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
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