Professional Documents
Culture Documents
J. Becker (Belgium)
J-L. Parpal (Canada)
M-H. Luton (France)
R. Schroth (Germany)
B. Parmigiani (Italy)
S. Katakai (Japan)
H.Geene (Netherlands)
J. Svahn (Sweden)
J. Head (United Kingdom)
CONTENTS
1
SUMMARY.....................................................................................................................................................................2
INTRODUCTION........................................................................................................................................................2
BASIC CONSIDERATIONS............................................................................................................................................ 4
CONCLUSIONS............................................................................................................................................................. 4
BASIC CONSIDERATIONS............................................................................................................................................ 3
CONCLUSIONS............................................................................................................................................................. 3
CONCLUSIONS ...........................................................................................................................................................5
1
b1.cigre.org/content/download/2237/26730/.../CIGRE+TF+B1-10ID44VER24.pdf
1 Summary
On request of IEC TC 20 a Task Force TF 21(B1)-10 was launched by SC 21 in 2001 with the
scope to review whether or not existing HV cable test specifications would appropriately
specify and verify the crucial thermal and thermo-mechanical characteristics of accessories.
TF B1-10 finished its work on schedule in 2003 with the following conclusions:
Thermal ratings of accessories need not be specified separately from cables, as they
are considered identical due to the presence of cable inside the accessory.
The successful completion of IEC thermal tests at a complete cable system can be
considered as simultaneous verification of the adequate thermal design of both, cables
and accessories, provided that comparable or higher conductor temperatures as rated
for the cable are achieved inside joints. These test conditions shall be realized by
applying only cable conductor current heating.
The thermal performance of terminations in normal operation is not considered
critical; therefore they do not have to reach the rated temperature for the cable during
test.
External thermo-mechanical forces can be reproduced in the IEC prequalification test
only for the specific installation conditions applied.
The thermal limits of accessories and external thermo-mechanical forces in service
operation cannot be reproduced comprehensively by standardized tests, but have to be
taken into account for each individual case by the systems design engineering.
will tend to reduce the conductor temperature within a joint in comparison to the
temperature of the remote cable conductor.
Some cable systems with additional thermal insulation may require extended heating (and
cooling) cycles.
Thermo-mechanical
ratings of accessories
External thermo-mechanical
(and other mechanical) forces
on accessories have to be
considered by systems design
engineering taking into
account:
the value of admissible
mechanical forces acting
on the accessory, to be
provided by the
accessorys supplier.
the thermo-mechanical
characteristics (e.g.
bending moments,
allowable thrust) of the
Figure 2. Joints in manholes, installed with wider spacing
cables involved, to be
provided by the cables
supplier.
the actual installation conditions, (annex 4).
6 Conclusions
Thermal ratings of accessories need not be specified separately from cables, as they are
considered identical due to the presence of cable inside the accessory.
The thermal performance of terminations in normal operation is not to be considered critical;
therefore they do not have to reach the rated temperature for the cable during test.
The successful completion of IEC thermal tests at the complete cable system can be
considered as simultaneous verification of the adequate thermal design of both, cables and
accessories, provided that comparable or higher conductor temperatures as rated for the cable
are achieved inside joints. These test conditions will be achieved by applying cable conductor
current heating only.
For the heating of cables and accessories during type test, the following clause is
recommended to IEC:
2.
3.
4.
2m
Tj
Tc
Tc
100
90
Temperature (C)
80
70
60
joint
cable
50
40
30
20
10
0
0
10
Time (hours)
Conclusion
In stationary conditions, the joint reached a higher temperature than the cable, as a result of higher thermal
resistance of the joint. In the first 6 hours of the heating cycle, the temperature in the joint is lower than in the
cable due to the longer thermal time constant of the joint.
Annex 1. (continued)
Example 2: Thermal behavior of a 400 kV joint during IEC loading cycles in air
1 Introduction
In order to evaluate the temperature difference between a 400 kV cable and the relevant premoulded joint during
the heating cycle voltage test, specified in IEC 60840 and 62067, thermal calculations have been carried out
using the finite element method.
The test loop assumed for the calculation is installed in air and includes 20 m of cable and a 400 kV premoulded
joint complete with its anticorrosion protection. The length of cable is such that the presence of the joint does not
affect the asymptotic temperature of the cable.
Due to the use of the FEM method, the joint is subdivided in finite elements where both radial and longitudinal
heat transmission is taken into account.
During the heating cycle test the cable conductor is heated by conductor current in order to reach in 6 hours a
conductor temperature of 95 C (far from the joint), followed by 2 hours where the current is reduced in order to
maintain the cable conductor temperature between 95 C and 100 C, then the current is switched off for 16
hours still maintaining the voltage on. This cycle under constant voltage of 2 Uo is repeated for 20 times.
The calculation has been made for 400 kV XLPE cables with a 1600 mm2 and a 2500 mm2 copper conductor.
Both conductor losses and dielectric losses have been considered in the calculation.
2 Loading cycle temperature profile calculation
2.1 2500 mm2 Cu 400 kV cable and joint
During the loading cycles a constant current of about 3450 A is circulated in the conductor, so that a temperature
of 95 C is reached in the cable conductor after 6 hours, starting from a uniform ambient temperature of 20 C.
Then the current is reduced in order to maintain the temperature in the cable conductor between 95 C and 100
C for two hours. Subsequently the conductor current is switched off for 16 hours.
The results of the calculations of the cable and joint daily cycles are shown in Figure 4.
It can be observed that initially the joint ferrule temperature is slightly lower than 95 C, then it increases and
reaches a stable value of about 101 C after four cycles.
2.2 1600 mm2 Cu 400 kV cable and joint
The initial conductor current in order to bring the cable conductor temperature to 95 C after 6 hours (including
dielectric losses) is of about 2500 A. The results of the joint and cable load cycle calculation are shown in Figure
5.
It can be observed that the temperature of the joint has the same behavior as in Figure 4, i.e. the periodic
asymptotic temperature in the joint is reached after 4 cycles, but its value is a little smaller (99 C instead of 101
C).
4 Conclusions
During IEC loading cycles, with only conductor current heating, the joint ferrule temperature of a 400 kV joint
follows the cable conductor temperature with a certain delay due to the higher thermal time constant of the joint
compared to the cable.
However, after about 4 cycles also the joint reaches stable periodic conditions with a maximum temperature
generally slightly higher than that of the cable conductor.
These conclusions depend on the design of the joint. Joints longer than the one considered in these calculations
or with thicker insulation would present a higher time constant, so that stable cycle conditions for the joint would
be reached after more than 4 cycles, but certainly within the 20 IEC cycles.
The higher periodic temperature in the joint is also due to the fact that, during the type test, the joint is provided
with the thick outer protection foreseen for the underground installation (as in the case of these calculations),
while for actual installations in air the casing is normally unprotected.
110
100
Temperature (C)
90
80
70
60
joint
cable
50
40
30
20
10
0
0
10
20
30
40
50
60
70
80
90
100
Time (hours)
Figure 4. Loading cycles (8 hours on, 16 hours off) on a 400 kV 2500 mm Cu cable and joint
110
100
Temperature (C)
90
80
70
60
50
joint
cable
40
30
20
10
0
0
10
20
30
40
50
60
70
80
90
100
Time (hours)
Figure 5. Loading cycles (8 hours on, 16 hours off) on a 400 kV 1600 mm Cu cable and joint
10
Annex 2. Overview of international standards on thermal aspects of accessories (as a result of a questionnaire under the members of the
Task Force)
Standards, relevant statements on thermal ratings and testing of accessories
Standard
BS 7912
(UK)
BS 7912 (Implementation of HD 632): the method for heat cycling assemblies containing accessories is
The assembly shall be heated until the cable conductor reaches a steady temperature 5C to 10C above the maximum conductor temperature in normal
operation. The heating arrangements shall be selected so that the cable conductor attains the temperature specified in this sub clause, remote from the
accessories and as far as practicable, also within the accessories.
EATS 09-16
(UK)
EATS 09-16 is the more widely used document which effectively expands on the requirements of the above BS. The latest revision of this, which is
still in draft form states:
The load cycle test shall be carried out as in clause 16.4 of BS 7912 except that the details of heating given in the last two sentences (i.e. the 2
sentences quoted from BS 7912 above) shall be replaced by the following:
The heating arrangements shall be selected so that the cable conductor attains the temperature specified above, remote from the accessories, and as far
as practicable, the conductor temperature in accessories shall reach at least the rated temperature of the accessory plus 5o C to 10 o C. The rated
temperature of the accessory shall have been declared previously by the supplier (the value shall be no lower than the maximum cable conductor
temperature in normal operation).
Alternatively, the test installation shall be heated by conductor current alone, until the cable conductor remote from the accessories reaches a steady
temperature of 5 o C to 10 o C above the maximum cable conductor temperature in normal operation. No thermal insulation or means of cooling or
further forms of heating shall be used.
NEN 3629
(Netherlands)
Thermal properties
According to this standard, in normal operation a conductor temperature of max 90C and during short-circuit (duration max 5 sec) of 250C is
acceptable.
Heating cycle voltage test with 30 cycles.
IEEE 48-1990
(USA)
IEEE standard test procedures and requirements for high-voltage alternating-current cable terminations
4. Rating
Note: regarding the continuous current rating (ampacity). The application of various types of cable terminations requires engineering consideration as to
the ampacity of the completed installation. A cable termination by itself cannot be assigned a design or nominal current or ampacity rating since this
11
parameter is completely dependent upon the type of cable insulation, the maximum allowable cable conductor temperature for the type of cable
insulation involved, and the anticipated maximum ambient temperature of the medium surrounding the termination
.
The supplier of cable terminating devices or material should be consulted for the ampacity of the design for the intended application with specific type
and size of cable.
.
7.4.2 Cyclic aging test
(Conductor heating is required. There shall be no current in the cable metallic shield.)
7.4.2.3
During the current-on period, the cable conductor temperature midway between the terminations shall be within 5 C of the cables maximum rated
emergency operating temperature for a period of 6h.
IEEE 4041993
(USA)
Note: the cyclic aging test is not intended to establish current rating for a termination (see section 4. Rating)
IEEE standard for cable joints for use with extruded dielectric cable rated 5000-138000V and cable joints for use with laminated dielectric
cable rated 2500-50000V
4.2 Unusual service conditions
12
SS 424 14 17
(Sweden)
Power cables XLPE-insulated cables with extruded over sheath and rated voltage 12-420 kV Testing
Load cycling:
Conductor temperature: 100-105o C. Achieved by a suitable method (no specifications)
Heating during at least 8 h and natural cooling during at least 16 h. The conductor temperature shall be between 100o C and 105o C during the
last 2 h of the heating period.
NF C 33-061
September
1999
(France)
NF C 33-062
September
1999
(France)
Joints for single-core cables with polymeric extruded insulation for rated voltages
above 30kV (U m = 36kV) up to 500kV (Um = 525 kV)
SF6 insulated metal enclosed terminations for single-core cables with polymeric
extruded insulation for rated voltages above 30kV (Um = 36kV) up to 500kV (U m =
525 kV)
6 Type tests:
"In case of temperature of the conductor is specified, its value
shall be obtained by circulation of adequate current in the cable
conductor"
" For tests requiring an increase of the cable conductor
temperature, this temperature can be obtained, if necessary, by
thermal insulation of the cable, in order not to induce a current
ampacity either too high or too low, non representative of normal
operation."
Long term test:
Thermal cycles:
Cycle time: 8h of heating and 16h of cooling.
Current applied to raise the conductor to a temperature up to 0C
to 10C higher than the maximum normal operating
temperature, for the first 167 cycles and up to 0C to 5C higher
than the maximum emergency overload temperature, during
the remaining 83 cycles.
13
NF C 33-063
September
1999
(France)
NF C 33-064
September
1999
(France)
C 33-065
February
2001
(France)
14
Annex 3. Guide to aid development engineers for testing the thermal properties of joints
Introduction
The aim of the guide is to give the development engineer some recommendations on how to measure the thermal
characteristics of a prefabricated joint in transient and steady state conditions.
Test installation
The test loop has to contain at least 15 m of cable and one joint. The distance between the joint and cable ends
has to be at least 5 m. No direct contact of the cable or joint with the lab floor is allowed. It is important that
cable and joint should be subjected to the same thermal ambient conditions. No additional thermal insulation
should be applied.
Thermocouples (or other temperature sensors) should be installed in the following positions:
at the cable, at least 5 m from the joint and 5 m from the cable end,
o on the conductor
o on the metallic sheath
o on plastic outer sheath
at the joint in the middle,
o on connector in the joint
o on metallic casing or metallic screen
o on insulating cover
near to the test loop to record the ambient temperature
Thermal test
The heating current shall be applied for at least 24h until the cable conductor, remote from the accessories,
reaches a steady temperature of at least 5C above the maximum conductor temperature in normal operation for
the cable. During the entire heating period, the temperatures shall be recorded. No other means than current
heating shall be used.
Test results
From the recorded heating curves the following characteristics can de calculated:
The thermal resistance between conductor and outer covering of the joint (deduced from the ratio
between the steady state temperatures)
The thermal resistance between the conductor and outer covering of the cable (deduced from the ratio
between the steady state temperatures)
Thermal time constant of the cable
Thermal time constant of the joint
15
Annex 4. Guide to aid design engineers in the correct design of systems: Thermal and
thermo-mechanical aspects of accessory performance
Introduction
The aim of the guide is to give the design engineer some recommendations regarding important thermal and
thermo-mechanical characteristics to check on accessories.
When possible or appropriate, the guide indicates the way to control or measure the described characteristics.
References
This guide has been established taking into account the recommendations and guidelines included in the
following documents:
Cigr WG 21-09 : Electra No. 140, February 1992
Considerations of ageing factors in extruded insulation cables
16
Annex 4 (continued)
Table 1: Characteristics to control or tests to perform for assessing the reliability of accessories on cable systems
Constraints
Steady-state
operation
Constraints Classification
Mechanical Thermal Thermo mechanical
X
X
X
X
Overload
Earthquake
Special
environments
X
X
Others
Angle of installation of terminations
Transition between ducts and manholes
Transition between flexible and rigid systems
(open air)
X
X
X
IEC tests
17