basis, a type of cable covered by this Standard, in order to demonstrate satisfactory performance characteristics to meet the intended application. These tests are of such a nature that, after they have been made, they need not be repeated, unless changes are made in the cable materials or design or manufacturing process, which might change the performance characteristics.4 VOLTAGE DESIGNATIONThe rated voltages are expressed in the form U0/U (Um):whereU0is the r.m.s. power frequency voltage to earth of the supply system for which the cable is designedUis the r.m.s. power frequency voltage between phases of the supply system for which the cable is designedUmis the maximum r.m.s. power-frequency voltage between any two conductors for which cables and accessories are designed. It is the highest voltage that can be sustained under normal operating conditions at any time and at any point in a system. It excludes temporary voltage variations due to fault conditions and sudden disconnection of large loads.The rated voltages U0/U (Um) of the cables recognized in this Standard are 6.35/11 (12) kVand 12.7/22 (24) kV.FIGURE 1 CROSS SECTION OF HV ABCFIGURE 2 COMPONENTS OF PHASE CABLE OF HV ABCThe Standard is downloaded from Standard Sharing5 MAXIMUM CONDUCTOR TEMPERATURESThe temperature of the conductor shall not exceed the following values:(a) Normal operation . 90C. (b)Emergency operation . 105C. (c)Short circuit operation (5 s max.) . 250C.NOTES:1The maximum temperatures given are based upon the properties of the insulation materials but in practice may need to be derated to take account of joints and terminations and environmental conditions.2The emergency operation temperature is applicable for an average over several years, of not more than one period per year. No period shall exceed 36 h and there shall not be more than three periods in any 12 consecutive months.3At the emergency operating temperature the insulation material shall not suffer thermal degradation. It may however suffer distortion due to external constraints caused by metallic screens, terminations or joints.6 CONDUCTORSConductors shall bestranded circular compacted aluminiumin accordancewithAS/NZS 1125 for conductors other than aerial cables.A rationalized range of conductor cross-sectional areas is given in Table 1.7 CONDUCTOR SCREENThe conductor screen shall comply with the requirements of AS/NZS 1429.1.8 INSULATIONInsulation shall be XLPE and shall comply with the requirements of AS/NZS 1429.1.9 INSULATION SCREENThe insulation screen shall comply with the requirements of AS/NZS 1429.1 and shall be designed to be hand-stripped without preconditioning (heating).10 BEDDING TAPEA textile reinforced semiconductive tape shall be applied over the insulation screen with an overlap of 2 mm or 10 percent of the tape width, whichever is the larger. The semiconductive tape may be water-swellable, as specified in Clause 12.2.The thickness of the semiconductive tape, before application, shall be not less than 0.1 mm.11 METALLIC SCREEN11.1 Material and applicationThe metallic screen shall comprise plain annealed copper wires, helically applied so that it is in electrical contact with the core throughout the length of cable. The screen wires shall comply with the requirements of AS/NZS 1125. The individual screen wires shall have the same nominal diameter, and not vary from the nominal by more than 5 percent. The length of lay of the screen wires shall not exceed 10 times the overall diameter of the core.The design gap, i.e. the gap between adjacent wires when equally spaced, calculated by taking into account the number and nominal diameter of wires and the calculated pitch circle diameter of the metallic screen, shall not exceed 4 mm.NOTE: For further information see Appendices A and B.11.2 Electrical recommendationsSee Appendix A.12 WATER-BLOCKING OF SCREENS (OPTIONAL)12.1 GeneralWater-blocking measures may be taken to restrict water penetration along the cable (in the region of the metallic screens).12.2 Materials and applicationThe blocking shall be achieved by a non-biodegradable, water-swellable tape applied under or over the metallic screen wires. Where applied under the metallic screen, the tape shall be semiconductive. This tape may replace the textile reinforced semiconductive tape specified in Clause 10.Where applied over the metallic screen it need not be semiconductive and may replace the separator tape(s) specified in Clause 13.NOTE: Other effective water-blocking materials may be acceptable with the exception of loose powders, which might constitute a health risk (see Appendix B).13 SEPARATOR TAPE(S)Non-hygroscopic tape(s) shall be helically applied, with an overlap, over the metallic screen, to prevent the penetration of sheath material between the screen wires. The tape(s) shall be applied so as to avoid the formation of creases.The separator tape may be water-swellable as specified in Clause 12.2.14 SHEATH14.1 MaterialThe sheath shall be bla
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