hv-ehv cables synthetic isolation
TRANSCRIPT
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High and extra high voltage cableswith synthetic insulation
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Gl ob a l e x p e r t i n c a b l e s a n d c a b l i n g s y s t e m s
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S u m m a r y
TheevolutionofHVandEHVcableswithsyntheticinsulation 5
Anoutlinehistoryofdevelopments 6
ProjectengineeringforHVcablelinks 7
ExamplesoftherangeofHVandEHV
cableswithsyntheticinsulation 8
Productiontools 9
420 kVcabletechnology 10
Checksandtests 11
References 12
Accessories 13
Services 15
Introduction 4
H i g h a n d e x t r a h i g h vo l t a g e c a b l e s
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Nexans Switzerland
supplieshighandvery
highvoltagepowercables
andaccessories,optical
fibercables,opticalwave-
guideandspecialcables
fortheinternationalmarket.
Nexans Switzerlandhas
threeproductioncentres:
theBreitenbachsite
theCortaillodsite
theCossonaysite.
4
I n t ro d u c t i o n
Nexans Switzerland is
Switzerlandsforemost
cablemakerandsupplier.
Itmanufactures,distributes,
fitsandinstallsacompre-hensiverangeofproducts
forunderground,submarine
andaerialinstallations:
high,mediumandlow
voltagepowercables
copperoropticalfiber
telecommunications
cables
specialcablesfor
manyapplications
powerandtelecom
accessories
connectionequipment.
Itsservicesrangefrom
thesupplyofcablestothe
implementationofcomplex
turnkeyproducts,including
development,engineering,
constructionwork,systemtechnology,laying,installa-
tionandprojectfinancing.
Pos i t i on of N e x a n s S w i t z e r l a n d
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T h e ev o lu t i o n o f H V a n d E H V c a b les
with synthet ic insulat ion
T h e Ca b l e s
aluminiumsheath
compositesheath
Thegreaterdemand
forenergyrequiresthe
implementationofinstallations
designedtosupportincreas-
inglyhighervoltageand
powerlevels.
ThisiswhyNexans
SwitzerlandLtdhasdevel-
opedcableswithsynthetic
(ordry)insulationforvoltages
upto420kVandcross-
sectionsthatcanbelarger
than2000mm2.
Con d u c t or s
Athighgradients,synthetic
insulationissensitivetothe
presenceofmoisture.Itis
thereforeessentialtoavoid
anycontactwithwateror
steamduringfabrication
processesandalsoduringlineoperation.
Thecross-linkingoperation
mustbecarriedoutinthe
absenceofhumidity,either
onacatenarylineinaninert
atmosphere,oronahorizon-
talline(MDCVprocess).
Forallcables,theexternal
protectionisprovidedbya
polyethylenesheath.Over
thisinsulation,theapplica-tionofawaterproofmetallic
sheath,whichalsoactsasa
screen,isgenerallyrequired.
I n s u l a t i on
Higherservicegradientsrequirebetterinsulation
qualities.
Thesematerialsshould
beperfectlycleanthis
isparticularlyimportant,
astheirlong-termperfor-
mancecanbeconsiderably
affected,evenbymicro-
impurities.Precautionsto
ensurecleanlinessshould
betakenbothduringtheproductionofrawmaterials
andthroughouttheentire
cablefabricationprocess.
S h e a t h s
Forconductorcross-sections
largerthan1000mm2,seg-
mentedconductorsmustbe
producedtoreduceconsider-ablytheirresistancetoalter-
natingcurrentbyreducing
theskineffect.
Thissheathcanbemadeof
unweldedextrudedaluminum
orlead,orofweldedor
gluedcopperoraluminum.
NexansSwitzerlandLtduses
allthesetechniqueswith
completemastery.
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An out l ine history of developments
De ve l op m e n t s f r om 1 9 7 3 t o t h e p r e s e n t d a y
Sincetheintroductionof
cross-linkablesynthetic
insulation,productionand
controltechniqueshavegone
throughawholeseriesof
developmentsteps.
1973
1974
1976
1977
1978
1983
1986
1987
19891991
1996
1998
2006
Implementation ofa cross-linkingcatenary line
Delivery of the firstHV cables with dryinsulation
Introduction of the triple-head extrusion process
Delivery of the first150 kV extruded
insulation cable
Modification of thecatenary line fornitrogen cross-linking
Delivery of the first220 kV cable withXLPE insulation
Construction andstart-up of a laboratoryfor measuring partialdischarges up to 480 kV
Production of the firstXLPE Cable 220kVwith a cross-section of2500 mm2
Production of the first275 kV cable withXLPE insulation
Implementation of a2nd cross-linking linefor large conductorcross-sections and thicklayers of insulation
Production of the first400 kV cable withXLPE insulation
Delivery of the first400 kV cable withXLPE insulationabroad
Delivery of the first400 kV cable with XLPEinsulation in Switzerland
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Project engineering for HV cable l inks
De ve l op m e n t
plan
territorialplanning
increaseddemand
connectionofheavyusers
networkplan
networkcalculation
powerflowdetermination
customer
Cause and nature of operations Effects Intervening parties
Pr e - s t u d y
plan decisiontoreinforcenetwork
preliminaryfeasibilitystudy
pilotstudy
choiceofconnectiontype :underground,overheadormixed
technicalsolutions
customer
Nexans
S t u d y
Impactstudy
collaborationwithotherdepartments :engineeringoffices,industrialdepartments,etc.
noticetomunicipalauthoritiesandlandowners
choiceofconnectiontype :underground,overheadormixed
drawingupofspecifications
customer
Nexans
Pr oje c t
choiceofdefinitiverun
definitionoflayingparameters
measurementoflinelength
preparationofcontractorsfile
customer
Nexans
O f f e r s
definitionofpossiblecabletypesorvariants
calculationofthecross-sectionaccordingtovoltage,powerandcivilengineeringparameters
distributionofpartiallengths
groundingsystem
preparationofrequestsforoffersandcontracttendersformaterialsandcontractors
costofcivilengineeringwork
costofinstallationandset-up,scheduleanddetails
customer
Nexans
Authorizations
filefortheauthoritiesconcerned
handlingofpossibleobjections
buildingauthorization customer inspectors
Nexans
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E x a m p les o f t h e ra n g e o f H V a n d E H V
c a b les w i t h sy n t h et i c i n su la t i o n
45kV
EPR insulation
60kV
XLPE insulation
150 kV
XLPE insulation
500 mm2
220 kV
XLPE insulation
2000 mm2
400 kV
XLPE insulation
800 mm2
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HVExtrusionline
Product ion tools
HVlaboratory
Aluminiumpress
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10
extrudedcross-linkedpoly-
ethylene(XLPE)insulation
cableswhich,withthe
progressofthetechniques
usedinthemanufacturing
ofbasicmaterialsand
aboveallforinstallation,
haveachievedtherelia-
bilitylevelrequiredfor
useinextrahighvoltage
(EHV)networks.
4 2 0 kV c a b le t ec hn o lo g y
For420kVcables,there
arecurrentlytwoalternatives
totraditionalfluidoilimpreg-
natedpaperinsulation :
cableswithPPLPinsulation,consistingofthree-layer
laminatedpaperand
polypropylenetapes,
formedintoribbonsand
impregnatedwithoil.
E H V c a b l e s w i t h PPL P a n d X L PE i n s u l a t i on
PPLPinsulation,whichwas
introducedattheendofthe
0s,isstilllimitedtocables
tobeusedatavoltageof
400 kVorhigher.Thisisdue
ontheonehandtoitsprice,
whichishigherthantheprice
ofpaper,andontheother
totheincreasinglygeneral-
izeduseofXLPEinsulationfor
voltagesupto220kVand400 kV.
XLPE Insulation
Cross-linkedpolyethylene
(XLPE)wasintroducedinthe
0s.Itwasinitiallyusedfor
mediumvoltagecables,but
isnowusedasinsulationfor
extrahighvoltagecables
(EHV).Itsuseatvoltage
levelsof400 kVandhigherrequires,ofcourse,sophisticat-
edstate-of-the-arttechnology.In
particular,weshouldmention :
PPLP Insulation
Forextrahighvoltage
(400 kVandhigher),new
typesoftapesmadeofPPLP
(PolyPropyleneLaminated
Paper)areused.Theyhave
theadvantageofcombin-
ingthetraditionalapplica-
tiontechnologyusedfor
impregnatedpapercables
withtheexcellentelectrical
anddielectricpropertiesof
syntheticinsulators.PPLPisa
three-layerinsulationconsist-
ingofapolypropylene(PP)
sheetlaminatedbetween
twosheetsofpaper.PP
improvesthequalityofthe
insulation,whilethesheetsof
paperensurethecirculation
ofoilbetweenthelayers.
Comparedwithpaperinsula-tion,PPLPhasahigherbreak-
downstrengthandaboveall
lowerdielectriclosses.
PPL P a n d X L PE i n s u l a t i on
therigorousselectionof
insulatingandsemi-con-
ductingmaterials,which
mustbeofaveryhigh
puritylevel,
thecheckingoffiltering
duringapplication,
three-layerextrusion(inter-
nalsemi-conductor,insula-
tionandexternalsemi-con-ductor)usingasingletool,
theobtentionofperfectly
smoothinsulationsemi-con-
ductorinterfaces,
protectionoftheinsulation
againstthepenetrationof
moisture,
stringentelectricalteststo
detectanyfaults.
Forconnectionprojectsat
420 kV,exhaustivetestshave
beensuccessfullycarried
outforbothXLPEandPPLP
cables.Themainfeaturesof
thesetwotypesofcablesare
comparedbelow.
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11
Forallthesetasks,reli-
ableandfastmeasurement
equipmentisrequired.
Considerableinvestments
havebeenmadetoequipourmaterialstestlaborato-
rieswiththemostmodern
equipment,suchasthermal
analysisinstruments,tensile
strengthapparatus,optical
Checks and tests
Thematerialsusedinthecon-
structionofEHVcablesare
subjectedtoverystringent
qualitycontrolchecks,both
beforeandafterproduction.Plastics,metalsandtapesall
undergoelectricalresistance
testsandmeasurementsof
theirdielectricormechanical
properties.
F r om c h e c k s on m a t e r i a l s . . .
After-laying tests
tocheckthequalityof
assemblyofaccessoriesafter
installationandtosimulate
cableoperationandrapidly
provideinformationoncable
efficiencyafterprolonged
periodsofuse.
Accelerated ageing teststosimulateworkinglifeand
toprovideinformationwithin
ashorttimeframeontheir
behaviorinlong-termuse.
Diagnostic tests
tohighlightanydegradation
phenomenainthelineinser-
viceandtoprovideinforma-
tionontheresidualcablelife.
Thequalityofhighvoltage
cablelinksishighlydepen-
dentontherigorousnature
ofthetestscarriedoutonthe
cablesandtheiraccessories.
Themorestringentthesetests
are,theloweristheriskof
failureduringoperation.
Theprincipaltestsareas
follows :
Routine tests
toevaluateproduction
quality.
Type tests
tovalidateatypeof
construction,foreither
cablesoraccessories.
Special tests
undertakeninthecase
ofmajordesignchanges.
. . . t o e l e c t r i c a l t e s t s
microscopes,infra-redspec-
trometer,chromatograph,
amongothers.
Theseexactingchecksenable
ustoreducetoaminimumthepresenceofundesirable
matterandtoguaranteethe
qualityofourcables.
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R ef eren c es
Pr e s t i g i ou s p r o je c t s
1990 Thefirst420kVcablewasinstalledinSwitzerlandwithXLPEinsulationconnectedtothenetworkatthe"Bassecourt"substationofthe
BerneseElectricityCompany.ThissubstationwasconnectedtoLaufenburgandFranceby0kVoverheadlines.Thecopperconductorcross-sectionwas1200mm2.
1996 Variousinstallationsofdesalinationplantsweresetupalongthecoastofcer-tainArabcountries.Themostimportantoneamongstthemissuppliedwithcablesandacces-
soriesfromNexansSwitzer-landLtd,formerlyCortaillodCossonayCable.Wesuppliedsectionsof400kVcable,withXLPEinsulationandacor-rugatedaluminiumsheath.
1997 NexansSwitzerlandLtd,wasawardedanimpor-tantcontractbyPowerGrid,awhollyownedsubsidiaryofSingaporePower,tosupplyandinstall20 kVXLPEpowercables,2'000mm2withacor-rugatedaluminiumsheathandaccessories.Thiscontractwasthefirstofitskindtobeaward-edbyPowerGridinSingapore.Theprojectconsistedoftwocablerouteswithatotalcablelengthofabout km.
1998 CleusonDixenceproject,Switzerland.
Withawaterfallof1m,
Peltonturbineof42MW,alternatorof.MVA/pole,thisPowerStationsetsworldrecords.
just.monthsbetweentheorderdateandcommissioning.
2000 NexansSwitzerlandlaidtwosublakelinksforSocietElettricaSopracenerina
inLagoMaggiore.Foreachlinkwithalengthof2200m,threecablesoftheXDAluWETtype,1x00mm2,0kVwereruninPEtubespreviouslyinstalledonthelakebed.
2000 Nexanscompleteda20kV(,00mofXAluWT,1x4000mm2)cableinstallationanda12kVinstallation(24 kmofXDFcuCuT,
1x0mm2
)fortwocustom-ersinSpain.
2004 WhentheextensionoftheChicoasenpowerstationnearTuxtlainMexicowasdecidedtoaddafurthergenerators(eachof10MW)tothegeneratorsalreadyinserviceandbringthetotalcapacityto240MW(practicallyonethirdofthetotalproductioninSwitzerland),
Nexansdeveloped,manufac-tured,installedandtestedthex400 kVcablelinks-400kVtypePoAluWET1x400mm2Cu-fromthetransformertothestartingpointoftheoverheadlines.Withthisproject,Nexansonceagainconfirmsitshighlevelsofexpertiseinprojectandinstallationengineering.
2004 WhenTranselectrica(thenationalRomanianelectric-
itytransmissioncompany)issuedaninternationalinvitationfortherestorationofa220 kVcircuitanda400kVcircuit
connectedtothesametrans-formerandbuildingupacrucialpartoftheoperatingsystemofthe"PortiledeFier"(doorsofsteel)powerstation,
Nexanswonthecontract.Incollaborationwithalocalcompanyandwithinanambi-tiouscompletiondate,Nexansremovedtheexistingoil-filledcablesandreplacedthemwithsyntheticallyinsulatedcableswithahigherpowerrating400 kVtypeXDCuTAluWET,1x0mm2Cuand220 kVtypeXKDAlT-Tsc,1x1000mm2Cu.
2006 NexansSuissebegantoexpandintoChinain1,inpartnershipwithanintegrator,withintheframeworkoftheDaYuanDuhydro-elec-tricpowerstationprojectinHunanprovince,forwhichasystemof110kVXLPEcableswassuppliedandinstalled.Furtherprojectsfollowed,inwhichNexansSuissehadthesameresponsibilitiesforthe
supplyofcompletecablingsystemsandfortheon-sitesupervisionoftheinstallations:thefirst220kVXLPEcablesfortheZhengJiangpowerstationweresuppliedinearly200;andsince200,almost0 kmofcables,inparticular220kVcableswithacoppercrosssectionof200mm2,forthesupplyofsub-stationsinPekinginanticipationofthe200OlympicGames.Over
aperiodof10years,nofewerthan21circuitsintotalhavebeeninstalledthroughoutthecountry.
NexansSwitzerlandLtd,manufacturedandinstalledx400m,400 kVXLPEcables,00mm2withacor-rugatedaluminiumsheathand
accessoriesforconnectingthethreetransformerslocatedintherock-cavetotheswitchingsta-tion,acrosstheRhoneriver.
1999 ThroughNexansFrance,NexansSwitzerlandhaswonacontractforthesup-plyof0 kmofXKDAlTcable,1x2000mm2,11kVforTaiwanPower,inTaiwan.
2000 Nexanssupplied
andinstalledXAluWTcablecircuits,1x400mm2and1x0mm2,20kVand120kVcablecircuitsonanindustrialsiteinDearbornintheUnitedStates.
2000 Followingamechani-calaccident,thegaspressurecablesofthe10kVForetailleChnesublakelinkingsec-tionoperatedbyServicesIndustrielsdeGenve,were
damagedinNovember1.NexansSwitzerlandreplacedthesublakelinkwithalengthof200mbycablesoftheXDAluTtypeinarecordtimeofmonthsbetweentheorderandcommissioning.
2000 Followingafireintheaccesstunneltothe"ElCajon"powerplantinHonduras,twooil-filled220kVcablesweredamaged.Nexans
replaced2circuitswithalengthofaround1000mbyXAluWTcables1x00mm2,220 kV.Thisprojectwascompletedin
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1
A c c esso r i es
O u t d oor s e a l i n g e n d s w i t h p or c e l a i n i n s u l a t or
Theconceptofthesealing
endwithporcelaininsulator
hasalong-termexperience
withpaperinsulatedcables
ofmorethan0years.The
sealingendincludesapre-moldedslip-onstresscone.
Com p os i t e i n s u l a t or s f or va r i ou s a p p l i c a t i on s
Thousandsofcompos-
iteinsulatorshavebeen
installedsince10byour
companies,someofthem
areinserviceundervery
severeconditions,atthefull
satisfactionoftheirusers.
Asanalternative,customers
worldwideaskmoreand
moreforsyntheticinsulators.
Suchinsulatorsarecomposed
ofafibreglassreinforced
epoxytubewithtwoalumi-
niumflangesandinsulated
bysiliconesheds.
Specialadvantagesare
lowweight,excellentseismic,
mechanicalandpollutionperformancesaswellas
noexplosionrisk.
Dr y t y p e ou t d oor s e a l i n g e n d s
to14kV,offersmany
additionaladvantageslike:
noriskofleakage;
noenvironmentaleffect
easyhandling
quickinstallation
Since20years,Nexans
offersslip-ondrytype
outdoorsealingends,
whichdontneedanyoilorgasfilling.
Amonoblocversion
availableforvoltagesup
O u t d o o r s e a l i n g e n d s w i t h c o m p o s i t e i n s u l a t o r
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GI S s e a l i n g e n d s / T r a n s f or m e r s e a l i n g e n d s
TheGISsealingendsaredesignedinaccordance
withIEC0standard,
eitheraccordingtoitem.1
forfluidfilledterminationsor
item.2,TypeAfordrytype
terminations.
FortheconnectionofHVcablestotransformer
orgasinsulatedswitch-
gears,Nexansmanu-
facturingprogramme
includesadequate
terminations.
Jo i n t s
coppertubeandarobustPEcovering.Shieldbrake
facilitiesareintegrated,
factorymadeandfactory
tested.
MOP :MediumOuter
Protectionconsistingofa
synthetic,rigidcover.
LOP :LightOuterProtection
madeofheatshrink
components.
Nexansprefabricatedhighvoltagejoints(2-0 kV)
arebasicallycomposedof
apremoldedelastomerjoint
body,andanoutercasing.
Forthe2 kVLevel,a
cablejointwithpremolded,
factoryexpandedjointbody
isavailable.
Outerprotectionsforjoints
areavailableindifferentversions :
HOP :HeavyOuterProtection
casingconsistingofastrong
Tr a n s i t i on jo i n t s
Nexanshasdevelopeda
conceptwhichguaranteesa
highreliableandcompactconnectionforHVcablesof
differenttechnologies.
Whenpaperinsulated
HVcableshavetobe
connectedtosyntheticinsulatedcables,aso
calledtransitionjointis
needed.
V a r i ou s a c c e s s or i e s a n d t ool s
acableinstallation,such
ascablescreendiscon-
nectingsystems,surgearrestors,cableclamps,
etc.
Wherespecialequipments
arerequiredfortheproper
installationofHVPowerAccessories,Nexansoffers
suchtools,aswellasthevar-
iousaccessoriestocomplete
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1
N ex a n s S w i t z er la n d
Nexans Switzerland
providesawiderange
ofservicestoitscustomers,
extendingfromengineering
tocablelayingandinstallation.
Workingtotheinstructions
ofexperiencedteamsof
engineers,highlyqualified
fittersinstallcablesystems
allovertheworld.Laying
andinstallationmaterials
whichareoptimizedinevery
respect,togetherwithmea-
suringandtestinginstrumentsforeveryneed,permitthe
implementationofallkinds
ofinstallationsunderthebest
possibletechnicalandcom-
mercialconditions.
Cablesdeliveredand
installedbyNexans
Switzerlandguarantee
areliableservicefor
manyyears.
Basedonitsextensiveexperi-
encewithlowandmedium
voltagecables,Nexans
Switzerlandoffersitsclients
anexpertpartnershipto
solveproblemsandimple-
mentpracticalsolutions.
A n e x p e r t a n d c om p r e h e n s i ve s e r v i c e
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Nexans Switzerland Ltd2, rue de la Fabrique CH 2016 Cortaillod
Phone. 41(0) 32 843 55 55 Fax 41(0) 32 843 54 43
http://www.nexans.ch
G l o b a l e x p e r t i n c a b l e s a n d c a b l i n g s y s t e m s
2006