Frankfurt (Germany), 6-9 June 2011 ROSSUM-NL-S1-0345 INTRODUCING HIGH-PERFORMANCE POLYPROPYLENE THERMOPLASTIC ELASTOMER (HPTE) INSULATION FOR MV CABLES

Frankfurt (Germany), 6-9 June 2011

ROSSUM-NL-S1-0345

INTRODUCING HIGH-PERFORMANCE POLYPROPYLENE THERMOPLASTIC ELASTOMER

(HPTE) INSULATION FOR MV CABLES IN THE NETHERLANDS


XLPE: is favorable insulation material for MV nowadays. has outstanding overall characteristics and performances

(electrical, thermo-mechanical and installation). has well-proven track record at all voltages.

ROSSUM-NL-S1-0345

Development alternative for XLPE

However, XLPE requires cross-linking which leads to by-products with carbon

footprint as a consequence. requires cross-linking thus leading to interrupted production

process. is non re-usable.


Prysmian objective: development thermoplastic insulation material with equivalent, or even better characteristics as XLPE.

Material found in HPTE: High-performance Polypropylene Thermoplastic Elastomer, also called P-Laser©

ROSSUM-NL-S1-0345


granulate Polypropylene chemical symbol


ROSSUM-NL-S1-0345


Production XLPE P-laser (HPTE)

Operating temperature 90oC 90oC (up to 110oC)

Emergency temperature 105oC 130oC

Dielectric strength Excellent

Electrical breakdown strength

Very good Excellent

Thermo-plastic resistance 105oC 130oC

Handeling characteristics Good

Qualification Prysmian HPTE insulation ‘P-laser’ after development test:


ROSSUM-NL-S1-0345

History Year Production Core facilities

2002/2003

HPTE insulated cables prototype production, evaluation of physical, chemical and electrical parameters.

Prysmian R&D laboratories, Milan, Italy

2004 Erection of HPTE production location at Pignataro, Italy.

Pignataro production


ROSSUM-NL-S1-0345

History (cont.) Year Production Core facilities

2005 12/20kV HPTE 1x185mm2,produced for ENEL, Italy.6/10kV HPTE core 1x240mm2, solidAl, produced for Alliander, Netherlands

30 km

9 km

Cores produced in Pignataro, core finishing elsewhere.

2006 12/20kV HPTE 3x1x185mm2, produced for ENEL, Italy.

10 km Cores produced in Pignataro, core finishing elsewhere.

Completion of Pignataro line with cable screening (overlapped Al tape), water blocking tape application and multi layer jacket extrusion


ROSSUM-NL-S1-0345

History (cont.)

Year Production Core facilities

2007 12/20kV HPTE 1x185mm2, produced for ENEL, Italy.

300 km

Cores produced in Pignataro, core finishing elsewhere

2008 12/20kV HPTE 1x185mm2, produced for ENEL, Italy.

150 km

Cores produced in Pignataro, core finishing in other plants.

2009 12/20kV HPTE, different conductor sizes, produced for ENEL and ACEA.

6/10kV HPTE core 1x240mm2, solidAl, produced for Alliander, Netherlands, second field test.

2400 km

9 km

Cores produced in Pignataro, core finishing elsewhere


ROSSUM-NL-S1-0345

History (cont.)Year Production Core facilities

2010 Industrialization of 12/20kV HPTE production with 70mm2, 95mm2 and 240mm2 conductor sizes.Industrialization of 18/30kV HPTE 1x240mm2 core production.

4000 km

Pignataro single step production line industrialized: 7 production steps in one single process.

Pignataro production


ROSSUM-NL-S1-0345

History (cont.)Year Production Core facilities

2011 More than 10.000 km of HPTE insulated core (10-30kV range) have been successfully produced in Pignataro factory, demonstrating the maturity of this insulation technology for MV cables.Based on this experience, HPTE insulated core production was implemented in the Prysmian Delft factory, the Netherlands.

2011 Pilot Production 18/30kV 1x800 SolidAl and 6/10kV 1x240 Solid Al

3 km5 km

Core production at modified existing horizontal insulation line for MV cables at Prysmian Delft Factory, the Netherlands.


ROSSUM-NL-S1-0345

Pignataro production line layout

conductorInsulation

+sc screens

Core coolingContinuity

device

Water blocking tapes

Metallic

screen

Protection

layersFinished cable

Single line process


ROSSUM-NL-S1-0345

Pignataro single line process

conductorFinished cable


ROSSUM-NL-S1-0345

Performed (type-)testsYear Test object Standard Production location

2005 HPTE insulated 12/20kV 1x150

HD620 S2, part 10, section J, appendix G: long duration test, 500Hz, 3000 h.

Core production: Pignataro

2006 HPTE insulated 12/20kV 3x1x185

IEC60502-2 + add. Core production: PignataroCable finishing: elsewhere

2006 HPTE insulated 6/10kV 1x240Solid Al




ROSSUM-NL-S1-0345

Performed (type-)tests

Year Test object Standard Production location

2007 HPTE insulated 6/10kV 3x240 SolidAl cable

HD620S1, part 6 section J, including accessories compatibility test

Core production: PignataroCable finishing: Delft

3-core joint ‘C’

HPTE insulated 3core cable

5 m 5 m

3-core termination ‘A’ 3-core termination ‘E’

XLPE insulated 3core cable

Test set-up compatibility test HPTE cable with XLPE cable


ROSSUM-NL-S1-0345

Year Test object Standard Production location

2010 HPTE insulated 6/10 kV 1x240Alrm



2011 HPTE insulated 18/30kV 1x800Alrm

HD620S1, part 6 section J, including accessories compatibility test. Test voltages based on Uo=20.5kV

Core production and cable finishing:

Prysmian Delft, the Netherlands

2011 HPTE insulated 6/10 kV 1x240Alrm


Performed (type-)tests


ROSSUM-NL-S1-0345

Eco-sustainable- 100% recyclable product- >25-50% reduction of carbon footprint (Delft plant)- >75% saving on water and energy during production (Delft plant)- zero-gas technology

Pallet, produced with recycled HPTE insulation


ROSSUM-NL-S1-0345

Summary and conclusionPrysmian HPTE insulated cable, also known as Prysmian is 100% recyclable, has reduced energy consumption and greenhouse gas emissions is fully compatible with existing XLPE insulated cables and

accessories can be used at higher operating temperatures compared to XLPE production time is reduced from days to hours has outstanding overall characteristics and performances (electrical,

thermo-mechanical and installation) has well-proven track record up to 30kV voltage class. is type tested in full accordance with present standards for XLPE


ROSSUM-NL-S1-0345

THANK YOU FOR YOUR ATTENTION

Documents

Frankfurt (Germany), 6-9 June 2011 ROSSUM-NL-S1-0345 INTRODUCING HIGH-PERFORMANCE POLYPROPYLENE THERMOPLASTIC ELASTOMER (HPTE) INSULATION FOR MV CABLES