XLPE Cables ABB Guide Line

XLPE Cable Systems
Users guide
CONTENT
Page
Page
Introduction........................................................................... 3
Cable drums ....................................................................... 14
XLPE cable systems - design, installation and testing....... 4
Selection of cable drum .................................................... 15
XLPE Cable Systems
XLPE cables .........................................................................

Cable accessories.................................................................
Installation of XLPE cable systems ...................................... 5
Sizes and weights of wooden drums.....................................

Large and special drums.......................................................
Testing of XLPE cables...........................................................
Testing of XLPE cable systems..............................................

XLPE cable and cable system standards............................ 6
IEC .....................................................................................
CENELEC .............................................................................
ICEA .....................................................................................
ISO Standards ......................................................................
Cable handling........................................................................
Minimum bending radius.......................................................
Maximum pulling forces ........................................................
XLPE cable design............................................................... 16
Conductors ............................................................................
Standards - IEC and ICEA.....................................................
XLPE cable system configurations...................................... 7

Trefoil and flat formation ........................................................
Bonding of metallic screens ..................................................
Conductor water sealing .......................................................

Insulation.................................................................................
Conductor screen .................................................................
Current rating for XLPE cable systems ............................... 8
XLPE insulation ................................................................. 17
Current rating for three-core cables, ampres ......................
Insulation screen ...................................................................
Current rating for single-core cables, ampres ................... 9
Metallic screen........................................................................
Rating factors ................................................................... 11
Copper wire screen, standard design....................................
Rating factor for cross section area of metal screen ..........
Copper wire screen, water tight design .................................
Rating factors for cables in the ground ..............................
Lead sheath..........................................................................
Rating factor for cables in pipes in the ground............... 12

Rating factor for cables installed in air ...............................
Copper tape screen ..............................................................
Example of the use of rating factors ..................................
Non-metallic outer sheath ................................................. 18
Overload ...............................................................................
Conductive outer layer ..........................................................
Short-circuit currents ............................................................
Flame retardant outer layer....................................................
Maximum short-circuit currents due to thermal restrictions..13
Fire behavior ...........................................................................
Dynamic forces at short circuits ............................................
Technical data for cables in the ABB XLPE cable system .....19
Formulae ............................................................................. 26
Support ................................................................................. 27
To make sure you have the latest version of this

brochure, have a look at www.abb.com/cables
ABB
INTRODUCTION
XLPE Cable Systems

Introduction
Interfaces you can trust
ABB manufactures underground and submarine power

cables up to the highest voltages available.
Furthermore, we produce associated joints, terminations
and other accessories for all types of cables. The products
are designed to work perfectly together. Thus, we know
what we connect.
Experience you can rely on
We have extensive experience of cable projects all over the

world, encompassing every aspect from planning to commissioning, including engineering, route surveys, cable-laying, installation and final testing. Very few manufacturers
can point to such a long tradition in the high voltage field
as ABB. We delivered our first electrical cable in 1883 and
introduced triple-extruded XLPE cables around 1970. In
the early 1970s we started to supply cables for over 100
kV and our first 245 kV XLPE cable was put into service in
1978. ABB has since then supplied more than 6,000 km of
XLPE cables above 100 kV. Experience you can rely on.
Research and development
ABB has always been a pioneer in the high voltage field

and we have many worlds first and world records among
our references. But there are no shortcuts to success.
Maintaining our position calls for innovative research and
development, backed up by the wealth of know-how we
have accumulated over the years. One of the driving forces
for our R&D is to meet the new and constantly increasing
requirements from the power industry and a deregulated

market. Today we aim to develop the solutions our customers will need tomorrow.
State-of-the-art manufacturing lines
Experience and state-of-the-art expertise go hand in hand

for us. We have been manufacturing cables for over 120
years and have since the beginning been one of the
leading producers. Our factories are among the most
modern in the world and our advanced quality system
leaves nothing to chance. Every cubic millimeter of the
cable has to be perfect. We design and produce cables in
accordance with internationally approved standards or/and
according to our customers specifications.
This guide presents XLPE cables and systems for underground applications mainly.
ABB
XLPE CABLE SYSTEMS - DESIGN, INSTALLATION AND TESTING
XLPE cable systems design, installation and testing

XLPE cables
Single- or three-core XLPE cables consist of the following
components:
Conductor
- Cu or Al stranded compacted conductor or
- Cu segmental conductor or
- Cu or Al conductor with key-stone shaped profiles
- Longitudinal water sealing of conductor
Triple extruded and dry cured XLPE insulation system
Metallic screen
Copper wire screen
Copper tape screen
Radial water sealing
- Al - PE laminate
- Cu - PE laminate
- Lead sheath
Longitudinal water sealing of metallic screen
Non-metallic outer sheath
- PE
- PVC
- Halogen free flame retardant
- Co-extruded conductive layer over the sheath for
special sheath testing
Armour
- Single wire armour
- Double wire armour
Cable accessories
The set-up of cable accessories for ABB XLPE cable systems
covers:
Straight joints and joints with integrated screen
separation for cross bonding
Transition joints for connection of XLPE to fluidfilled cables
Outdoor terminations with porcelain or composite
insulators
Screened separable connectors for switchgears and
transformers
Terminations connecting to transformers and
Gas Insulated Switchgears (GIS)
Link boxes for earthing and cross-bonding
Distributed Temperature Sensing (DTS) Systems
More information about our accessories is available on
www.abb.com
ABB
XLPE CABLE SYSTEMS STANDARD DESIGN AND OPTIONS
Installation of XLPE cable systems

The installation of cable systems consists mainly of
trenching, cable pulling, clamping of cable as well as
mounting of accessories. ABBs certified installers perform
the high quality work necessary to achive a reliable operation of the cable system.
ABB has long and good experience from different
installation technologies like direct burial, duct, shaft, trough,
tunnel and submarine installations, but also trenchless
technologies like directional drilling, pipe jacking and others.
Testing of XLPE cable systems

The standard routine tests, sample tests, type tests and after
laying tests are normally performed according to IEC-standards. Other international or national standards may be followed upon agreement between contractor and purchaser.
Routine tests of XLPE cables and accessories
PD-measurement test.
High-voltage test of main insulation
Electrical Test of oversheath, if required
Visual inspection
Sample tests
Sample tests are carried out with a frequency according to
applicable IEC standards.
Conductor examination
Electrical resistance of conductor
Check of dimensions
Capacitance test
Hot set test
Electrical Tests
After laying tests
DC voltage test of oversheath
An AC voltage test of main insulation
ABB
XLPE CABLE AND CABLE SYSTEM STANDARDS
XLPE cable and cable system standards

ABBs XLPE cable systems are designed to meet requirements set in international or national standards. Some of
these are listed below.
IEC
XLPE cable systems specified according to IEC
(International Electrotechnical Commission) are among
many other standards accepted. IEC standards are considered to express an international consensus of opinion.
HD 632
Power cables with extruded insulation and their accessories for rated voltage above 36 kV (Um=42 kV) up to 150
kV (Um=170 kV). Part 1- General test requirements.
Part 1 is based on IEC 60840, and follows that standard
closely.
HD 632 is completed with a number of parts and subsections for different cables intended to be used under
special conditions which can vary nationally in Europe.
Some frequently used standards are:

IEC 60228
Conductors of insulated cables.
ICEA
For North America cables are often specified according to
ICEA (Insulated Cable Engineers Association, Inc.)
IEC 60287
Electric cables - Calculation of the current rating.
S-97-682
Standard for utility shielded power cables rated 5-46 kV.
IEC 60332
Tests on electric cables under fire conditions.
IEC 60502
Power cables with extruded insulation and their accessories for rated voltage from 1 kV (Um=1,2 kV) up to 30 kV
(Um=36 kV).
IEC 60840
Power cables with extruded insulation and their accessories
for rated voltage above 30 kV (Um=36 kV) up to 150 kV
(Um=170 kV). Test methods and requirements.
ISO Standards
ABB has well-developed systems for quality and environmental management which put the needs and wishes of
the customer first. Our systems comply with the requirements of ISO 9001 and ISO 14001 and are certified by
Bureau Veritas Quality International.
ISO 14001 Certificate of Approval
ISO 9001 Certificate of Approval
IEC 60853
Calculation of the cyclic and emergency current rating of
cables.
IEC 61443
Short-circuit temperature limits of electric cables with rated
voltages above 30 kV (Um=36 kV)
IEC 62067
Power cables with extruded insulation and their accessories
for rated voltage above 150 kV (Um=170 kV) up to 500 kV
(Um=550 kV). Test methods and requirements.
CENELEC
In Europe, cable standards are issued by CENELEC.
(European Committee for Electrotechnical Standardization.)
They are as a rule implementations of the IEC specifications. Special features in design may occur depending on
national conditions.
HD 620
Distribution cables with extruded insulation for rated voltages from 3.6/6 (7.2) kV up to and including 20.8/36 (42) kV.
ABB
XLPE CABLE SYSTEM CONFIGURATIONS
XLPE cable system configurations

Trefoil and flat formation
One group of XLPE cables may be placed in trefoil (triangular) or flat formation according to figure. The choice
depends on several factors like screen bonding method,
conductor area and available space for installation.
Trefoil
or
flat formation
Bonding of the metallic screens

Different methods of bonding the metallic sheaths may be
chosen when designing a cable system. The usual bonding
methods are described below:
Both-ends bonding
A system is both ends bonded if the arrangements are such
that the cable sheaths provide path for circulating currents
at normal conditions. This will cause losses in the screen,
which reduces the cable current carrying capacity. These
losses are smaller for cables in trefoil formation than in flat
formation with separation.
Single-point bonding
A system is single point bonded if the arrangements are
such that the cable sheaths provide no path for the flow of
circulating currents or external fault currents. In such case,
a voltage will be induced between screens of adjacent
phases of the cable circuit and between screen and earth,
but no current will flow. This induced voltage is proportional to the cable length and current. Single-point bonding
can only be used for limited route lengths, but in general
the accepted screen voltage potential limits the length.
Cross-bonding
A system is cross-bonded if the arrangements are such
that the circuit provides electrically continuous sheath runs
from earthed termination to earthed termination but with
the sheaths so sectionalised and cross-connected in order
to eliminate the sheath circulating currents. In such case, a
voltage will be induced in between screen and earth, but
no significant current will flow. The maximum induced
voltage will appear at the link boxes for cross-bonding.
This method permits a cable current-carrying capacity as
high as with single-point bonding but longer route lengths
than the latter. It requires screen separation and additional
link boxes.
ABB
CURRENT RATING FOR XLPE CABLE SYSTEMS
Current rating for XLPE cable systems

The XLPE cable should at least have a conductor cross
section adequate to meet the system requirements for
power transmission capacity. The cost for energy losses
can be reduced by using larger conductor.
On-load losses are basically the ohmic losses in the
conductor and the metallic screen. The XLPE cables can be
loaded continuously to a conductor temperature of 90C.
However, in order to keep a load margin, or to keep the
losses lower, or to avoid possible thermal instability due to
drying out the surrounding soil, it may be advantageous to
limit the operating temperature to, approximately, 65C.
The dielectric losses of XLPE insulation are present also
at no load. Those losses depend on the operation voltage
applied and shall be considered above 100 kV.
The dielectric losses are lower for XLPE insulated cables
than for EPR insulated cables.
The continuous current ratings for three-core cables are
given in Table 1 and for single-core cables in Tables 2-5.
The continuous current ratings are calculated according
to IEC 60287 series of standards and with the following
conditions:
- One multi-core cable or one three-phase group of
single-core cables
- Ground temperature
20C
- Ambient air temperature
35C
- Laying depth L
1.0 m
- Distance s between cable
axes laid in flat formation
70 mm + De
- Ground thermal resistivity
1.0 Km/W
Current rating for three-core cables, ampres

Table 1
Rated voltage up to 220 kV
Cross
section
mm2
Aluminium conductor
In ground
65 C
o
90 C
65 C
Copper conductor
In air
o
In ground
90 C
o
65 C
90 C
In air
65 C
90oC
16
74
89
60
82
96
115
78
105
25
95
115
80
110
120
145
105
140
35
115
135
97
130
145
175
125
170
50
135
160
120
165
175
210
155
210
70
165
195
145
195
210
250
185
250
95
195
230
170
230
250
300
220
290
120
220
265
200
270
285
340
255
345
150
245
295
225
300
315
380
285
390
185
280
335
255
345
355
430
325
440
240
320
385
300
400
410
495
380
515
300
365
435
335
455
460
555
430
580
400
410
490
385
525
515
625
490
680
500
465
560
445
610
580
700
560
780
630
525
635
510
705
640
785
635
890
800
585
715
585
810
705
865
715
1000
1000
645
785
655
915
755
935
785
1100
Rating factors for single-core cables are given in Tables 6

to 14.
ABB
Current rating for single-core cables, ampres

Table 2
Rated voltage 10-70 kV, aluminium conductor 25 or 35 mm2 screen
Cross
section
conductor
Cables in Ground
Flat formation
Crossbonded
Cables in Air
Trefoil formation
Both ends
Cross bonded
Flat formation
Both ends
Crossbonded
Trefoil formation
Both ends
Cross bonded
Both ends
mm2
65oC
90oC
65oC
90oC
65oC
90oC
65oC
90oC
65oC
90oC
65oC
90oC
65oC
90oC
65oC
90oC
95
220
265
215
260
205
250
210
250
230
310
225
305
200
270
200
270
120
250
300
245
295
235
285
240
285
265
360
260
350
225
310
230
310
150
280
340
270
325
265
320
265
320
305
410
290
395
260
355
260
355
185
320
385
304
365
300
360
300
360
350
470
330
450
295
405
295
405
240
370
445
345
420
350
420
345
420
415
560
380
520
350
480
350
480
300
420
505
385
465
395
475
390
470
475
645
430
590
400
550
400
545
400
480
575
430
520
450
540
445
535
555
750
490
675
470
640
465
635
500
550
660
475
580
515
620
505
610
645
875
555
770
545
745
535
735
630
625
755
525
645
585
705
570
690
755
1025
625
870
630
865
615
850
800
710
855
575
710
660
795
635
775
875
1190
700
980
725
995
705
975
1000
790
955
625
770
730
885
700
855
995
1355
770
1080
820
1130
790
1100
1200
850
1035
655
815
785
950
745
910
1095
1490
820
1160
890
1235
855
1190
1400
910
1105
685
850
830
1010
785
960
1185
1620
865
1230
960
1330
915
1275
1600
960
1165
705
880
870
1060
815
1005
1265
1735
905
1285
1015
1410
960
1345
2000
1045
1270
740
930
935
1145
870
1075
1405
1930
965
1380
1115
1555
1045
1470
Table 3
Rated voltage 10-70 kV, copper conductor 25 or 35 mm2 screen
Cross
section
conductor
Segmental conductor for 1200 mm2 or more.
Cables in Ground
Flat formation
Crossbonded
Cables in Air
Trefoil formation
Both ends
Cross bonded
Flat formation
Both ends
Crossbonded
Trefoil formation
Both ends
Cross bonded
Both ends
mm2
65oC
90oC
65oC
90oC
65oC
90oC
65oC
90oC
65oC
90oC
65oC
90oC
65oC
90oC
65oC
90oC
95
285
340
275
330
270
320
270
325
300
400
285
390
255
350
255
350
120
325
390
310
375
305
365
305
365
345
465
325
445
295
400
295
400
150
365
435
340
410
340
410
340
410
390
530
360
495
335
455
335
455
185
410
495
375
455
385
465
385
460
450
610
405
560
380
520
380
520
240
475
570
425
515
445
535
440
535
530
720
465
645
445
615
445
610
300
540
645
465
570
505
605
495
600
610
830
520
725
510
705
505
695
400
610
735
515
630
570
690
555
675
710
960
585
815
595
815
580
800
500
695
835
560
690
645
780
625
755
820
1115
650
915
680
940
660
915
630
785
950
610
755
725
875
690
845
950
1295
720
1020
780
1080
750
1045
800
880
1065
655
815
800
975
760
930
1085
1485
790
1125
880
1220
840
1175
1000
965
1170
695
870
870
1065
815
1005
1215
1665
855
1220
980
1360
925
1300
1200
1115
1350
745
935
1035
1255
915
1125
1440
1965
950
1355
1190
1645
1070
1505
1400
1200
1450
775
970
1105
1345
960
1185
1575
2145
1000
1430
1290
1785
1145
1610
1600
1270
1540
795
1000
1165
1420
995
1235
1685
2305
1035
1490
1370
1905
1205
1695
2000
1395
1695
830
1045
1265
1545
1055
1315
1890
2590
1100
1585
1520
2115
1300
1845
ABB
Table 4
Rated voltage 110-500 kV, aluminium conductor 95 mm2 screen
Cross
section
conductor
Cables in Ground
Flat formation
Crossbonded
Cables in Air
Trefoil formation
Both ends
Cross bonded
Flat formation
Both ends
Crossbonded
Trefoil formation
Both ends
Cross bonded
Both ends
mm
65 C
90 C
65 C
90 C
65 C
90 C
65 C
90 C
65 C
90 C
65 C
90 C
65 C
90 C
65oC
90oC
300
405
490
365
445
390
465
380
460
455
610
415
565
405
550
400
540
400
465
560
405
495
445
535
430
525
535
715
470
640
470
635
460
625
500
535
640
450
550
505
610
485
590
620
835
530
725
545
740
525
720
630
610
735
495
605
575
695
545
665
725
975
595
820
625
855
605
830
800
690
830
535
660
650
785
605
740
835
1130
655
910
720
985
680
940
1000
770
935
575
710
720
875
660
815
955
1295
715
990
810
1115
760
1055
1200
825
1005
605
750
770
940
700
865
1045
1415
765
1070
880
1215
820
1140
1400
880
1075
630
780
820
1000
740
910
1125
1520
800
1125
945
1305
875
1220
1600
930
1130
649
805
855
1050
765
950
1200
1635
835
1175
1000
1385
920
1285
2000
1005
1230
680
845
920
1135
810
1010
1330
1820
885
1250
1095
1525
995
1395
Table 5
Rated voltage 110-500 kV, copper conductor 95 mm2 screen
Cross
section
conductor
Cables in Ground
Flat formation
Crossbonded
Cables in Air
Trefoil formation
Both ends
Cross bonded
Flat formation
Both ends
Crossbonded
Trefoil formation
Both ends
Cross bonded
Both ends
mm
65 C
90 C
65 C
90 C
65 C
90 C
65 C
90 C
65 C
90 C
65 C
90 C
65 C
90 C
65oC
90oC
300
520
625
440
540
495
600
475
580
585
785
505
690
515
700
505
685
400
595
715
480
590
560
680
535
650
680
915
560
775
595
810
575
785
500
675
815
525
645
635
770
595
725
785
1060
620
860
680
930
650
890
630
760
925
565
700
710
865
655
805
910
1230
680
950
780
1070
730
1010
800
850
1035
600
745
790
960
715
880
1035
1410
740
1040
875
1210
810
1130
1000
935
1140
635
790
855
1050
765
945
1160
1590
790
1115
970
1345
885
1240
1200
1070
1295
675
840
995
1215
820
1015
1365
1850
875
1235
1155
1590
990
1390
1400
1145
1390
695
870
1060
1300
855
1065
1480
2010
915
1295
1245
1720
1050
1480
1600
1210
1475
715
900
1120
1375
885
1110
1605
2185
950
1350
1340
1850
1110
1570
2000
1310
1610
740
930
1210
1490
930
1165
1780
2435
995
1425
1465
2040
1185
1685
2500
1415
1745
770
970
1300
1605
970
1225
2010
2760
1055
1515
1625
2270
1275
1825
3000
1490
1840
790
995
1365
1695
1000
1265
2175
2995
1095
1575
1735
2435
1340
1925
10
Segmental conductor for 1200 mm2 or more.
ABB
Rating factors
Rating factor for cross section area of metal screen
Applicable to single-core cables in trefoil formation. Screens
bonded at both ends.
For single-point bonding or cross-bonding no rating factor
applies for the cross section area of metal screen.
Table 6
10-70 kV 35 mm2 screen
Table 7
110-500 kV 95 mm2 screen
Rating factor for tables 2 and 3

Conductor
mm2
Al
Copper screen mm
Cu
300
Rating factor for tables 4 and 5

Conductor
mm2
25
35
50
95
150
240
300
Al
1.00
0.99
0.98
0.97
0.96
0.95
300
Copper screen mm2
Cu
25
35
50
95
150
240
300
1.02
1.02
1.01
0.99
0.98
0.97
500
300
1.00
0.99
0.97
0.95
0.93
0.93
500
300
1.03
1.03
1.02
0.98
0.96
0.96
800
500
1.01
0.99
0.96
0.93
0.90
0.90
800
500
1.05
1.04
1.03
0.97
0.94
0.94
1200
630
1.01
0.99
0.95
0.92
0.89
0.88
1200
630
1.06
1.05
1.04
0.97
0.93
0.92
2000
2000
800
1.01
0.98
0.94
0.91
0.87
0.86
800
1.07
1.06
1.04
0.96
0.92
0.91
1200
1.02
0.97
0.91
0.85
0.81
0.80
1200
1.12
1.1
1.07
0.94
0.89
0.88
2000
1.03
0.96
0.88
0.82
0.77
0.76
2000
1.16
1.13
1.09
0.93
0.87
0.86
3000
1.03
0.96
0.88
0.82
0.76
0.75
3000
1.17
1.14
1.10
0.93
0.87
0.85
1 mm2 copper screen is equivalent to: 1.66 mm2 aluminium sheath

12.40 mm2 lead sheath
Rating factor for cables in the ground

Table 8
Table 9
Rating factor for laying depth

Laying depth, m
Rating factor
0.50
1.10
0.70
1.05
0.90
1.01
1.00
1.00
1.20
0.98
1.50
0.95
Rating factor for ground temperature

Conductor
temperature,
o
C
Ground temperature, oC
10
15
20
25
30
35
40
45
90
1.07
1.04
0.96
0.93
0.89
0.84
0.80
65
1.11
1.05
0.94
0.88
0.82
0.74
0.66
Table 10
Rating factor for ground thermal resistivity
Thermal resistivity,
Km/W
0.7
1.0
1.2
1.5
2.0
2.5
3.0
Rating factor
1.14
1.00
0.93
0.84
0.74
0.67
0.61
Table 11
Rating factor for phase spacing
One group in flat formation with cross-bonded or single-bonded
screens
Spacing s, mm
Rating factor
ABB
De
De+70
200
250
300
350
400
0.93
1.03
1.05
1.07
1.08
1.10
11
Table 12
Rating factor for groups of cables in the ground
One three-core cable is equivalent to one group of single-core cables
Distance cc
between groups,
mm
Number of groups
1
100
0.76
0.67
0.59
0.55
0.51
0.49
0.47
0.46
200
0.81
0.71
0.65
0.61
0.49
0.56
0.53
0.52
400
0.85
0.77
0.72
0.69
0.66
0.64
0.63
0.62
600
0.88
0.81
0.77
0.74
0.72
0.71
0.70
0.69
800
0.90
0.84
0.81
0.79
0.77
0.76
0.75
0.75
2000
0.96
0.93
0.92
0.91
0.91
0.91
0.90
0,90
Rating factor for cables installed in pipes in the ground

The rating factor given for single-core cables partially
installed in separate pipes, applies only when a cable section between screen earthing points must be partially laid
in pipes, under the following conditions:
- the cables are laid in trefoil formation over the major
portion of the section
- the pipes are laid in flat formation
- the piped length is less than 10% of the section
between earthing points
- one cable per pipe
- the pipe diameter is two times the cable diameter.
Table 13
Rating factor for cables in pipes in ground
Single-core
cables
partially
installed in
separate
pipes
Single-core
cables in
separate
pipes
Single-core
cables in
a common
pipe
Three-core
cable
in a pipe
0.94
0.90
0.90
0.90
Rating factor for cables installed in air

Table 14
Rating factor for ambient air temperature
Air temperature, oC
Rating factor
10
15
20
25
30
35
40
45
50
55
1.28
1.24
1.19
1.15
1.10
1.05
1.0
0.95
0.89
0.83
0.77
Example of the use of rating factors

2 groups of 60 kV XLPE cables with aluminium conductors
1 x 500/150 mm2 in the ground in trefoil formation. Metal
screens bonded at both ends, 90C conductor temperature.
Table 2 gives current rating 610 A, unadjusted value.
Current rating 610 A

Screen area
Laying depth
Ground temperature
Ground thermal resistivity
Distance between groups
150 mm2
1.5 m
30C
1.5 Km/W
400 mm
Table
2
6
8
9
10
12
Rating factor
0.95
0.95
0.93
0.84
0.85 (2 groups)
Overload
As infrequently as possible, an XLPE-cable may be overloaded above 90C and the conductor temperature may
reach up to 105C. Singular emergency overloads are not
expected to produce any significant damage to the cable.
However both occurrence and duration of these overloads
should be kept at a minimum. Cyclic and emergency ratings
can be calculated according to IEC publication 60853.
12
Adjusted current rating per group;

610 x 0.95 x 0.95 x 0.93 x 0.84 x 0.85 = 365 A
Please note that use of rating factors gives good general

indication during planning future circuits.
Once a circuit layout is defined, an accurate calculation
should be performed to confirm the assumptions.
Short-circuit currents
During short circuit conditions the maximum allowable
temperature in conductor or screen/metallic sheath is
determined by the adjoining insulation and sheath materials. This is specified in IEC 61443 Short circuit temperature
limits of electric cables with rated voltage above 30 kV
(Um=36 kV). The dynamic forces between the conductors
must be taken into account for cable installations.
ABB
Maximum short circuit currents due to thermal restrictions

The thermal energy developed during a short-circuit is
determined by the short-circuit magnitude and duration.
For design purposes, an equivalent short-circuit current
with a duration of 1 sec is used according to formula
below. This formula is valid for a short-circuit duration of
0.2 to 5.0 sec.
Ish=short-circuit current during time tsh

I1=short-circuit current rating during 1 second. See the 1svalue in tables 15 for the conductor and in Table 16 for
the metal screen.
tsh=short-circuit duration
Copper screens may reach a temperature of 250oC without

damaging adjacent insulating material. With an initial temperature of 50oC this corresponds to a current density of
150 A/mm2 during 1s. (Both higher and lower current densities may be allowed if other conditions apply.)
Lead sheaths are limited to 210oC at short circuit. With an
initial temperature of 50oC this corresponds to a current
density of 28 A/mm2 during 1 s.
Table 16
Max. short-circuit current on the screen during 1 s, kA
Metallic screen
cross section, mm2
Copper
screen
Metallic screen
temperature
before the short-circuit
Lead sheath
50oC
70oC
16
94
2.6
2.4
25
147
4.1
3.8
35
206
5.8
5.4
Max. short-circuit current on the conductor during 1 s, kA
50
295
8.3
7.7
Conductor temperature before the short-circuit
95
560
16
15
150
884
25
23
300
1768
50
46
0.165
0.153
0.028
0.026
For XLPE insulated conductors the maximum allowable

short circuit temperature is 250oC.
Table 15
Cross
section
Aluminium
conductor
Copper
conductor
mm2
65oC
90oC
65oC
90oC
25
2.6
2.4
3.9
3.6
35
3.6
3.3
5.5
5.0
50
5.2
4.7
7.8
7.2
70
7.2
6.6
11.0
10.0
95
9.8
9.0
14.9
13.6
120
12.4
11.3
18.8
17.2
150
15.5
14.2
23.5
21.5
185
19.2
17.5
29.0
26.5
240
24.8
22.7
37.6
34.5
300
31.1
28.3
47.0
42.9
400
41.4
37.8
62.7
57.2
500
51.8
47.2
78.4
71.5
630
65.2
59.5
98.7
90.1
800
82.8
75.6
125
114
1000
104
94.5
157
143
1200
124
113
188
172
1400
145
132
219
200
1600
166
151
251
229
2000
207
189
313
286
per mm2
0.104
0.0945
0.157
0.143
ABB
per mm Cu
2
per mm2 Pb
Dynamic forces at short circuits

Apart from the thermal stress in case of short-circuit, the
dynamic stresses in cables and accessories must be taken
into consideration.
The dynamic effect of parallel conductors carrying current is responsible for the dynamic stress.
The dynamic forces between two conductors, can be calculated as:
Where; Ipeak=
Ish=
S=
F=
2.5 Ish [kA]

Short current [kA] RMS
Centre to centre spacing between
conductors [m]
maximum force [N/m]
13
CABLE DRUMS
Cable drums
Wooden drums/reels are standardised . For certain purposes steel
drums/reels are applicable. Both wooden and steel-drums can be
obtained for special purposes with other measures than stated below.
Table 17
Selection of cable drum
Cable lengths in metres on standard drum
Cable
diameter
Drum type
mm
K14
K16
K18
K20
K22
K24
K26
K28
K30
36
570
760
850
1155
1560
2090
2860
4000
5800
38
470
630
820
1075
1290
1780
2490
3600
4900
40
450
610
690
900
1100
1560
2220
3200
4400
42
430
500
660
870
1070
1510
2160
3100
3950
44
340
480
530
720
1030
1310
1830
2800
3900
46
330
450
510
690
860
1260
1780
2430
3460
48
310
360
480
660
820
1070
1540
2360
3130
50
360
400
550
670
1020
1490
2090
2820
52
340
385
530
670
910
1280
1830
2750
54
320
360
505
640
870
1280
1775
2450
56
260
360
475
610
825
1090
1715
2380
58
240
275
385
510
720
1040
1550
2090
60
275
365
480
680
990
1490
2030
62
250
365
480
680
460
1270
1770
64
250
345
450
545
825
1270
1730
66
240
345
370
545
825
1230
1535
68
240
320
345
515
785
1025
1475
70
250
345
515
670
1030
1475
72
250
345
480
635
985
1260
74
250
320
400
635
985
1260
76
230
320
400
625
810
1210
78
230
320
400
600
810
1210
80
230
325
500
810
1015
82
230
325
470
775
1015
84
210
300
470
660
1015
86
210
300
470
615
965
88
210
275
440
615
840
90
210
275
440
615
840
92
355
585
800
94
325
585
800
96
325
485
755
98
325
485
640
325
455
640
100
>100
Cable drums with bigger barrel diameter are needed for big diameter cables
(normally steel drums)
The drums are made of high-quality wood.
14
ABB
CABLE DRUMS | TESTING | CABLE HANDLING
Table 18
Sizes and weights of wooden drums
Drum type
K14
K16
K18
K20
K22
K24
K26
K28
K30
2.14
2.86
3.58
5.12
6.15
7.36
10.56
13.88
17.15
kg
185
275
320
485
565
625
1145
1460
1820
a Diameter incl battens
mm
1475
1675
1875
2075
2275
2475
2700
2900
3100
b Flange diameter
mm
1400
1600
1800
2000
2200
2400
2600
2800
3000
c Barrel diameter
mm
800
950
1100
1300
1400
1400
1500
1500
1500
d Total width
mm
982
1018
1075
1188
1188
1200
1448
1650
1800
e Spindle hole diameter
mm
106
106
131
131
131
131
132
132
132
Shipping volume
Drum weight incl. battens
Large and special drums.

Steel drums with larger outer diameters are available, but
transport restrictions have to be considered. Special lowloading trailers and permits from traffic authorities can be
needed depending on local regulations and conditions.
Special wooden drums with larger barrel diameter or
larger width are also available.
Testing of XLPE cables
Cable handling
Table 19
Table 20
Rated voltage and corresponding test voltages

according to IEC
Type test
Nominal
voltage
Impulse
voltage
Minimum bending radius for standard designs

Single-core
cable
Three-core
cable
At laying
15 De
12 De
When installed
10 De
8 De
Routine tests
AC voltage
test
Partial discharge
test at
kV
kV
kV
Duration
minutes
10
75
21
10
20
125
42
21
30
170
63
31
45
250
65
30
39
66
325
90
30
54
110
550
160
30
96
132
650
190
30
114
150
750
218
30
131
220
1050
318
30
190
275
1050
400
30
240
330
1175
420
60
285
400
1425
440
60
330
500
1550
580
60
435
kV
De is the external diameter of the cable

Other designs may apply other bending radii.
Maximum pulling forces

The following pulling forces should not be exceeded:
Aluminium conductors
40 N/mm2 (4 kg/mm2)
Copper conductors
70 N/mm2 (7 kg/mm2)
Tests according to other standards can be carried out upon

agreement.
ABB
15
CONDUCTORS | INSULATION
XLPE Cable Design

Conductors
Table 21
Table 22
IEC
Cross section
Diameter
approx.
ICEA
Maximum d.c. resistance
at 20oC, ohm/km
Cross section
mm2
kcmil
mm
aluminium
copper
AWG
25
49
5.8
1.20
0.727
35
69
7.0
0.868
0.524
50
99
8.0
0.641
70
138
9.6
0.443
kcmil
Diameter
approx.
mm2
mm
21.2
32.6
0.387
0.268
1/0
Nominal d.c. resistance

at 20oC, ohm/km
aluminium
copper
5.4
1.36
0.830
6.8
0.857
0.521
42.4
7.6
0.680
0.413
53.5
8.5
0.539
0.328
95
187
11.2
0.320
0.193
2/0
67.4
9.6
0.428
0.261
120
237
12.8
0.253
0.153
3/0
85
10.7
0.383
0.206
150
296
14.2
0.206
0.124
4/0
107
12.1
0.269
0.164
185
365
15.9
0.164
0.0991
250
127
13.2
0.228
0.139
240
474
18.0
0.125
0.0754
300
152
14.5
0.190
0.116
300
592
20.5
0.100
0.0601
350
177
15.6
0.162
0.0990
400
789
23.1
0.0778
0.0470
500
253
18.7
0.114
0.0695
500
987
26.4
0.0605
0.0366
750
380
23.0
0.0759
0.0462
630
1243
30.2
0.0469
0.0283
1000
507
26.9
0.0563
0.0347
800
1579
33.9
0.0367
0.0221
1250
633
30.2
0.0454
0.0278
1000
1973
37.9
0.0291
0.0176
1500
760
33.5
0.0380
0.0231
1200
2368
41.4
0.0247
0.0151
1750
887
36.2
0.0325
0.0198
1600
3158
47.4
0.0186
0.0113
2000
1013
38.0
0.0285
0.0173
2000
3947
53.5
0.0149
0.0090
2500
1267
42.5
0.0230
0.0140
2500
4934
66
0.0120
0.0072
3000
1520
46.2
0.0192
0.0117
3000
5920
72
0.0100
0.0060
Standards IEC and ICEA

Conductors are manufactured according to the following
standards:
IEC (International Electrotechnical Commission) Standard
Publication 60228, Class 2: Stranded circular or shaped
conductors of copper or aluminium.
ICEA, Standard Publication No. S-97-682, further specified in
ASTM B 400-18 for aluminium, ASTM B 496-81 for copper.
1 ohm/100 ft = 3.28 ohm/km
Insulation
Conductor screen
The conductor screen consists of an extruded layer firmly
bonded to the XLPE insulation. A very smooth material is
used to obtain a high quality of the electrical performance.
Conductor water sealing

If required, the conductor can be water sealed by:
- Swelling material between the conductor strands.
This material turns into jelly when in contact with water.
- Filling compound between the conductor strands.
16
ABB
INSULATION | METALLIC SCREEN
XLPE insulation
The XLPE insulation is extruded simultaneously with the
conductor screen and the insulation screen, e.g. triple
extrusion. The interface surfaces between insulation and
conductive screens are not exposed at any stage of the
manufacturing. High quality material-handling systems,
triple extrusion, dry curing and super-clean XLPE materials
guarantee high quality products. The insulation thickness
is determined by the design electrical stresses for AC or
impulse. The actual thickness for different voltage levels
and conductor sizes is given in Tables 23 to 39.
Insulation screen
This screen consists of an extruded layer firmly bonded to
the XLPE insulation. The material is a high quality conductive
compound. The interface between the screen and the insulation is smooth.
Metallic screen
Copper wire screen, standard design
A polymeric sheath covers the copper wire screen.
Copper wire screen, water tight design

Radial water sealing is achieved by using a metal-PE
laminate. The metal is normally aluminium. Copper may
also be used. The laminate is bonded to the polyethylene,
which gives excellent mechanical properties. Longitudinal
water sealing is achieved by using a water swelling material at the copper wires or swelling powder between the
screen wires.
Lead sheath
Radial water sealing achieved by a corrosion resistant lead
sheath. Longitudinal water sealing is achieved by using a
water swelling material applied under the lead sheath.
Copper tape screen

Cross section defined by the geometrical cross section of
the copper tapes.
ABB
17
N O N - M E T A L L I C O U T E R S H E A T H | C O N D U C T I V E O U T E R L AY E R | F L A M E R E T A R D E N T O U T E R L AY E R | F I R E B E H AV I O R
Non-metallic outer sheath

PE or PVC are normally used for the non-metallic outer
sheath. IEC 60502 recommends a thickness of t = 0.035 x
D + 1.0 mm, where D is the diameter under the sheath.
For heavy installations a larger thickness is recommended.
PE is the first choice for most applications. PVC is used
when there are high requirements on fire retardation behaviour.
Conductive outer layer

A conductive outer layer facilitates testing of the nonmetallic outer sheath. This testing is important to ensure
the physical integrity of the cable from time to time, either
in factory, after transportation, directly after laying, upon
completion of the installation, or periodically thereafter.
A conductive outer layer obtained by simultaneous extrusion with the non-conductive outer sheath presents superior
electrical and structural properties.
Flame retardant outer layer

For PE-sheathed cables a halogen free and flame retardant
layer can be applied in order to limit the fire spread in
buildings and tunnel installations.
Fire behavior
This relates to cables in buildings and tunnels.
Several serious fire accidents have focused attention on
the fire behaviour of cables. Experience shows that cables
seldom initiate fires. However, in some cases cable installations have influenced the extent of a fire, as a propagator
of flames and or as a source of intense aggressive smoke.
Cables having a PVC sheath are considered as flame retardant. However, once PVC is on fire, it generates hydrochloric acid fumes (HCl) acid. This gas is highly corrosive
and irritating to inhale. Cables with a standard PE outer
sheath do not generate any corrosive HCl but are not
flame retardant. Special polyolefines with flame retardant
properties but without chlorine or any other halogenes are
optional for the outer sheath.
18
ABB
TECHNICAL DATA FOR CABLES IN THE ABB XLPE CABLE SYSTEM
Technical data for cables in the ABB XLPE cable system

Crosssection
of conductor
Diameter
of conductor
Insulation
thickness
Diameter
over
insulation
Crosssection
of
screen
Outer
diameter
of cable
Cable
weight
(Al-conductor)
Cable
weight
(Cu-conductor)
Capacitance
Charging
current
per
phase
at 50 Hz
Inductance
Surge
impedance
mm2
mm
mm
mm
mm2
mm
kg/m
kg/m
F/km
A/km
mH/km
mH/km
Table 23
Single-core cables, nominal voltage 10 kV (Um = 12 kV)
50
3.4
16.4
16
24.0
0.7
1.0
0.24
0.4
0.42
0.73
24.5
70
9.6
3.4
18.0
16
26.0
0.7
1.2
0.27
0.5
0.40
0.70
21.6
95
11.2
3.4
19.6
25
28.0
0.9
1.5
0.30
0.5
0.38
0.67
19.3
120
12.8
3.4
21.0
25
29.0
1.0
1.8
0.33
0.6
0.37
0.64
17.3
150
14.2
3.4
22.6
35
31.0
1.3
2.2
0.36
0.6
0.35
0.63
16.1
185
15.9
3.4
24.2
35
32.0
1.4
2.5
0.39
0.7
0.34
0.61
14.7
240
18
3.4
26.9
35
35.0
1.6
3.1
0.44
0.8
0.33
0.59
13.5
300
20.5
3.4
29.2
35
38.0
1.9
3.7
0.48
0.9
0.32
0.57
12.1
400
23.1
3.4
32.0
35
41.0
2.2
4.7
0.53
1.0
0.31
0.55
11.1
500
26.4
3.4
35.4
35
44.0
2.6
5.7
0.60
1.1
0.30
0.53
9.9
630
30.2
3.4
39.0
35
48.0
3.1
7.0
0.67
1.2
0.29
0.51
8.7
800
33.9
3.4
42.9
35
53.0
3.7
8.6
0.74
1.3
0.28
0.49
8.0
1000
37.9
3.4
47.1
35
58.0
4.4
10.6
0.82
1.5
0.28
0.48
7.3
1200
44
3.4
52.8
35
64.0
5.1
12.5
0.93
1.7
0.27
0.46
6.3
1400
49
3.4
59.8
35
71.0
6.0
14.7
1.06
1.9
0.27
0.45
6.1
1600
52
3.4
62.8
35
74.0
6.7
16.6
1.11
2.0
0.26
0.44
5.8
2000
56
3.4
66.8
35
79.0
7.9
20.3
1.19
2.2
0.26
0.43
5.4
Table 24
50
5.5
20.6
16
29.0
0.8
1.1
0.17
0.6
0.46
0.74
33.4
70
9.6
5.5
22.2
16
30.0
0.9
1.4
0.19
0.7
0.43
0.70
29.7
95
11.2
5.5
23.8
25
32.0
1.1
1.7
0.21
0.7
0.41
0.68
26.8
120
12.8
5.5
25.2
25
34.0
1.2
2.0
0.22
0.8
0.39
0.65
23.7
150
14.2
5.5
26.8
35
35.0
1.5
2.4
0.24
0.9
0.38
0.63
21.9
185
15.9
5.5
28.4
35
37.0
1.6
2.8
0.26
0.9
0.37
0.62
20.0
240
18
5.5
31.1
35
40.0
1.9
3.4
0.29
1.1
0.35
0.60
17.7
300
20.5
5.5
33.4
35
42.0
2.1
4.0
0.32
1.2
0.34
0.57
16.1
400
23.1
5.5
36.2
35
45.0
2.5
5.0
0.35
1.3
0.33
0.56
14.5
500
26.4
5.5
39.6
35
49.0
2.9
6.0
0.39
1.4
0.32
0.54
12.7
630
30.2
5.5
43.2
35
53.0
3.4
7.3
0.43
1.6
0.31
0.52
11.2
800
33.9
5.5
47.1
35
58.0
4.0
9.0
0.48
1.7
0.30
0.50
10.1
1000
37.9
5.5
51.3
35
62.0
4.8
11.0
0.53
1.9
0.29
0.48
9.1
1200
44
5.5
57.0
35
68.0
5.5
13.0
0.60
2.2
0.28
0.46
7.2
1400
49
5.5
64.0
35
76.0
6.5
15.2
0.68
2.5
0.28
0.45
6.7
1600
52
5.5
67.0
35
79.0
7.2
17.1
0.71
2.6
0.27
0.45
7.6
2000
56
5.5
71.0
35
83.0
8.4
20.8
0.76
2.8
0.27
0.44
6.9
ABB
19
Crosssection
of conductor
Diameter
of conductor
Insulation
thickness
Diameter
over
insulation
Crosssection
of
screen
Outer
diameter
of cable
Cable
weight
(Al-conductor)
Cable
weight
(Cu-conductor)
Capacitance
Charging
current
per
phase
at 50 Hz
Inductance
Surge
impedance
mm2
mm
mm
mm
mm2
mm
kg/m
kg/m
F/km
A/km
mH/km
mH/km
Table 25
95
11.2
8.0
28.6
25
37
1.4
2.0
0.16
0.9
0.44
0.67
34.2
120
12.8
8.0
30.2
25
39
1.6
2.4
0.17
0.9
0.42
0.65
30.8
150
14.2
8.0
31.7
35
41
1.9
2.8
0.19
1.0
0.41
0.63
28.2
185
15.9
8.0
33.4
35
42
2.1
3.2
0.20
1.1
0.39
0.61
26.3
240
18
8.0
35.7
35
45
2.3
3.8
0.22
1.2
0.38
0.59
23.7
300
20.5
8.0
37.9
35
48
2.6
4.5
0.24
1.3
0.37
0.57
21.5
400
23.1
8.0
41.3
35
51
3.0
5.5
0.26
1.4
0.35
0.55
19.5
500
26.4
8.0
44.4
35
54
3.5
6.6
0.29
1.6
0.34
0.53
17.6
630
30.2
8.0
48.2
35
58
4.0
8.0
0.32
1.8
0.33
0.51
15.5
800
33.9
8.0
52.9
35
63
4.9
10.0
0.36
1.9
0.32
0.49
14.0
1000
37.9
8.0
56.9
35
67
5.7
12.1
0.40
2.2
0.31
0.48
12.9
1200
44
8.0
60.4
35
74
6.6
14.2
0.43
2.3
0.29
0.45
10.9
1400
49
8.0
63.4
35
81
7.4
16.2
0.45
2.5
0.29
0.44
9.6
1600
52
8.0
67.0
35
84
8.1
18.2
0.48
2.6
0.29
0.43
9.1
2000
56
8.0
73.1
35
88
9.6
22.3
0.53
2.9
0.28
0.42
8.2
Table 26
95
11.2
7.5
27.8
25
37
1.4
2.0
0.16
0.9
0.43
0.67
34.2
120
12.8
7.5
29.2
25
39
1.6
2.4
0.17
0.9
0.42
0.65
30.8
150
14.2
7.5
30.8
35
41
1.9
2.8
0.19
1.0
0.40
0.63
28.2
185
15.9
7.5
32.4
35
42
2.1
3.2
0.20
1.1
0.39
0.61
26.3
240
18
7.5
35.1
35
45
2.3
3.8
0.22
1.2
0.37
0.59
23.7
300
20.5
7.5
37.4
35
48
2.6
4.5
0.24
1.3
0.36
0.57
21.5
400
23.1
7.5
40.2
35
51
3.0
5.5
0.26
1.4
0.35
0.55
19.5
500
26.4
7.5
43.6
35
54
3.5
6.6
0.29
1.6
0.34
0.53
17.6
630
30.2
7.5
47.2
35
58
4.0
8.0
0.32
1.8
0.32
0.51
15.5
800
33.9
7.5
51.1
35
63
4.9
10.0
0.36
1.9
0.31
0.49
14.0
1000
37.9
7.5
55.3
35
67
5.7
12.1
0.40
2.2
0.30
0.48
12.9
1200
44
7.5
61.0
35
74
6.6
14.2
0.43
2.3
0.29
0.45
10.9
1400
49
7.5
68.0
35
81
7.4
16.2
0.45
2.5
0.29
0.44
9.6
1600
52
7.5
71.0
35
84
8.1
18.2
0.48
2.6
0.29
0.43
9.1
2000
56
7.5
75.0
35
88
9.6
22.3
0.53
2.9
0.28
0.42
8.2
20
ABB
Crosssection
of conductor
Diameter
of conductor
Insulation
thickness
Diameter
over
insulation
Crosssection
of
screen
Outer
diameter
of cable
Cable
weight
(Al-conductor)
Cable
weight
(Cu-conductor)
Capacitance
Charging
current
per
phase
at 50 Hz
Inductance
Surge
impedance
mm2
mm
mm
mm
mm2
mm
kg/m
kg/m
F/km
A/km
mH/km
mH/km
Table 27
Single-core cables, nominal voltage 60 kV (Um = 72.5 kV)
95
11.2
9.0
30.8
25
39.0
1.5
2.1
0.14
1.7
0.45
0.69
38.0
120
12.8
9.0
32.2
25
41.0
1.6
2.4
0.15
1.8
0.43
0.67
35.1
150
14.2
9.0
33.8
35
43.0
1.9
2.8
0.17
2.0
0.42
0.65
31.9
185
15.9
9.0
35.4
35
44.0
2.1
3.2
0.18
2.1
0.40
0.63
29.8
240
18
9.0
38.1
35
47.0
2.3
3.8
0.20
2.4
0.39
0.61
27.4
300
20.5
9.0
40.4
35
50.0
2.6
4.5
0.22
2.6
0.37
0.59
24.8
400
23.1
9.0
43.2
35
53.0
3.0
5.5
0.24
2.8
0.36
0.57
22.8
500
26.4
9.0
46.6
35
56.0
3.5
6.6
0.26
3.1
0.35
0.55
20.9
630
30.2
9.0
50.2
35
60.0
4.0
7.9
0.29
3.4
0.34
0.53
18.7
800
33.9
9.0
54.1
35
65.0
4.7
9.7
0.31
3.8
0.32
0.51
17.4
1000
37.9
9.0
58.3
35
70.0
5.5
11.7
0.35
4.1
0.31
0.50
15.7
1200
44
9.0
64.0
35
76.0
6.3
13.7
0.40
4.8
0.30
0.47
13.7
1400
49
9.0
71.0
35
83.0
7.4
16.0
0.44
5.2
0.30
0.46
13.0
1600
52
9.0
74.0
35
86.0
8.1
18.0
0.46
5.5
0.29
0.45
12.4
2000
56
9.0
78.0
35
91.0
9.4
21.8
0.49
5.8
0.29
0.45
11.6
Table 28
Single-core cables, nominal voltage 70 kV (Um=84 kV)
185
15.9
10.0
37.4
35
47.0
2.2
3.3
0.17
2.1
0.41
0.63
31.7
240
18
10.0
40.1
35
49.0
2.5
4.0
0.18
2.3
0.40
0.61
29.8
300
20.5
10.0
42.4
35
52.0
2.8
4.6
0.20
2.5
0.38
0.59
27.0
400
23.1
10.0
45.2
35
55.0
3.2
5.7
0.22
2.8
0.37
0.57
24.7
500
26.4
10.0
48.6
35
59.0
3.6
6.7
0.24
3.0
0.36
0.55
22.6
630
30.2
10.0
52.2
35
62.0
4.2
8.1
0.26
3.3
0.34
0.53
20.5
800
33.9
10.0
56.1
35
67.0
4.9
9.9
0.29
3.7
0.33
0.51
18.6
1000
37.9
10.0
60.3
35
72.0
5.7
11.9
0.32
4.0
0.32
0.50
17.0
1200
44
10.0
66.0
35
78.0
6.5
14.0
0.37
4.7
0.31
0.48
14.8
1400
49
10.0
73.0
35
85.0
7.6
16.3
0.40
5.1
0.30
0.47
14.1
1600
52
10.0
76.0
35
88.0
8.3
18.3
0.42
5.3
0.30
0.46
13.4
2000
56
10.0
80.0
35
93.0
9.7
22.1
0.44
5.6
0.29
0.45
12.7
ABB
21
Crosssection
of conductor
Diameter
of conductor
Insulation
thickness
Diameter
over
insulation
Crosssection
of
screen
Outer
diameter
of cable
Cable
weight
(Al-conductor)
Cable
weight
(Cu-conductor)
Capacitance
Charging
current
per
phase
at 50 Hz
Inductance
Surge
impedance
mm2
mm
mm
mm
mm2
mm
kg/m
kg/m
F/km
A/km
mH/km
mH/km
Table 29
150
14.2
14.5
44.8
95
55.0
3.3
4.2
0.12
2.4
0.46
0.65
41.6
185
15.9
14.0
45.4
95
56.0
3.4
4.6
0.13
2.6
0.44
0.65
40.2
240
18
14.0
48.1
95
59.0
3.7
5.2
0.15
2.9
0.43
0.63
36.2
300
20.5
13.0
48.4
95
59.0
3.9
5.7
0.16
3.3
0.40
0.60
32.8
400
23.1
13.0
51.2
95
62.0
4.3
6.8
0.18
3.6
0.39
0.58
29.7
500
26.4
13.0
54.6
95
66.0
4.8
7.9
0.20
3.9
0.38
0.56
27.0
630
30.2
13.0
58.2
95
69.0
5.4
9.3
0.21
4.3
0.36
0.54
25.0
800
33.9
13.0
62.1
95
74.0
6.2
11.1
0.23
4.7
0.35
0.52
22.9
1000
37.9
13.0
66.3
95
79.0
7.0
13.2
0.26
5.1
0.34
0.51
20.7
1200
44
13.0
72.0
95
85.0
7.9
15.3
0.30
5.9
0.32
0.49
18.1
1400
49
13.0
79.0
95
93.0
9.1
17.8
0.32
6.4
0.32
0.48
17.3
1600
52
13.0
82.0
95
96.0
9.9
19.8
0.34
6.7
0.31
0.47
16.4
2000
56
13.0
86.0
95
100.0
11.2
23.6
0.35
7.1
0.31
0.46
15.7
2500
66
13.0
96.0
95
111.0
13.3
28.8
0.40
8.1
0.29
0.41
13.7
3000
72
13.0
102.0
95
117.0
15.2
33.8
0.43
8.7
0.29
0.39
12.7
Table 30
150
14.2
18.5
52.8
95
63.0
4.0
5.0
0.11
2.5
0.49
0.66
46.7
185
15.9
17.5
52.4
95
63.0
4.1
5.2
0.12
2.8
0.47
0.66
44.6
240
18
16.5
53.1
95
64.0
4.2
5.7
0.13
3.1
0.44
0.64
40.8
300
20.5
15.5
53.4
95
64.0
4.3
6.2
0.15
3.5
0.42
0.61
35.7
400
23.1
15.0
55.2
95
66.0
4.7
7.2
0.16
3.9
0.40
0.59
33.0
500
26.4
15.0
58.6
95
70.0
5.2
8.3
0.18
4.2
0.39
0.57
29.8
630
30.2
15.0
62.2
95
74.0
5.8
9.7
0.19
4.6
0.37
0.55
27.6
800
33.9
15.0
66.1
95
79.0
6.6
11.6
0.21
5.0
0.36
0.53
25.2
1000
37.9
15.0
70.3
95
83.0
7.5
13.7
0.23
5.5
0.35
0.51
23.2
1200
44
15.0
76.0
95
89.0
8.4
15.9
0.26
6.3
0.33
0.49
20.5
1400
49
15.0
83.0
95
97.0
9.7
18.4
0.28
6.8
0.33
0.48
19.4
1600
52
15.0
86.0
95
100.0
10.5
20.4
0.30
7.1
0.32
0.47
18.3
2000
56
15.0
90.0
95
105.0
11.9
24.3
0.32
7.5
0.31
0.46
17.2
2500
66
15.0
100.0
95
115.0
14.0
29.5
0.36
8.6
0.30
0.41
15.2
3000
72
15.0
106.0
95
122.0
15.9
34.5
0.38
9.2
0.29
0.39
14.3
22
ABB
Crosssection
of conductor
Diameter
of conductor
Insulation
thickness
Diameter
over
insulation
Crosssection
of
screen
Outer
diameter
of cable
Cable
weight
(Al-conductor)
Cable
weight
(Cu-conductor)
Capacitance
Charging
current
per
phase
at 50 Hz
Inductance
Surge
impedance
mm2
mm
mm
mm
mm2
mm
kg/m
kg/m
F/km
A/km
mH/km
mH/km
Table 31
185
15.9
22.0
62.4
95
73.0
5.0
6.1
0.10
2.8
0.50
0.67
52.3
240
18
20.5
61.1
95
73.0
5.1
6.5
0.11
3.1
0.47
0.65
47.1
300
20.5
19.5
61.4
95
73.0
5.2
7.1
0.13
3.4
0.45
0.62
41.1
400
23.1
18.5
62.2
95
74.0
5.5
7.9
0.14
3.8
0.42
0.60
37.6
500
26.4
17.5
63.6
95
75.0
5.8
8.9
0.16
4.3
0.40
0.58
33.2
630
30.2
17.0
66.2
95
78.0
6.3
10.2
0.18
4.8
0.38
0.55
29.5
800
33.9
17.0
70.1
95
83.0
7.1
12.1
0.19
5.2
0.37
0.54
27.7
1000
37.9
17.0
74.3
95
87.0
8.0
14.2
0.21
5.7
0.36
0.52
25.3
1200
44
17.0
80.0
95
94.0
9.0
16.5
0.24
6.5
0.34
0.50
22.3
1400
49
17.0
87.0
95
101.0
10.3
19.0
0.26
7.0
0.33
0.48
21.0
1600
52
17.0
90.0
95
105.0
11.1
21.0
0.27
7.3
0.33
0.48
20.2
2000
56
17.0
94.0
95
109.0
12.5
24.9
0.28
7.7
0.32
0.47
19.2
2500
66
17.0
104.0
95
120.0
14.8
30.3
0.32
8.8
0.31
0.41
16.9
3000
72
17.0
110.0
95
126.0
16.7
35.3
0.35
9.4
0.30
0.39
15.6
Table 32
400
23.1
22.5
70.2
185
84.0
7.4
9.9
0.12
5.0
0.44
0.61
43.0
500
26.4
21.5
71.6
185
85.0
7.7
10.8
0.14
5.5
0.42
0.59
37.8
630
30.2
20.5
73.2
185
88
8.3
12.2
0.15
6.1
0.40
0.56
34.4
800
33.9
20.5
77.1
185
93
9.2
14.1
0.16
6.6
0.39
0.55
32.0
1000
37.9
20.5
81.3
185
98
10.2
16.4
0.18
7.1
0.37
0.53
29.1
1200
44
20.5
87.0
185
104
11.6
19.0
0.20
8.1
0.36
0.51
26.1
1400
49
20.5
94.0
185
111
12.6
21.3
0.22
8.7
0.35
0.50
24.3
1600
52
20.5
97.0
185
114
13.5
23.4
0.23
9.1
0.34
0.49
23.3
2000
56
20.5
101.0
185
119
15.0
27.4
0.24
9.6
0.33
0.48
22.2
2500
66
20.5
111.0
185
129
17.4
32.9
0.27
10.8
0.32
0.41
19.6
3000
72
20.5
117.0
185
136
19.3
37.9
0.29
11.6
0.31
0.39
18.3
Table 33
500
26.4
25.5
79.6
185
91.0
8.9
12.0
0.12
6.4
0.44
0.60
42.9
630
30.2
24.0
80.2
185
93.0
9.2
13.1
0.13
7.1
0.42
0.57
38.8
800
33.9
23.0
82.1
185
97.0
9.9
14.8
0.16
7.8
0.40
0.55
33.3
1000
37.9
22.5
85.3
185
101.0
10.7
16.9
0.17
8.5
0.38
0.54
30.9
1200
44
22.5
91.0
185
107.0
11.8
19.2
0.19
9.6
0.36
0.51
27.7
1400
49
22.5
98.0
185
115.0
13.2
21.8
0.21
10.4
0.36
0.50
25.7
1600
52
22.5
101.0
185
118.0
14.0
23.9
0.22
10.8
0.35
0.49
24.6
2000
56
22.5
105.0
185
122.0
15.5
27.9
0.23
11.4
0.34
0.48
23.4
2500
66
22.5
115.0
185
133.0
18.0
33.5
0.26
12.8
0.33
0.41
20.7
3000
72
22.5
121.0
185
139.0
20.0
38.6
0.27
13.7
0.32
0.39
19.6
ABB
23
Crosssection
of conductor
Diameter
of conductor
Insulation
thickness
Diameter
over
insulation
Crosssection
of
screen
Outer
diameter
of cable
Cable
weight
(Al-conductor)
Cable
weight
(Cu-conductor)
Capacitance
Charging
current
per
phase
at 50 Hz
Inductance
Surge
impedance
mm2
mm
mm
mm
mm2
mm
kg/m
kg/m
F/km
A/km
mH/km
mH/km
8.3
0.43
0.57
38.2
Table 34
630
21.8
26.0
84.2
185
99.5
9.8
13.7
0.13
800
33.7
24.5
85.1
185
100.9
10.3
15.2
0.15
9.3
0.40
0.54
34.1
1000
37.9
23.5
87.3
185
103.5
11.0
17.2
0.17
10.3
0.39
0.52
30.6
1200
44
23.0
92.0
185
110.6
12.3
19.7
0.19
11.9
0.37
0.49
26.6
1400
49
23.5
100.0
185
117.1
13.5
22.2
0.20
12.6
0.36
0.47
25.1
1600
52
24.0
104.0
185
121.3
14.6
24.5
0.21
12.9
0.36
0.46
24.5
2000
56
24.5
109.0
185
126.7
16.3
28.7
0.21
13.4
0.35
0.44
23.6
2500
66
25.0
120.0
185
138.5
19.0
34.5
0.24
14.8
0.33
0.41
21.3
3000
72
25.0
126.0
185
144.9
21.1
39.7
0.25
15.8
0.33
0.39
20.0
Table 35
630
29.8
31.0
94.2
185
110.2
11.4
15.3
0.12
8.2
0.45
0.57
42.6
800
33.7
30.0
96.1
185
112.7
12.1
17.1
0.13
9.0
0.43
0.54
38.9
1000
37.9
28.5
97.3
185
114.2
12.7
18.9
0.14
10.0
0.41
0.52
34.9
1200
44
27.5
101.0
185
120.3
13.9
21.3
0.17
11.5
0.38
0.49
30.2
1400
49
26.5
106.0
185
123.5
14.6
23.3
0.18
12.7
0.37
0.47
27.4
1600
52
26.5
109.0
185
126.7
15.5
25.5
0.19
13.2
0.36
0.46
26.3
2000
56
27.0
114.0
185
132.0
17.3
29.7
0.20
13.7
0.36
0.44
25.4
2500
66
27.0
124.0
185
142.7
19.9
35.4
0.22
15.4
0.34
0.41
22.6
3000
72
27.5
131.0
185
150.2
22.2
40.8
0.23
16.2
0.33
0.39
21.5
Table 36
24
800
33.7
35.0
106.1
185
123.4
14.0
18.9
0.12
10.7
0.45
0.54
42.8
1000
37.9
33.0
106.3
185
123.8
14.3
20.5
0.13
11.9
0.42
0.52
38.4
1200
44
31.0
108.0
185
127.8
14.8
22.3
0.15
14.0
0.40
0.49
32.8
1400
49
31.0
115.0
185
133.1
16.4
25.1
0.16
15.0
0.39
0.47
30.6
1600
52
31.0
118.0
185
136.3
17.4
27.3
0.17
15.5
0.38
0.46
29.5
2000
56
32.0
124.0
185
142.7
19.4
31.8
0.18
16.0
0.37
0.44
28.7
2500
66
32.5
135.0
185
154.5
22.4
37.9
0.19
17.6
0.36
0.41
26.0
3000
72
33.0
142.0
185
162.0
24.9
43.5
0.20
18.5
0.35
0.39
24.7
ABB
Crosssection
of conductor
Diameter
of conductor
Insulation
thickness
Diameter
over
insulation
Crosssection
of
screen
Outer
diameter
of cable
Cable
weight
(Al-conductor)
Cable
weight
(Cu-conductor)
Capacitance
Charging
current
per phase
at 50 Hz
Inductance
mm2
mm
mm
mm
mm2
mm
kg/m
kg/m
F/km
A/km
mH/km
Table 37
Three-core cables nominal voltage 10 kV (Um = 12 kV)
25
5.8
3.4
14.2
10
41.0
1.2
1.7
0.20
0.3
0.38
35
7.0
3.4
15.4
16
44.0
1.5
2.1
0.22
0.4
0.36
50
8.0
3.4
16.4
16
46.0
1.7
2.6
0.24
0.4
0.34
70
9.6
3.4
18.0
16
50.0
2.0
3.3
0.27
0.5
0.33
95
11.2
3.4
19.6
25
54.0
2.5
4.3
0.30
0.5
0.31
120
12.8
3.4
21.0
25
57.0
2.9
5.1
0.33
0.6
0.30
150
14.2
3.4
22.6
35
61.0
3.4
6.2
0.36
0.6
0.29
185
15.9
3.4
24.2
35
64.0
3.9
7.4
0.39
0.7
0.28
240
18.0
3.4
26.9
35
70.0
4.8
9.3
0.44
0.8
0.28
Table 38
Three-core cables nominal voltage 20 kV (Um = 24 kV)
25
5.8
5.5
18.4
10
51.0
1.7
2.2
0.14
0.5
0.43
35
7.0
5.5
19.6
16
54.0
2.0
2.6
0.16
0.6
0.40
50
8.0
5.5
20.6
16
56.0
2.2
3.2
0.17
0.6
0.39
70
9.6
5.5
22.2
16
60.0
2.6
3.9
0.19
0.7
0.37
95
11.2
5.5
23.8
25
63.0
3.1
4.9
0.21
0.7
0.35
120
12.8
5.5
25.2
25
67.0
3.5
5.8
0.22
0.8
0.33
150
14.2
5.5
26.8
35
70.0
4.1
6.9
0.24
0.9
0.32
185
15.9
5.5
28.4
35
74.0
4.7
8.1
0.26
0.9
0.31
240
18.0
5.5
31.1
35
80.0
5.6
10.1
0.29
1.1
0.30
Table 39
Three core cables nominal voltage 30 kV (Um = 36 kV)
25
5.8
7.5
22.4
10
62
2.4
2.9
0.11
0.6
0.48
35
7.5
23.6
16
65
2.7
3.4
0.12
0.7
0.45
50
7.5
24.6
16
67
3.0
3.9
0.13
0.7
0.43
70
9.6
7.5
26.2
16
71
3.4
4.7
0.14
0.8
0.41
95
11.2
7.5
27.8
25
75
4.0
5.8
0.16
0.9
0.39
120
12.8
7.5
29.2
25
78
4.5
6.7
0.17
0.9
0.37
150
14.2
7.5
30.8
35
82
5.1
7.9
0.18
1.0
0.35
185
15.9
7.5
32.4
35
85
5.7
9.1
0.20
1.1
0.35
240
18
7.5
35.1
35
92
6.7
11.2
0.22
1.2
0.33
300
20.5
7.5
37.5
35
97
9.2
14.8
0.24
1.3
0.31
ABB
25
FORMULAE
Formulae
Formula for capacitance
Where
d0
di
XLPE
PAPER
Formula for dielectric losses
= relative permittivity of the insulation

= external diameter of the insulation (mm)
= diameter of condutor, including screen (mm)
= 2.3
= 3.3
Where U
=
f
=
C
=
tan =
rated voltage (kV)

frequency (Hz)
capacitance (F/km)
loss angle
Formula for inductance
Where trefoil formation: K = 1

flat formation: K = 1.26
s = distance between conductor axes (mm)
r = conductor radius (mm)
Formula for inductive reactance
Where f = frequency (Hz)

L = inductance (mH/km)
Formula for electric stress
Formula for maximum short circuit currents
Conductor screen:
Ish=short-circuit current during time tsh
I1=short-circuit current rating during 1 second. See the 1svalue in tables 15 for the conductor and in Table 16 for
the metal screen.
tsh=short-circuit duration
Insulation screen:
For XLPE insulated conductors the maximum allowable

short circuit temperature is 250oC.
XLPE
di = radius of conductor screen

d0 = radius of XLPE insulation
U = voltage across insultaion
d0
di
Formula for calculation of dynamic forces between

two conductors
Where; Ipeak=
Ish=
S=
F=
26
2.5 Ish [kA]

Short current [kA] RMS
Centre to centre spacing between
conductors [m]
maximum force [N/m]
ABB
SUPPORT
Support
The transmission network in most countries is very large
and complex. It may incorporate different systems e.g. different types of over-head lines systems, fluid-filled cable
systems and extruded cable systems. Sometimes both AC
and DC-systems are present as well as both land and
submarine cable systems.
ABB experienced project managers, technical specialists
and other staff will give their professional support in this
evaluation of suitable solutions. We aim to offer the most
optimal solution and we can supply the complete underground or submarine cable system which can include:
Power cables for underground or submarine
applications
Cable accessories
Control- and telecommunication cables
System design for network optimisation
Project management
Civil works
Installation and supervision
Testing and start-up operations
Disassembly and recovery of old cables
Fault location and repair
Maintenance of fluid-filled systems
Leasing of installation equipment
Training
NOTE: All figures given in this brochure are non-binding
and indicative only
ABB
27
Elanders Novum, Vsters 0306

2GM 5007 GB.pdf
For additional information please contact

your local ABB Sales Office or visit us under
www.abb.com/cables

XLPE Cables ABB Guide Line

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XLPE Cable Systems

Cable drums ....................................................................... 14

XLPE cable systems - design, installation and testing....... 4

Selection of cable drum .................................................... 15

XLPE Cable Systems

XLPE cables .........................................................................

Sizes and weights of wooden drums.....................................

Testing of XLPE cable systems..............................................

XLPE cable system configurations...................................... 7

Conductor water sealing .......................................................

Current rating for XLPE cable systems ............................... 8

XLPE insulation ................................................................. 17

Current rating for three-core cables, ampres ......................

Insulation screen ...................................................................

Current rating for single-core cables, ampres ................... 9

Rating factors ................................................................... 11

Copper wire screen, standard design....................................

Rating factor for cross section area of metal screen ..........

Copper wire screen, water tight design .................................

Rating factors for cables in the ground ..............................

Rating factor for cables in pipes in the ground............... 12

Copper tape screen ..............................................................

Example of the use of rating factors ..................................

Non-metallic outer sheath ................................................. 18

Conductive outer layer ..........................................................

Short-circuit currents ............................................................

Flame retardant outer layer....................................................

Maximum short-circuit currents due to thermal restrictions..13

Fire behavior ...........................................................................

Dynamic forces at short circuits ............................................

To make sure you have the latest version of this

XLPE Cable Systems

ABB manufactures underground and submarine power

We have extensive experience of cable projects all over the

ABB has always been a pioneer in the high voltage field

requirements from the power industry and a deregulated

Experience and state-of-the-art expertise go hand in hand

XLPE CABLE SYSTEMS - DESIGN, INSTALLATION AND TESTING

XLPE cable systems design, installation and testing

XLPE CABLE SYSTEMS STANDARD DESIGN AND OPTIONS

Installation of XLPE cable systems

Testing of XLPE cable systems

XLPE CABLE AND CABLE SYSTEM STANDARDS

XLPE cable and cable system standards

Some frequently used standards are:

ISO 14001 Certificate of Approval

ISO 9001 Certificate of Approval

XLPE CABLE SYSTEM CONFIGURATIONS

XLPE cable system configurations

Bonding of the metallic screens

CURRENT RATING FOR XLPE CABLE SYSTEMS

Current rating for XLPE cable systems

Current rating for three-core cables, ampres

Rating factors for single-core cables are given in Tables 6

CURRENT RATING FOR XLPE CABLE SYSTEMS

Current rating for single-core cables, ampres

Segmental conductor for 1200 mm2 or more.

CURRENT RATING FOR XLPE CABLE SYSTEMS

Segmental conductor for 1200 mm2 or more.

CURRENT RATING FOR XLPE CABLE SYSTEMS

10-70 kV 35 mm2 screen

110-500 kV 95 mm2 screen

Rating factor for tables 2 and 3

Rating factor for tables 4 and 5