1. Western Underground Committee Brent Richardson September 24, 2014
Sustainable and Environmentally Sound Lead-Free Filled EAM Insulation For Utility Medium Voltage Power Cable
Western Underground Committee
Brent Richardson
September 24, 2014

2. Overview
Background and Value Proposition
Why Lead-Free? Why Elastomers?
ANSI/ICEA Ethylene Alkene Copolymer (EAM) Definition
LF Filled EAM Insulation for Cable Applications
LF Filled EAM Insulation Cable Testing
LF Filled EAM Insulation Cable Field Experience
Summary and Features & Benefits
Path Forward/Objectives

3. Background
The medium voltage filled insulation market has been dominated by Ethylene Propylene Rubber (EPR) based “leaded” insulations for the last forty (40) years.
The solution for increasing cable performance, dealing with environmental concerns, and addressing changing market dynamics requires modifications to the insulation system’s base polymer and stabilization package.
Over the last ten (10) years the performance of metallocene catalyzed Ethylene-Alkene Copolymers (EAM’s) have improved significantly; in concert with GCC stabilizer package development, lead-free EAM insulation meeting Utility MV performance requirements has been created.

4. Value Proposition LF Filled EAM insulation offers:
Improved installation performance and an environmentally
conscious alternative for demanding MV insulation applications:
Improved flexibility and trainability
Less spring-back
Eliminates the last hazardous material from the MV cable
Sustainable solution
LF Filled EAM has demonstrated thermal, wet & dry electrical stability:
Meets or exceeds the Qualification and Production requirements of ANSI/ICEA S , S and AEIC CS8
Core Material Qualification (HVTT, Hot Impulse, Load Cycle, AWTT, etc.)
Dry-Electrical Test for Class III Insulation (MV-105)
Dissipation Factor Characterization Test
Thermomechanical Qualification Test at 140°C
Good original and retention of physical properties
Long term wet aging performance demonstrated by ACLT and AWTT testing
Field installation and evaluation completed with Consolidated Edison

5. Why Lead-Free?
With safety as a top concern, the industry has focused on removing hazardous materials from cable products.
RoHS, California Prop. 65, REACH all restrict lead use; EPA currently says that the lead content in MV EPR insulation is below threshold limit, but what will be the future limits?
> 250,000 lb of red lead oxide used in MV EPR insulation production by GCC per year; Each year as the volume of traditional EPR consumption keeps growing the amount of red lead oxide grows.
≈ 43 lb of red lead oxide per circuit mile of 4/0 Al 220 mils wall EPR-insulated MV cable.

6. Why Elastomers are Used in Utility Cable Applications
Elastomers are polymers that exhibit high extension and flexibility when placed under low mechanical stress.
Low crystallinity of elastomers permit excellent flexibility that enables ease of cable installation.
Low crystallinity of elastomers permit higher filler incorporation that in turn permits cross linked compounds to exhibit high heat and oil resistance.

7. Definition of Insulation Materials per ANSI/ICEA
ANSI/ICEA S and S allow alternate EAM insulating materials meeting the same physical and electrical requirements of XLPE, TRXLPE, and EPR.
EAM materials are first identified in a footnote under Table 4-1 in ANSI/ICEA S and S and are further explained in Appendix I and Appendix H respectively. EAM materials have been listed since 1996

8. Definition of Insulation Materials per ANSI/ICEA
Ethylene Propylene Rubber (EPR) Insulating Compound is defined as a mixture of ethylene propylene base resin and selected ingredients.

9. LF Filled EAM Insulation for Cable Applications
Continuing technological developments in polymer catalyst technology make available more diverse polymers suitable for medium voltage cable applications.
GCC developed LF Filled EAM with a Dow elastomer which uses the traditional ethylene backbone of an EPR formulation, but with a longer side chain.
The increasing side chain lengths in EAM compounds improves flexibility and the resulting electrical performance improved without lead
Ease of installation: Improved flexibility and trainability; Less spring-back
Environmental sustainability is gained and recyclability is improved
LF Filled EAM retains the inherent benefits of EPR insulations with improved thermal stability.

10. Comparison of Insulation Materials
The chart below compares key attributes of MV cables for each of the
three major insulation types

11. LF Filled EAM Insulation Cable Testing
Comparison testing between commercial Leaded EPR and Lead-Free EAM
Heating Aging (Elongation)
EAM insulation systems have inherently higher elongation.

12. LF Filled EAM Insulation Cable Testing
Heating Aging (Elongation)
Both compounds maintain high elongation during heat aging.

13. LF Filled EAM Insulation Cable Testing
Heating Aging (Tensile)
Both compounds maintain high tensile during heat aging;
> 80% of initial tensile strength retained through five (5) weeks.

14. LF Filled EAM Insulation Cable Testing
Flexibility Testing
Lead-Free EAM
Leaded EPR
Key value proposition
Lead-Free EAM is more flexible than Leaded EPR;
33% reduction in flex modulus when compared to Leaded EPR.

15. LF Filled EAM Insulation Cable Testing
AWTT High Voltage Time Test
Long term wet aging performance demonstrated in AWTT testing
Both compounds exceed ICEA HVTT requirements after AWTT wet aging;
Lead-Free EAM performs equal or better than Leaded EPR.

16. LF Filled EAM Insulation Cable Testing
Dry Electrical Testing (MV-105)
Lead-Free EAM cables show stable dissipation factor under dry aging conditions;
Lead-Free EAM has lower, more stable dissipation factor at elevated temperature.

17. LF Filled EAM Insulation Cable Testing
Accelerated Cable Life Testing (ACLT)
R&D testing beyond Industry Standard requirements
Tested per IEEE Std. 1407
Tests for MV (5 kV – 35 kV) Extruded Electric Power Cables Using Water-Filled Tanks
37B Retained Breakdown Strength Protocol
72 hours pre-conditioning at 90°C
Specimens are wet aged in a tank filled with deionized water; Water is injected into the conductor during aging
3 Vg is applied continuously during wet aging
The cable is load cycled with current for 8 hours each day to achieve a conductor temperature of 75°C in water
The tank water temperature is controlled to 50°C

18. LF Filled EAM Insulation Cable Testing
Accelerated Cable Life Testing (ACLT)
Long term wet aging performance demonstrated in ACLT testing
Lead-Free EAM performs equal or better than Leaded EPR;
Good performance even in high stress design

19. LF Filled EAM Insulation Cable Field Experience
EAM used as insulation for secondary low-voltage network cable for over a decade (Consolidated Edison 600V Network)
≈ 22,000 miles of 600V EAM-insulated network cables installed since 2000
Introduction of Lead-Free EAM to Consolidated Edison June 2007 for primary medium-voltage insulation
Initial field trial of 3x1/C Triplex 750 kcmil Cu LF-EAM FS PP 15kV Cable completed with Consolidated Edison in February 2010
Positive Feedback from Consolidated Edison Installation Crew
“Holds its rack better and does not spring back as much”
“A lot easier to rack in manhole than current cable”
“Cable was easy to install.  Weather was very cold”
Cable installed along with equivalent leaded EPR design. Both cables removed from service in January 2012 for comparative evaluation
Lead-Free EAM performance was equal or better than Leaded EPR field aged cable

20. LF Filled EAM Insulation Cable Field Experience
A second cable design manufactured in October 2011 consisting of 23,000 circuit feet of 3x1/C Triplex 500 kcmil Cu LF EAM FS PP 27kV
Installation started January 2012 by Consolidated Edison. Cable is still in service with no plans to remove it.
The development of the new insulation material has taken several years of testing to ensure reliability of and confidence in the product.
Consolidated Edison has given the green light to start completely transitioning over to Lead-Free EAM insulation for all medium-voltage primary cables
First design transitioned in 3rd Quarter 2013; >250,000 linear feet shipped.
Transitioning all MV cable designs between 3rd and 4th Quarter 2014.
Consolidated Edison cables are designed to perform in harsh operating environment
High stress / Reduced insulation wall.

21. Summary and Features & Benefits
Lead-Free Filled EAM compounds offer improved installation performance and an environmentally conscious alternative for demanding MV Utility insulation applications.
Lead-free Filled EAM has demonstrated thermal, wet & dry electrical stability.
GCC has commercialized Lead-free Filled EAM insulation (EmPowr® Fill LF).
Features & Benefits of Lead-free Filled EAM
Improved flexibility; Improved trainability and less spring-back
Easier handling during installations.
Appealing for the installation crew; Better ergonomics; Less fatigue after handling.
Better wet electrical aging performance vs. a Leaded EPR as demonstrated by AWTT and ACLT testing.
Meets or exceeds ANSI/ICEA S & S and AEIC CS8.
GCC offers a “Green” Sustainable Solution
Eliminates the last hazardous material from MV cable designs.
Low and stable dissipation factor (lower losses) at elevated temperatures.
Green solution may aid in rate case approvals.
EmPowrFill LF is the commercial brand

22. LF Filled EAM Insulation Path Forward/Objectives
For additional information from General Cable, contact Tom Lewnard or P-M Leblanc.
For additional information from Dow Chemical, contact Brent Richardson
Contact Information:
Brent Richardson:
The Dow Chemical Company
Manager, End Use Marketing-North America
Office
Cell
Tom Lewnard:
General Cable
Product Manager, Utility Products
Office:
Mobile:
Pierre-Marc Leblanc:
Manager Specification Engineering, Utility Products
Office:
Mobile:
References Contact Information:
EmpowrFill LF is the commercial name of the product
George Murray:
Section Manager, Distribution Cable Systems
Consolidated Edison Company
Office:
Tom Campbell:
Sr. Engineer, Distribution Cable Systems
Consolidated Edison Company
Office: