HV XLPE CABLES

STATE OF THE ART DESIGN / MANUFACTURE ISSUES

Nigel Hampton, Application Manager - Power Cables Borealis AB, Sweden.

Content
n State of the art Stress / thickness Service performance Downsizing n Design Temperature Strength Length Ageing n Manufacture Degassing Scorch

ICC Fall 2003 Education Session

Content n State Of The Art Stress / Thickness Service Performance Downsizing

n Design Temperature Strength Length Ageing n Manufacture
Moisture Degassing Scorch Purity
ICC Fall 2003 Education Session

Thicknesses of Insulation for HV Cables

A verag e w all th ickn ess (m m ) 25 20 15 10 5 0 25 50 75 100 125 150 175 Cable Voltage (kV)
ICC Fall 2003 Education Session

Electrical Stresses
8 6 4 2 0 0 2 4 6 8 10 12 14 16 Conductor stress (kV/mm)
Mean & 90% Conf Limits
ICC Fall 2003 Education Session

Core Stress (kV/m m )

EHV HV MV

Selected HV Experience
2000
CONDUCTOR SIZE (SQMM)

1500 1000 500 0 25 50 75 100

VOLTAGE (kV)

125

150

175

Size Of Bubble Represents Length Of Installed Cores

ICC Fall 2003 Education Session

Thicknesses of Transmission Cables

25 20 15 10 5

Thickness (m m )

66
0 1965 1970

110
1975 1980

132
1985

138
1990

154
1995 2000 2005

ICC Fall 2003 Education Session

Use of EHV Technology to Down Size

1,1
MATERIAL COST

R e la tiv e V a lu e

EHV TECHNOLOGY 9 / 6 kV/mm

WEIGHT

0,9

0,8

HV TECHNOLOGY 6 / 3 kV/mm

0,7 10 12 14 16 18 20 22

Wall Thickness (mm)

1000SQMM, Pb SHEATH
ICC Fall 2003 Education Session

High Stress Gives Smaller Cables

>15% reduction in weight 5 - 10% reduction in material cost

ICC Fall 2003 Education Session

Size Affects Electrical Requirement

8 7 6 5 4 3 2 1 0 12 14 16 Wall thickness 18 20 22 Requirement Volume Average stress

Reference case - 2000mm2 150kV

ICC Fall 2003 Education Session

Content
n State of the Art Stress / Thickness Service Performance Downsizing

n Design Temperature Strength Length Ageing

n Manufacture
Moisture Degassing Scorch Purity

ICC Fall 2003 Education Session

Breakdown Stress - Design Stress

ICC Fall 2003 Education Session

Breakdown Stress - Design Stress

the winner of the 100m should complete the marathon in 1 hour 10 mins

ICC Fall 2003 Education Session

Designing Cables

n Design Life n Size n Temperature n Safety

E breakdown E design = Fage Fsize Ftemp Fsafety

ICC Fall 2003 Education Session

What Is The Outcome?

E breakdown @ temp E design = Fage Fsize Fsafety

ICC Fall 2003 Education Session

What Is The Outcome?

40

E breakdown @ temp E design = Fage Fsize Fsafety

2,2 - 3,8 2,2 1,1

ICC Fall 2003 Education Session

What Is The Outcome?

40

E breakdown @ temp E design = Fage Fsize Fsafety

2,2 - 3,8 2,2 1,1

Edesign =

40 3 * 2.2 *1.1

= 5.5kV / mm Thickness = 150 / 3

5.5

= 16mm

ICC Fall 2003 Education Session

Endurance Tests
0,9 Probability of failure 50kV/mm 33kV/mm 0,6

0,3

model transmission cables

0 0,1 1 10 100 1000 10000 100000

Time to failure (hours)

ICC Fall 2003 Education Session

115kV cables taken from service after 20 Years

UN USED USED Slices Of Insulation Taken From Cables

ICC Fall 2003 Education Session

Endurance Curve - Transmission Cables

M ean electrical stress (kV/m m ) 40 35 30 25 20 15 10 5
1,E+00 1,E+01

FAIL ON TEST NO FAIL ON TEST NO FAIL IN SERVICE

TYPE TESTS

LONG TERM TESTS

1,E+02 1,E+03 1,E+04 1,E+05 1,E+06

Time (Hours)
ICC Fall 2003 Education Session

Size

25mm 5mm

ICC Fall 2003 Education Session

Size

70 Electric Strength (kV/mm) 60 50 40 30 20 10 0 10 100 Length (m)

ICC Fall 2003 Education Session

25mm

5mm

1000

10000

Content
n State Of The Art Stress / Thickness Service Performance Downsizing n Design Temperature Strength Length Ageing

n Manufacture Moisture Degassing Scorch Purity

ICC Fall 2003 Education Session

Water / Moisture Remains A Concern

n Moisture Has A Dramatic Effect On Ageing
M ean E lectrical S tress (kV /m m )

60 50 40 30 20 10
1,E -02

n Water Barrier Has To Be Effective And Protected n Oversheaths & Jackets Are Important Parts Of The Cable Design

VIRGIN RAMP BREAKDOWN RAMP BREAKDOWN AFTER DRY AGEING RAMP BREAKDOWN AFTER WET AGEING
1,E -01 1,E + 00 1,E + 01 1,E + 02 1,E + 03 1,E + 04 1,E + 05 1,E + 06

TIME (HOURS)

ICC Fall 2003 Education Session

Dielectric Loss Measurements - HV Cable Models

Tangent D elta (10E -4)
30 DEGAS 130C AS MADE 130C 20 DEGAS 22C AS MADE 22C

10

0 0 20 40 60 80 100

Measuring Voltage (kV)

Industry Standard HV Insulation
ICC Fall 2003 Education Session

110kV Foil Laminate Sheathed Cable

6

Overpressure at 90C
4

Overpressure inin bar Ueberdruck bar

Overpressure at 23C

0 0 20 40 60 80 100 120 140 160 180 200 Aus g as ung s ko nz e ntratio n de s in Me than in de r Is ppm o lie rung in ppm methane concentration insulation in
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Time taken for Degassing

30 25 20 15 10 5 0 5 10 15 Wall thickness (mm)
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D egassing tim e (days)

20

25

Degassing Data - TGA Method HD632

2,5

Weight Loss (%)

1,5

0,5

as made

max permitted

long degassing

GOAL FOR TOMORROW

ICC Fall 2003 Education Session

Cable Inspection, Hot Oil Test

Lump found in inner semiconductive layer Width: 0.5 mm Height: 0.05-0.1 mm

ICC Fall 2003 Education Session

The Carrot Scorch Test

Scorch [vol-%] 80
- Effect of Temperature Level and Sensitivity Effected -

60

Die
40 T=8C 20

SC=45%

Typical Carrot
0 125 130 135 Temperature [C]
ICC Fall 2003 Education Session

140

Optimal Parameters For High Productivity

Time to critical scorch evolution [mins] Increasing Run Length

Tomorrow

Today

By product concentration [WT%] Decreasing Degassing Requirement

ICC Fall 2003 Education Session

CLEANLINESS - TAPE TEST

SIZE RANGE (MICRONS) HV TECHNOLOGY MV TECHNOLOGY

NUMBER AND SIZE IS NOT EVERYTHING! HOW DO WE ALLOW FOR DIFFERENT: MATERIALS SHAPES

50 70 70 100 100 200

10 0

3
STRESS ENHANCEMENT FACTOR 8 6 4 2 0 1

WE NEED A SMARTER SET OF CRITERIA!!

R/a=1 R/a=0,1 10 PERMITTIVITY

ICC Fall 2003 Education Session

100

Electrical Stresses
8 6 4 2 0 0 5 10 15 20 25 30 35 Conductor stress (kV/mm)
ICC Fall 2003 Education Session

Core Stress (kV/m m )

Conclusions
n XLPE HV Cables have come a long way and have some exciting challenges ahead n Much of the technology is well established and known n Challenges for the future
use of proven EHV technology to downsize long lengths increased need

ATTENTION TO DETAIL

RELIABILITY

ICC Fall 2003 Education Session