Offshore and Marine Shipboard Cables IEEE 1580 Type P Polyrad® XT-125 Single Conductor Specification BR-781 Polyrad® XT-125 Flexible Marine Type P Irradiated Cross-linked Polyolefin Single Conductor Rated for 600/1000 Volts or 2000/1000 Volts (AC or DC) For Use on Oil Rig-Shipboard-Apparatus TABLE OF CONTENTS SECTION SUBJECT PAGE I. SCOPE ..............................................................................................................................1 II. APPLICABLE DOCUMENTS ...............................................................................................1 III. CONDUCTOR .....................................................................................................................2 IV. SEPARATOR .....................................................................................................................2 V. INSULATION ....................................................................................................................2 A. Physical Properties ....................................................................................................2 B. Electrical Properties ...................................................................................................3 C. Qualification Testing ..................................................................................................3 1. Tension Set ..........................................................................................................3 2. Ozone Resistance .................................................................................................3 3. Flammability Requirements .................................................................................3 4. Corrosion Tests ....................................................................................................3 a) Copper Mirror ................................................................................................3 b) Acid Gas Detection........................................................................................3 5. Oil Resistance ......................................................................................................4 6. Smoke Emission ...................................................................................................4 7. Abrasion Resistance ............................................................................................4 8. Crush Resistance..................................................................................................4 VI. ARCTIC-GRADE JACKET (OPTIONAL) ...............................................................................5 VII. CABLE IDENTIFICATION ...................................................................................................6 VIII. REEL MARKINGS ..............................................................................................................6 Revision 15 Date: 04/04/13 Phone (888) 593-3355 • Fax (800) 335-1270 • Int’l Phone +1 859 572 8000 • Int’l Fax + 1 859 572 8058 www.generalcable.com INS-0147-R0413 Offshore and Marine Shipboard Cables IEEE 1580 Type P Polyrad® XT-125 Single Conductor Specification BR-781 Polyrad® XT-125 Flexible Marine Type P Irradiated Cross-linked Polyolefin Single Conductor Rated for 600/1000 Volts or 2000/1000 Volts (AC or DC) For Use on Oil Rig-Shipboard-Apparatus I. Scope This specification covers single conductor wire and cable rated at 600/1000 volts or 2000/1000 volts, AC or DC, insulated with General Cable’s Polyrad XT-125 Type P Marine insulation, a thermosetting irradiation cross-linked polyolefin which is flame retardant, moisture- and oil-resistant, and mechanically tough. Armor of aluminum or bronze and an arctic-grade overall sheath in accordance with IEEE Standard 45/ IEEE Standard 1580-2010 is available at the option of the purchaser. IEEE 1580 Type P cables should be designed, engineered and produced by cable manufacturers that have manufactured these specific cables for a minimum of 15 years. These manufacturers should be actively involved in the standards organizations that support the continued development, safety and quality of IEEE 1580 Type P cables. II. Applicable Documents The wire and cable manufactured under this specification shall be tested and inspected in accordance with the latest issues of the following standards, as applicable or as modified herein: ASTM B33 Tinned Soft or Annealed Copper Wire ASTM D149 Test for Dielectric Breakdown Voltage and Dielectric Strength of Electrical Insulation Materials at Commercial Power Frequencies CSA C22.2 No. 245/ UL 1309 Marine Shipboard Cable IEEE Std 45 IEEE Recommended Practice for Electrical Installation on Shipboard IEEE Std 1580 IEEE Recommended Practice for use on Shipboard and Marine Fixed or Floating Platforms IEEE Std 383 Type Test of Class 1E Electrical Cable, Field Splices & Connectors for Nuclear Power Generating Stations IEEE Std 1202 Standard for Flame Testing of Cables for use in Cable Tray in Industrial and Commercial Occupancies IEC-92-3 Electrical Installations in Ships, Part 3; Cables (Construction, Testing and Installation) IEC 60332-2A Tests on Electric Cables Under Fire Conditions ICEA S-95-658 ICEA/NEMA Standard for Non-shielded Power Cables Rated 2000 Volt or Less for Distribution of Electrical Energy (NEMA WC 70) UL 44 Standard for Rubber Insulated Wire & Cable UL (UBVZ) Shipboard Cable, Marine 1 Phone (888) 593-3355 • Fax (800) 335-1270 • Int’l Phone +1 859 572 8000 • Int’l Fax + 1 859 572 8058 www.generalcable.com INS-0147-R0413 Offshore and Marine Shipboard Cables IEEE 1580 Type P Polyrad® XT-125 Single Conductor Specification BR-781 Polyrad® XT-125 Flexible Marine Type P Irradiated Cross-linked Polyolefin Single Conductor Rated for 600/1000 Volts or 2000/1000 Volts (AC or DC) For Use on Oil Rig-Shipboard-Apparatus III. Conductor Conductors shall be of soft annealed tinned copper per ASTM B33 and shall conform to requirements as listed in the Dimensional Data section of the Type P data sheets. IV. Separator A suitable separator may be used if deemed necessary by the manufacturer. V. Insulation The insulation shall be Polyrad XT-125 Type P Marine, an irradiated cross-linked polyolefin, with a minimum average thickness as listed in the Dimensional Data section of the Type P data sheets. The insulated conductor shall meet the following requirements: A. Physical Properties Unaged Requirement Tensile Strength, Min. PSI Elongation at rupture, Min. % 2000 Min. 250 Min. Aged Requirements After air oven 7 days @ 158°C ± 2°C Tensile Strength (% of original) Elongation (% of original) 90 Min. 55 Min. After air oven 7 days @ 121°C ± 2°C Tensile Strength (% of original) Elongation (% of original) 90 Min. 90 Min. Oxygen Bomb 7 days @ 80°C @ 300 PSI Tensile Strength (% of original) Elongation (% of original) 90 Min. 90 Min. Air Bomb 42 hours @ 127°C 80 PSI Tensile Strength (% of original) Elongation (% of original) 90 Min. 90 Min. Heat Distortion, 1 hour @ 200°C Clause 4.3.6.1 CSA Std. C22.2 No. 0.3 Cold Bend, 120 hours @ -55°C 20% Max. 6 kV - 5 Min. 2 Phone (888) 593-3355 • Fax (800) 335-1270 • Int’l Phone +1 859 572 8000 • Int’l Fax + 1 859 572 8058 www.generalcable.com INS-0147-R0413 Offshore and Marine Shipboard Cables IEEE 1580 Type P Polyrad® XT-125 Single Conductor Specification BR-781 Polyrad® XT-125 Flexible Marine Type P Irradiated Cross-linked Polyolefin Single Conductor Rated for 600/1000 Volts or 2000/1000 Volts (AC or DC) For Use on Oil Rig-Shipboard-Apparatus B. Electrical Properties Dielectric Strength per ASTM D-149 > 700 V/Mil Insulation Resistance > 5000 Megohms/M’ = 20,000 Insulation Resistance K Accelerated Water Absorption Gravimetric 7 days @ 70°C 5 MG/in2 Electrical SIC 24 hours @ 75°C Increase in Capacitance 1 - 14 Days 7 - 14 Days Stability Factor after 14 Days C. Qualification Testing 1. Tension Set Gauge marks are 4” apart. 6.0 3.0 1.5 .5 10% Max. 2. Ozone Resistance After 24 hours exposure to an ozone concentration of 0.03% by volume at 90°C ± 2°C, there shall be no insulation cracks. 3. Flammability Requirements Insulated conductors shall pass the flame test described in ICEA S-19-81 and the VW-1 vertical flame test described in UL Subject 44. Insulated conductors shall also pass the flammability requirements described in IEEE Std. 45, IEEE Std. 1580, IEEE 1202 and IEC 60332-3A for flame tests. 4. Corrosion Tests a) Copper Mirror: (Ref. ASTM 2671) A 0.4 gram sample of insulation is placed in the bottom of a 2 inch x 12 inch test tube. A copper coated glass mirror shall be suspended 6 inches over the sample by a thin copper wire. The lower two inches of the test tube shall be heated to 175°C for 16 hours. Requirement: Remove less than 5% of the copper film. b) Acid Gas Detection: A 1.0 mg sample shall be heated to combustion in a closed quartz tube. The resulting gases are drawn through a detector tube (MSA #91636) using a special air sampling pump manufactured by Mine Safety Apparatus Company. The amount of acid gas is determined by measuring the length of the color change in the detector tube. Requirement: 220 PPM/MG typical. 3 Phone (888) 593-3355 • Fax (800) 335-1270 • Int’l Phone +1 859 572 8000 • Int’l Fax + 1 859 572 8058 www.generalcable.com INS-0147-R0413 Offshore and Marine Shipboard Cables IEEE 1580 Type P Polyrad® XT-125 Single Conductor Specification BR-781 Polyrad® XT-125 Flexible Marine Type P Irradiated Cross-linked Polyolefin Single Conductor Rated for 600/1000 Volts or 2000/1000 Volts (AC or DC) For Use on Oil Rig-Shipboard-Apparatus 5. Oil Resistance Hot Oil Swell Tests - Insulated wires are premeasured and immersed in a hot oil bath. After the required exposure time, they are removed and measured for the amount of swell. Requirement: A. IRM 902 Oil 100 hours @ 150°C Max. Max. % Swell 40 B. Diesel Oil 100 hours @ 60°C Max. Max. % Swell 60 Note: When tested in accordance with AAR 589 (IRM 902 oil at 121°C for 18 hours), the retention of tensile and elongation shall be: Tensile - 70% Minimum Elongation - 90% Minimum 6. Smoke Emission The test shall be performed in an N.B.S. Smoke Chamber using #12 AWG wire insulated with 45 mils of Polyrad XT Type P Marine. The procedures are per NFPA Standard 258 in the flaming (F) and non-flaming (N) modes. Dm T16 T.9Dm (F) Flaming plus Radiant Furnace 485 1.20 7.15 (N) Non-flaming Radiant Furnace 203 10.3 25.7 Dm = Max. Specified Optical Density T16 = Time to reach critical Ds (Specified Optical Density) T.9 Dm = Time to reach 90% of Dm 7. Abrasion Resistance Rotating Scrap abrader (Ref. MIL-C-915) - A 24 inch specimen is draped over an 8 inch rotating drum with two (2) 90° vee edge abrading tools 180° apart. Failure is detected by electrical contact between abrading tool and conductor. The cable is weighted with a 450 gram weight. Requirement: 2500 cycles minimum 8. Crush Resistance A wire sample is placed between two (2) parallel flat plates and compressed until electrical contact is detected across conductor to the plate. Requirement: 7500 lbs. minimum 4 Phone (888) 593-3355 • Fax (800) 335-1270 • Int’l Phone +1 859 572 8000 • Int’l Fax + 1 859 572 8058 www.generalcable.com INS-0147-R0413 Offshore and Marine Shipboard Cables IEEE 1580 Type P Polyrad® XT-125 Single Conductor Specification BR-781 Polyrad® XT-125 Flexible Marine Type P Irradiated Cross-linked Polyolefin Single Conductor Rated for 600/1000 Volts or 2000/1000 Volts (AC or DC) For Use on Oil Rig-Shipboard-Apparatus VI. Arctic-Grade Jacket (Optional) The optional arctic-grade jacket, when required, shall meet NEK 606 ester-based mud oil resistant requirements and be black irradiated cross-linked Chlorosulfonated Polyethylene meeting the following requirements when tested in accordance with IEEE Standard 1580-2010. Jacket & Overall Sheath Physical Properties Material (Arctic-Grade Chlorosulfonated Polyethylene) Physical Requirements Unaged: Tensile Strength, min. psi Elongation at rupture, min. percent Set, max. percent Requirements Per IEEE 1580-2010 Table 16 General Cable Type CP Jacket Thermosetting Thermosetting Chlorosulfonated Polyethylene Chlorosulfonated Polyethylene 1800 300 30 2200 350 12 Aging Requirements After air oven at °C Hours Tensile Strength percent of unaged, min. Elongation at rupture, percent of unaged, min. 121 ± 1 168 85 65 121 ± 1 168 100 90 After oil immersion at °C Hours Tensile Strength percent of unaged, min. Elongation at rupture, percent of unaged, min. 121 ± 1 18 60 60 121 ± 1 18 90 90 -40 -55 Cold Impact, °C (Note 1) -40 -40 Mechanical water absorption, mg/in2 100 87 Cold Bend, no cracks, °C (Note 1) NOTE: (1) For test procedures refer to CSA Standard C22.2, No. 38, Clause 6.4.7. The insulation system used for this test shall be representative of the final product. Cable intended for arctic or severe cold application should be capable of passing both cold bend at -40°C and cold impact at -40°C. 5 Phone (888) 593-3355 • Fax (800) 335-1270 • Int’l Phone +1 859 572 8000 • Int’l Fax + 1 859 572 8058 www.generalcable.com INS-0147-R0413 Offshore and Marine Shipboard Cables IEEE 1580 Type P MOR™ Polyrad XT-125, Unarmored ® Specification BR-781 Polyrad® XT-125 Flexible Marine Type P Irradiated Cross-linked Polyolefin Single Conductor Rated for 600/1000 Volts or 2000/1000 Volts (AC or DC) For Use on Oil Rig-Shipboard-Apparatus VII. Cable Identification The surface of the cable shall be printed with the following minimum information at intervals not greater than two feet. “POLYRAD® XT-125 (UL) E85994 BR781 110C 1/C XXAWG 2000V or (CSA) 245/1309 FT4 –40C IEC 1KV 60332.3A IEEE 1580 TYPE P OR (ETL) 109229 YEAR OF MFG SEQUENTIAL FOOTAGE MARK” VIII.Reel Markings Each reel to be shipped shall be marked to include the following minimum information in addition to any other information specified by the purchaser: General Cable Polyrad XT-125 Type P Marine Voltage Rating Conductor Size & No. of Conductors Footage on Reel Month/Year of Manufacture 6 Phone (888) 593-3355 • Fax (800) 335-1270 • Int’l Phone +1 859 572 8000 • Int’l Fax + 1 859 572 8058 www.generalcable.com INS-0147-R0413