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High and extra high voltage cableswith synthetic insulation
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
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S u m m a r y
•TheevolutionofHVandEHVcableswithsyntheticinsulation 5
•Anoutlinehistoryofdevelopments 6
•ProjectengineeringforHVcablelinks 7
•ExamplesoftherangeofHVandEHVcableswithsyntheticinsulation 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 v o l t a ge c a b l e s
Nexans Switzerland supplieshighandveryhighvoltagepowercablesandaccessories,opticalfibercables,opticalwave-guideandspecialcablesfortheinternationalmarket.
Nexans Switzerlandhasthreeproductioncentres:
•theBreitenbachsite
•theCortaillodsite
•theCossonaysite.
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I n t r o d u c t i o n
Nexans Switzerland isSwitzerland’sforemostcablemakerandsupplier.
Itmanufactures,distributes,fitsandinstallsacompre-hensiverangeofproductsforunderground,submarineandaerialinstallations:
•high,mediumandlowvoltagepowercables
•copperoropticalfibertelecommunicationscables
•specialcablesformanyapplications
•powerandtelecomaccessories
•connectionequipment.
Itsservicesrangefromthesupplyofcablestotheimplementationofcomplexturnkeyproducts,includingdevelopment,engineering,constructionwork,systemtechnology,laying,installa-tionandprojectfinancing.
P o s i t i o n o f Ne x a n s S w i t z e r l a n d
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T h e e v o l u t i o n o f H V a n d E H V cables w i t h synt het ic insulat ion
T h e C a b l e s
aluminiumsheath
compositesheath
Thegreaterdemandforenergyrequirestheimplementationofinstallationsdesignedtosupportincreas-inglyhighervoltageandpowerlevels.
ThisiswhyNexansSwitzerlandLtdhasdevel-opedcableswithsynthetic(ordry)insulationforvoltagesupto420 kVandcross-sectionsthatcanbelargerthan2000 mm2.
C o n d u c t o r s
Athighgradients,syntheticinsulationissensitivetothepresenceofmoisture.Itisthereforeessentialtoavoidanycontactwithwaterorsteamduringfabricationprocessesandalsoduringlineoperation.
Thecross-linkingoperationmustbecarriedoutintheabsenceofhumidity,eitheronacatenarylineinaninertatmosphere,oronahorizon-talline(MDCVprocess).
Forallcables,theexternalprotectionisprovidedbyapolyethylenesheath.Overthisinsulation,theapplica-tionofawaterproofmetallicsheath,whichalsoactsasascreen,isgenerallyrequired.
I n s u l a t i o n
Higherservicegradientsrequirebetterinsulationqualities.
Thesematerialsshouldbeperfectlyclean–thisisparticularlyimportant,astheirlong-termperfor-mancecanbeconsiderablyaffected,evenbymicro-impurities.Precautionstoensurecleanlinessshouldbetakenbothduringtheproductionofrawmaterialsandthroughouttheentirecablefabricationprocess.
S h e a t h s
Forconductorcross-sectionslargerthan1000 mm2,seg-mentedconductorsmustbeproducedtoreduceconsider-ablytheirresistancetoalter-natingcurrentbyreducingtheskineffect.
Thissheathcanbemadeofunweldedextrudedaluminumorlead,orofweldedorgluedcopperoraluminum.NexansSwitzerlandLtdusesallthesetechniqueswithcompletemastery.
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An out l ine his tor y of developments
D e v e l o p m e n t s f r o m 197 3 t o t h e p r e s e n t d ay
Sincetheintroductionofcross-linkablesyntheticinsulation,productionandcontroltechniqueshavegonethroughawholeseriesofdevelopmentsteps.
1973
1974
1976
1977
1978
1983
1986
1987
1989 – 1991
1996
1998
2006
Implementation of a cross-linking catenary line
Delivery of the first HV cables with dry insulation
Introduction of the triple- head extrusion process
Delivery of the first 150 kV extruded insulation cable
Modification of the catenary line for nitrogen cross-linking
Delivery of the first 220 kV cable with XLPE insulation
Construction and start-up of a laboratory for measuring partial discharges up to 480 kV
Production of the first XLPE Cable 220 kV with a cross-section of 2500 mm2
Production of the first 275 kV cable with XLPE insulation
Implementation of a 2nd cross-linking line for large conductor cross-sections and thick layers of insulation
Production of the first 400 kV cable with XLPE insulation
Delivery of the first 400 kV cable with XLPE insulation abroad
Delivery of the first 400 kV cable with XLPE insulation in Switzerland
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Pr oject engineer ing for HV cable l ink s
D e v e l o p m e n t p l a n
• territorialplanning
• increaseddemand
• connectionofheavyusers
• networkplan
• networkcalculation
• powerflowdetermination
• customer
Cause and nature of operations Effects Intervening parties
P r e - s t u d y p l a n
• decisiontoreinforcenetwork
• preliminaryfeasibilitystudy
• pilotstudy
• choiceofconnectiontype :underground,overheadormixed
• technicalsolutions
• customer
• Nexans
St u d y
• Impactstudy
• collaborationwithotherdepartments :engineeringoffices,industrialdepartments,etc.
• noticetomunicipalauthoritiesandlandowners
• choiceofconnectiontype :underground,overheadormixed
• drawingupofspecifications
• customer
• Nexans
P r o j e c t
• choiceofdefinitiverun
• definitionoflayingparameters
• measurementoflinelength
• preparationofcontractor’sfile
• 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 mp l e s o f t h e r a n ge o f H V a n d E H V c a b l e s w i t h s y n t h e t i c i n s u l a t i o n
45 kV EPR insulation
60 kV XLPE insulation
150 kV XLPE insulation
500 mm2
220 kV XLPE insulation
2000 mm2
400 kV XLPE insulation
800 mm2
HVExtrusionline
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Pr oduct ion tools
HVlaboratory
Aluminiumpress
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•extrudedcross-linkedpoly-ethylene(XLPE)insulationcableswhich,withtheprogressofthetechniquesusedinthemanufacturingofbasicmaterialsandaboveallforinstallation,haveachievedtherelia-bilitylevelrequiredforuseinextrahighvoltage(EHV)networks.
420 kV cable technology
For420 kVcables,therearecurrentlytwoalternativestotraditionalfluidoilimpreg-natedpaperinsulation :
•cableswithPPLPinsulation,consistingofthree-layerlaminatedpaperandpolypropylenetapes,formedintoribbonsandimpregnatedwithoil.
E H V c a b l e s w i t h P P L P a n d X L P E i n s u l a t i o n
PPLPinsulation,whichwasintroducedattheendofthe�0’s,isstilllimitedtocablestobeusedatavoltageof400 kVorhigher.Thisisdueontheonehandtoitsprice,whichishigherthanthepriceofpaper,andontheothertotheincreasinglygeneral-izeduseofXLPEinsulationforvoltagesupto220 kVand400 kV.
XLPE Insulation
Cross-linkedpolyethylene(XLPE)wasintroducedinthe�0’s.Itwasinitiallyusedformediumvoltagecables,butisnowusedasinsulationforextrahighvoltagecables(EHV).Itsuseatvoltagelevelsof400 kVandhigherrequires,ofcourse,sophisticat-edstate-of-the-arttechnology.Inparticular,weshouldmention :
PPLP Insulation
Forextrahighvoltage(400 kVandhigher),newtypesoftapesmadeofPPLP(PolyPropyleneLaminatedPaper)areused.Theyhavetheadvantageofcombin-ingthetraditionalapplica-tiontechnologyusedforimpregnatedpapercableswiththeexcellentelectricalanddielectricpropertiesofsyntheticinsulators.PPLPisathree-layerinsulationconsist-ingofapolypropylene(PP)sheetlaminatedbetweentwosheetsofpaper.PPimprovesthequalityoftheinsulation,whilethesheetsofpaperensurethecirculationofoilbetweenthelayers.Comparedwithpaperinsula-tion,PPLPhasahigherbreak-downstrengthandabovealllowerdielectriclosses.
P P L P a n d X L P E i n s u l a t i o n
•therigorousselectionofinsulatingandsemi-con-ductingmaterials,whichmustbeofaveryhighpuritylevel,
•thecheckingoffilteringduringapplication,
•three-layerextrusion(inter-nalsemi-conductor,insula-tionandexternalsemi-con-ductor)usingasingletool,
•theobtentionofperfectlysmoothinsulationsemi-con-ductorinterfaces,
•protectionoftheinsulationagainstthepenetrationofmoisture,
•stringentelectricalteststodetectanyfaults.
Forconnectionprojectsat420 kV,exhaustivetestshavebeensuccessfullycarriedoutforbothXLPEandPPLPcables.Themainfeaturesofthesetwotypesofcablesarecomparedbelow.
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Forallthesetasks,reli-ableandfastmeasurementequipmentisrequired.Considerableinvestmentshavebeenmadetoequipourmaterialstestlaborato-rieswiththemostmodernequipment,suchasthermalanalysisinstruments,tensilestrengthapparatus,optical
Check s and tes ts
Thematerialsusedinthecon-structionofEHVcablesaresubjectedtoverystringentqualitycontrolchecks,bothbeforeandafterproduction.Plastics,metalsandtapesallundergoelectricalresistancetestsandmeasurementsoftheirdielectricormechanicalproperties.
F r o m c h e c k s o n m a t e r i a l s . . .
After-laying tests
tocheckthequalityofassemblyofaccessoriesafterinstallationandtosimulatecableoperationandrapidlyprovideinformationoncableefficiencyafterprolongedperiodsofuse.
Accelerated ageing tests
tosimulateworkinglifeandtoprovideinformationwithinashorttimeframeontheirbehaviorinlong-termuse.
Diagnostic tests
tohighlightanydegradationphenomenainthelineinser-viceandtoprovideinforma-tionontheresidualcablelife.
Thequalityofhighvoltagecablelinksishighlydepen-dentontherigorousnatureofthetestscarriedoutonthecablesandtheiraccessories.Themorestringentthesetestsare,theloweristheriskoffailureduringoperation.
Theprincipaltestsareasfollows :
Routine tests
toevaluateproductionquality.
Type tests
tovalidateatypeofconstruction,foreithercablesoraccessories.
Special tests
undertakeninthecaseofmajordesignchanges.
. . . t o e l e c t r i c a l t e s t s
microscopes,infra-redspec-trometer,chromatograph,amongothers.
Theseexactingchecksenableustoreducetoaminimumthepresenceofundesirablematterandtoguaranteethequalityofourcables.
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Refer ences
P r e s t i g i o u s p r o j e c t s
1990 • Thefirst420 kVcablewasinstalledinSwitzerlandwithXLPEinsulationconnectedtothenetworkatthe"Bassecourt"substationoftheBerneseElectricityCompany.
ThissubstationwasconnectedtoLaufenburgandFranceby��0 kVoverheadlines.Thecopperconductorcross-sectionwas1200 mm2.
1996 • Variousinstallationsofdesalinationplantsweresetupalongthecoastofcer-tainArabcountries.Themostimportantoneamongstthemissuppliedwithcablesandacces-soriesfromNexansSwitzer-landLtd,formerlyCortaillodCossonayCable.Wesupplied�sectionsof400 kVcable,withXLPEinsulationandacor-rugatedaluminiumsheath.
1997 • NexansSwitzerlandLtd,wasawardedanimpor-tantcontractbyPowerGrid,awhollyownedsubsidiaryofSingaporePower,tosupplyandinstall2�0 kVXLPEpowercables,2'000 mm2withacor-rugatedaluminiumsheathandaccessories.Thiscontractwasthefirstofitskindtobeaward-edbyPowerGridinSingapore.Theprojectconsistedoftwocablerouteswithatotalcablelengthofabout�� km.
1998 • Cleuson—Dixenceproject,Switzerland.
Withawaterfallof1��� m,Peltonturbineof42� MW,alternatorof��.�MVA/pole,thisPowerStationsets�worldrecords.
just�.�monthsbetweentheorderdateandcommissioning.
2000 • NexansSwitzerlandlaidtwosublakelinksforSocietàElettricaSopracenerinainLagoMaggiore.Foreachlinkwithalengthof2200 m,threecablesoftheXDAluWETtype,1x�00 mm2,�0kVwereruninPEtubespreviouslyinstalledonthelakebed.
2000 • Nexanscompleteda2�0kV(�,�00 mofXAluWT,1x4000 mm2)cableinstallationanda1�2 kVinstallation(24 kmofXDFcuCuT,1x��0 mm2)fortwocustom-ersinSpain.
2004 • WhentheextensionoftheChicoasenpowerstationnearTuxtlainMexicowasdecidedtoaddafurther�generators(eachof�10MW)tothe�generatorsalreadyinserviceandbringthetotalcapacityto24�0MW(practicallyonethirdofthetotalproductioninSwitzerland),Nexansdeveloped,manufac-tured,installedandtestedthe�x400 kVcablelinks-400 kVtypePoAluWET1x400 mm2Cu-fromthetransformertothestartingpointoftheoverheadlines.Withthisproject,Nexansonceagainconfirmsitshighlevelsofexpertiseinprojectandinstallationengineering.
2004 • WhenTranselectrica(thenationalRomanianelectric-itytransmissioncompany)issuedaninternationalinvitationfortherestorationofa220 kVcircuitanda400 kVcircuit
connectedtothesametrans-formerandbuildingupacrucialpartoftheoperatingsystemofthe"PortiledeFier"(doorsofsteel)powerstation,Nexanswonthecontract.Incollaborationwithalocalcompanyandwithinanambi-tiouscompletiondate,Nexansremovedtheexistingoil-filledcablesandreplacedthemwithsyntheticallyinsulatedcableswithahigherpowerrating–400 kVtypeXDCuTAluWET,1x��0 mm2Cuand220 kVtypeXKDAlT-Tsc,1x1000 mm2Cu.
2006 • NexansSuissebegantoexpandintoChinain1���,inpartnershipwithanintegrator,withintheframeworkoftheDaYuanDuhydro-elec-tricpowerstationprojectinHunanprovince,forwhichasystemof110kVXLPEcableswassuppliedandinstalled.Furtherprojectsfollowed,inwhichNexansSuissehadthesameresponsibilitiesforthesupplyofcompletecablingsystemsandfortheon-sitesupervisionoftheinstallations:thefirst220kVXLPEcablesfortheZhengJiangpowerstationweresuppliedinearly200�;andsince200�,almost�0 kmofcables,inparticular220 kVcableswithacoppercrosssectionof2�00 mm2,forthesupplyofsub-stationsinPekinginanticipationofthe200�OlympicGames.Overaperiodof10years,nofewerthan21circuitsintotalhavebeeninstalledthroughoutthecountry.
NexansSwitzerlandLtd,manufacturedandinstalled�x400 m,400 kVXLPEcables,�00 mm2withacor-rugatedaluminiumsheathandaccessoriesforconnectingthethreetransformerslocatedintherock-cavetotheswitchingsta-tion,acrosstheRhoneriver.
1999 • ThroughNexansFrance,NexansSwitzerlandhaswonacontractforthesup-plyof�0 kmofXKDAlTcable,1x2000 mm2,1�1kVforTaiwanPower,inTaiwan.
2000 • Nexanssuppliedandinstalled�XAluWTcablecircuits,1x400 mm2and1x��0 mm2,2�0kVand�120 kVcablecircuitsonanindustrialsiteinDearbornintheUnitedStates.
2000 • Followingamechani-calaccident,thegaspressurecablesofthe1�0 kVForetaille–Chênesublakelinkingsec-tionoperatedbyServicesIndustrielsdeGenève,weredamagedinNovember1���.NexansSwitzerlandreplacedthesublakelinkwithalengthof�200 mbycablesoftheXDAluTtypeinarecordtimeof�monthsbetweentheorderandcommissioning.
2000 • Followingafireintheaccesstunneltothe"ElCajon"powerplantinHonduras,twooil-filled220 kVcablesweredamaged.Nexansreplaced2circuitswithalengthofaround1000 mbyXAluWTcables1x�00 mm2,220 kV.Thisprojectwascompletedin
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A ccessor ies
O u t d o o r s e a l i n g e n d s w i t h p o r c e l a i n i n s u l a t o r
Theconceptofthesealingendwithporcelaininsulatorhasalong-termexperiencewithpaperinsulatedcablesofmorethan�0years.Thesealingendincludesapre-moldedslip-onstresscone.
C o mp o s i t e i n s u l a t o r s f o r v a r i o u s a p p l i c a t i o n s
Thousandsofcompos-iteinsulatorshavebeeninstalledsince1��0byourcompanies,someofthemareinserviceunderverysevereconditions,atthefullsatisfactionoftheirusers.
Asanalternative,customersworldwideaskmoreandmoreforsyntheticinsulators.
Suchinsulatorsarecomposedofafibreglassreinforcedepoxytubewithtwoalumi-niumflangesandinsulatedbysiliconesheds.
Specialadvantagesarelowweight,excellentseismic,mechanicalandpollutionperformancesaswellasnoexplosionrisk.
D r y t y p e o u t d o o r s e a l i n g e n d s
to14�kV,offersmanyadditionaladvantageslike:
•noriskofleakage;noenvironmentaleffect
•easyhandling
•quickinstallation
Since20years,Nexansoffersslip-ondrytypeoutdoorsealingends,whichdon’tneedanyoilorgasfilling.Amonoblocversionavailableforvoltagesup
O u t d o o r s e a l i n g e n d s w i t h c o mp o s i t e i n s u l a t o r
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G I S s e a l i n g e n d s / Tr a n s f o r m e r s e a l i n g e n d s
TheGISsealingendsaredesignedinaccordancewithIEC�0���standard,eitheraccordingtoitem�.1forfluidfilledterminationsoritem�.2,TypeAfordrytypeterminations.
FortheconnectionofHVcablestotransformerorgasinsulatedswitch-gears,Nexansmanu-facturingprogrammeincludesadequateterminations.
J o i n t s
coppertubeandarobustPEcovering.Shieldbrake facilitiesareintegrated,factorymadeandfactory tested.
MOP :MediumOuterProtectionconsistingofasynthetic,rigidcover.
LOP :LightOuterProtectionmadeofheatshrink components.
Nexansprefabricatedhighvoltagejoints(�2-��0 kV)arebasicallycomposedofapremoldedelastomerjointbody,andanoutercasing.
Forthe�2 kVLevel,acablejointwithpremolded,factoryexpandedjointbodyisavailable.
Outerprotectionsforjointsareavailableindifferentversions :
HOP :HeavyOuterProtectioncasingconsistingofastrong
Tr a n s i t i o n j o i n t s
NexanshasdevelopedaconceptwhichguaranteesahighreliableandcompactconnectionforHVcablesofdifferenttechnologies.
WhenpaperinsulatedHVcableshavetobeconnectedtosyntheticinsulatedcables,asocalledtransitionjointisneeded.
Va r i o u s a c c e s s o r i e s a n d t o o l s
acableinstallation,suchascablescreendiscon-nectingsystems,surgearrestors,cableclamps,etc.
WherespecialequipmentsarerequiredfortheproperinstallationofHVPowerAccessories,Nexansofferssuchtools,aswellasthevar-iousaccessoriestocomplete
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Ne x a n s S w i t z e r l a n d
Nexans Switzerlandprovidesawiderangeofservicestoitscustomers,extendingfromengineeringtocablelayingandinstallation.
Workingtotheinstructionsofexperiencedteamsofengineers,highlyqualifiedfittersinstallcablesystemsallovertheworld.Layingandinstallationmaterialswhichareoptimizedineveryrespect,togetherwithmea-suringandtestinginstrumentsforeveryneed,permittheimplementationofallkindsofinstallationsunderthebestpossibletechnicalandcom-mercialconditions.
CablesdeliveredandinstalledbyNexans Switzerlandguaranteeareliableserviceformanyyears.
Basedonitsextensiveexperi-encewithlowandmediumvoltagecables,Nexans Switzerlandoffersitsclientsanexpertpartnershiptosolveproblemsandimple-mentpracticalsolutions.
A n e x p e r t a n d c o mp r e h e n s i v e s e r v i c e
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