INSULATED POWER CABLES XLPE

1. CABLE DESIGN, MANUFACTURING AND TESTING OF XLPE CABLES

(1) DESIGN AND MANUFACTURING 4

(2) REQUIREMENTS FOR CABLE TYPES(IEC 60502-1,2) 6

(3) QUALITY CONTROL FLOW CHART 10

2. RESEARCH AND DEVELOPMENT FACILITIES

(1) HIGH VOLTAGE LABORATORY 11

(2) INVESTIGATION AND INSPECTION EQUIPMENT 12

3. CONSTRUCTION DATA OF CABLES 13

4. TECHNICAL DATA

(1) PHYSICAL CHARACTERISTICS OF INSULATING MATERIALS 40

(2) ELECTRICAL CHARACTERISTICS OF INSULATING MATERIALS 41

(3) HEAT CHARACTERISTICS OF INSULATING MATERIALS 44

(4) CURRENT CARRYING CAPACITY 46

(5) SHORT CIRCUIT CURRENT RATING 58

(6) HANDLING AND INSTALLATION OF XLPE CABLES 59

CONTENTS

INSULATION

SCREEN

CONDUCTOR

SHEATH

CU TAPE

METAL WIRE

(TRIPLE HEAD EXTRUSION)

DRAWING

ROUTINE TEST PACKING

CDCC PROCESS STRANDING

EXTRUSION

1. CABLE DESIGN, MANUFACTURINGAND TESTING OF XLPE CABLES(1) DESIGN AND MANUFACTURING

Carrying current Withstanding pulling force

Preventing concentration of electricfield at any point on the conductor Ensuring close contact

Withstanding during the cable servicelife voltage ; different stress and the following - rating voltage- lightning voltage- switching voltage

Ensuring close contact with the insulation Preventing concentration of theinsulation electric field at any point

To provide;electrical screeningan active conductor for the capacitiveand homopolar short circuita contribution for mechanical protection

Protecting the metallic screen fromthe surrounding medium in order to protect it against corrosion

CONDUCTOR

CONDUCTOR SCREEN

INSULATION

INSULATION SCREEN

METALLIC SCREEN

OUTER SHEATH

ANNEALED COPPER or ALUMINIUM

SEMI-CONDUCTINGCOMPOUND

XLPE

SEMI-CONDUCTINGCOMPOUND

COPPER TAPE COPPER WIRE

ALUMINIUM WIRE

PVC or PE

CONSTRUCTION ROLE MATERIALS

VOLTAGE TEST

ELECTRICAL RESISTANCE

PARTIAL DISCHARGE TEST

PARTIAL DISCHARGE TEST AFTER BENDING TEST

Tan MEASUREMENT (at 90 C)

PARTIAL DISCHARGE TEST AFTER HEATING CYCLE TEST

IMPULSE TEST

VOLTAGE TEST AFTER IMPULSE TEST

VOLTAGE TEST FOR 4hr

RESISTIVITY OF SEMI-CONDUCTINGSCREENS (at 90 C)

TEST ITEM TEST CONDITION REQUIREMENT UNIT

ELECTRICAL TEST

2.5U +2/5min

3.5U /5min

IEC 60502-2 16. 3

IEC 60502-2 18.1.3

10pC

5pC

at 20 C IEC 60228

No Breakdown

IEC 60502-2 18.1.4 5pC

IEC 60502-2 18.1.5 0.8%

IEC 60502-2 18.1.6 5pC

IEC 60502-1 17.4 &

IEC 60502-2 18.1.7,18.2.4

Withstand

Without Failure

IEC 60502-2 18.1.7 No Breakdown

4U /4hr No Breakdown

IEC 60502-2 18.1.9

Conductor screen

Insulation screen

1000 -m

500 -m

KV

-

KV

KV

KV

KV

KV

KV

KV

-

1.73U

(2) REQUIREMENTS FOR CABLE TYPES (IEC 60502-1,2)

RATED VOLTAGE OF EACH CABLE [Uo/U(Um)]

0.6/1 KV

1.8/3(3.6) KV

3.6/6(7.2) KV

6/10(12) KV

8.7/15(17.5) KV

12/20(24)KV

18/30(36) KV

26/35 KV REMARK

* Sample test is applicable only to cables of rated voltages 6/10(12) KV and above R.T. : Routine Test S.T. : Sample Test T.T. : Type Test

3.5

-

Compliance with the requirement for conductor construction of IEC 60502-1,2

-

-

-

-

-

This test is applicable only to cables having conductor screen andinsulation screen

-

2.4

6.5

-

-

-

-

40

-

-

7.2

-

12.5

6

6

6

60

12.5

-

14.4

-

21

10

10

10

75

21

2

24

-

30.5

15

15

15

95

30.5

2

35

-

42

20

20

20

125

42

2

48

-

63

31

31

31

170

63

2

72

-

91

45

45

45

250

91

2

104

R. T.

R. T.

R. T.

T. T.

T. T.

T. T.

T. T.

T. T.

T. T.

T. T.

S. T. , T. T.

XLPE INSULATION

PVC SHEATH

MEASUREMENT OF THICKNESS OF SHEATH

MECHANICAL PROPERTIES - TENSILE STRENGTH (min.) - ELONGATION (min.)

LOSS OF MASS (max.)

PRESSURE TEST AT HIGH TEMPERATURE

BEHAVIOUR AT LOW TEMPERATURE

HEAT SHOCK TEST

MEASUREMENT OF THICKNESS OF INSULATION

MECHANICAL PROPERTIES - TENSILE STRENGTH (min.) - ELONGATION (min.)

HOT-SET TEST

WATER ABSORPTION TEST

SHRINKAGE TEST

TEST ITEM TEST CONDITION REQUIREMENT

IEC 60502-1 18.1 &IEC 60502-2 19.1

IEC 60502-1 18.11 & IEC 60502-2 19.11

IEC 60502-1 18.13 & IEC 60502-2 19.13

IEC 60502-1 18.6 &IEC 60502-2 19.16

IEC 60502-1 18.2 & IEC 60502-2 19.2

IEC 60502-1 18.7 & IEC 60502-2 19.7

IEC 60502-1 18.6 & IEC 60502-2 19.6

IEC 60502-1 18.9 & IEC 60502-2 19.9

IEC 60502-1 18.4 & IEC 6050-2 19.4

IEC 60502-1 18.8 &IEC 60502-2 19.8

IEC 60502-1 18.3 &IEC 60502-2 19.3

Before Aging

After Aging

Before Aging

After Aging

Elongation

Impact

tm tn-(0.1+0.1tn) tm:minimum thickness tn:nominal thickness

175% ,15%

1 /

4%

IEC 60502-1 18.2.3 & IEC 60502-2 17.5.3

50% of thickness value

1.5 /

No Crack

1.275 / ,200%

Variation, 25%

1.275 / ,150%

Variation, 25%

20%

No Crack

The measurements shall be made as described in Clause 6 of IEC 60502-1, 2

T. T.

The test procedures shall be carried out in accordance with Clause 9 of IEC 60811-2-1 S.T., T. T.

The test procedures shall be carried out in accordance with Clause 9.2 of IEC 60811-1-3 T. T.

The test procedures shal l be carried out in accordance with Clause 10 of IEC 60811-1-3 T. T.

The measurements shall be made as described in Clause 13 of IEC 60502-1 and 14 of IEC 60502-2

T. T.

The test result for unaged and aged test pieces shall comply with therequirments given in Table 16 of IEC 60502-1 and 18 of IEC 60502-2

T. T.

The test procedures shall be in accordance with Clause 8.2 of IEC 60811-3-2 T. T.

The test procedures shall be in accordance with Clause 8 of IEC 60811-3-1 T. T.

T. T.The test procedures shall be in accordance with Clause 8 of IEC 60811-1-4

The test procedures shall be in accordance with Clause 9 of IEC 60811-3-1 T. T.

T. T.The test result for unaged and aged test pieces shall comply with the requirments given in Table 15 of IEC 60502-1 and 17 of IEC 60502-2

RATED VOLTAGE OF EACH CABLE [Uo/U(Um)]

R.T. : Routine Test S.T. : Sample Test T.T. : Type Test

0.6/1 KV

1.8/3(3.6) KV

3.6/6(7.2) KV

6/10(12) KV

8.7/15(17.5) KV

12/20(24)KV

18/30(36) KV

26/35 KV REMARK

MATERIALS FLOW

V.D.T.L.M.E.[CHECK POINT]V:VISUALD:DIMENSIONT:TENSIONL:LENGTHM:MARKINGP:PRESSURER:D.C.RESISTANCEE:TEMPERATURE

COPPER or

ALUMINIUM

DRAWINGand

STRANDING

XLPE

SEMI-CONDUCTINGCOMPOUND

TRIPLE COMMONEXTRUSION and

DRY-CURING

COPPER TAPECOPPER WIRE

ALUMINIUM WIRESCREENING

PVC or PE SHEATHING

TESTING

V.D.T.L.

D.P.E.T.L.

V.D.R.T.L.

(3) QUALITY CONTROL FLOW CHART

2. RESEARCH AND DEVELOPMENTFACILITIES(1)HIGH VOLTAGE LABORATORY

MELT INDEXER

PILOT EXT.

FT-IR

DSC

(2) INVESTIGATION AND INSPECTION EQUIPMENT

3. CONSTRUCTION DATA OF CABLES

1027

6/10(12)kVXLPE Insulated WireArmoured Cable (XLPE / WA / PVC)

ConductorNominal

Areamm2

InsulationThickness

mm

SeparationSheath

Thicknessmm

ArmourWireSizemm

OuterSheath

Thicknessmm

Approx.Overall

Diametermm

StandardLength

Per Drumm

Single Core

3.43.43.43.43.43.43.43.43.43.43.43.43.43.4

16

25

35

50

70

95

120

150

185

240

300

400

500

630

1.21.21.21.21.21.21.21.21.21.21.21.31.31.4

1.61.61.61.61.61.62.02.02.02.02.02.52.52.5

1.81.81.81.81.92.02.02.12.12.22.32.42.52.6

2425262830313435373942475055

770910

1,0401,1901,4801,7802,1502,4802,8903,5904,2305,3206,5008,060

670750820900

1,0401,1901,4101,5601,7302,0502,3302,8903,3803,990

500500500500500500500500500500500500500400

Approx.Cable Weight

kg / km

Copper Aluminium

ConductorNominal

Areamm2

InsulationThickness

mm

SeparationSheath

Thicknessmm

ArmourWireSizemm

OuterSheath

Thicknessmm

Approx.Overall

Diametermm

StandardLength

Per Drumm

Three Core

3.43.43.43.43.43.43.43.43.43.43.43.4

16

25

35

50

70

95

120

150

185

240

300

400

1.21.31.31.41.41.51.61.61.71.81.92.0

2.02.52.52.52.52.52.52.53.153.153.153.15

2.32.52.52.62.82.93.03.13.23.43.63.8

424650525660636772808492

3,0003,9004,4605,0806,0507,1808,2309,38011,61014,21016,42020,260

2,7003,4303,7704,1904,7505,3805,9606,5808,1109,51010,63012,880

500500500500500500400300300250200200

Approx.Cable Weight

kg / km

Copper Aluminium

10

12/20(24)kVXLPE Insulated WireArmoured Cable (XLPE / WA / PVC)

ConductorNominal

Areamm2

InsulationThickness

mm

SeparationSheath

Thicknessmm

ArmourWireSizemm

OuterSheath

Thicknessmm

Approx.Overall

Diametermm

StandardLength

Per Drumm

Single Core

5.55.55.55.55.55.55.55.55.55.55.55.5

35

50

70

95

120

150

185

240

300

400

500

630

1.21.21.21.21.21.21.21.21.31.31.41.5

1.62.02.02.02.02.02.02.02.52.52.52.5

1.92.02.12.12.22.22.32.42.52.62.72.8

303335373840424548525560

1,3501,5501,8402,1602,4702,8103,2404,1504,8005,7806,9708,600

1,0701,2501,4201,5701,7301,8902,0902,5802,8903,3503,8504,500

500500500500500500500500500500500400

Approx.Cable Weight

kg / km

Copper Aluminium

ConductorNominal

Areamm2

InsulationThickness

mm

SeparationSheath

Thicknessmm

ArmourWireSizemm

OuterSheath

Thicknessmm

Approx.Overall

Diametermm

StandardLength

Per Drumm

Three Core

5.55.55.55.55.55.55.55.55.55.5

35

50

70

95

120

150

185

240

300

400

1.51.61.61.71.81.81.92.02.12.2

2.52.52.52.53.153.153.153.153.153.15

2.93.03.13.23.43.53.63.83.94.2

606266727580839095103

5,7006,3707,3709,40010,53011,80013,35016,43018,87023,260

5,0105,4806,0707,6008,2708,9409,85011,82013,08015,930

500500400300300300250200200200

Approx.Cable Weight

kg / km

Copper Aluminium

1038

26/35kVXLPE Insulated WireArmoured Cable (XLPE / WA / PVC)

ConductorNominal

Areamm2

InsulationThickness

mm

SeparationSheath

Thicknessmm

ArmourWireSizemm

OuterSheath

Thicknessmm

Approx.Overall

Diametermm

StandardLength

Per Drumm

Three Core

10.510.510.510.510.510.510.510.510.510.5

35

50

70

95

120

150

185

240

300

400

1.92.02.12.12.22.32.32.42.52.6

3.153.153.153.153.153.153.153.153.153.15

3.73.83.94.14.24.34.44.64.75.0

86899396100105106111117124

11,70012,68013,85015,40016,70018,20020,06022,90027,00028,900

11,07511,83512,62513,70014,57515,54716,73018,52021,46521,835

400400400300300300200200200200

Approx.Cable Weight

kg / km

Copper Aluminium

26/35kVXLPE Insulated TapeArmoured Cable (XLPE / DTA / PVC)

ConductorNominal

Areamm2

InsulationThickness

mm

SeparationSheath

Thicknessmm

ArmourTape

Thicknessmm

OuterSheath

Thicknessmm

Approx.Overall

Diametermm

StandardLength

Per Drumm

Three Core

10.510.510.510.510.510.510.510.510.510.5

35

50

70

95

120

150

185

240

300

400

1.92.02.12.12.22.32.32.42.52.6

0.80.80.80.80.80.80.80.80.80.8

3.63.73.83.94.14.24.34.54.64.9

8386909397101103108113121

8,9509,67010,82012,30013,52014,90016,62019,25023,17024,820

8,3258,8249,59510,59511,39412,24813,29014,87017,63217,754

400400400400300300300200200200

Approx.Cable Weight

kg / km

Copper Aluminium