Professional Documents
Culture Documents
Cat-Ehv1 CCI Make
Cat-Ehv1 CCI Make
EHV
CABLES
I N TR OD UC TI ON
As India marches towards the 21 s t century, power becomes an essential ingredient for infrastructural development. W ith rapid urbanisation around the corner to sustain the industrial growth, the necessity of transmitting large blocks of power to load centres assumes significance. Over the years, there has been a marked increase in the voltage level for transmission of bulk power, due to the distinct advantages offered by the use of high voltage. This had ushered in the generation of Extra high voltage (EHV) power transmission systems with voltage grades of 66 kV and above. In this context, long-distance underground cable networks provide an ideal solution in many situations where the safety and logistic considerations preclude the use of cross-country overhead tower lines. Underground EHV cables are also used for evacuating bulk power generated in pumped storage hydroelectric power generating stations, situated at a lower altitude, at outdoor switchyard located at a higher altitude. Similarly, underground cable systems are the appropriate means of power transmission over short distances where erection of overhead tower lines would be infeasible considering the space constraints. The distinct advantages in achieving low transmission losses when such cable systems are operated at higher voltages for bulk power transfer are well-known. It is in this context that Cross-linked Polyethylene (XLPE) insulated cables offer significant advantages. As an insulating material, XLPE combines the advantages of improved mechanical and thermal properties with excellent electrical characteristics of high dielectric strength, low relative permittivity and low loss factor. These advantages have rendered what XLPE cables can achieve today carrying large currents at voltages upto 220 kV and above, with an inherent higher short circuit withstand capacity of 250 o C. Additional benefits that accrue are simple construction, easy installation and trouble free operation.
T Y P I C AL C O N S T R U C T I O N
EHV XLPE cables are manufactured generally in accordance with IEC:502 and IS:7098 (Part 3) standards. The typical constructions and their salient features are as shown below. Features of Metal Laminate Sheathed Cable
1. 2. 3. 4. 5. 6.
Im perv ious to ingress of w at er. Layer is very thin, hence com pac t cable. Lighter in weight. Sm aller diam eter as com pared at m et allic sheathed cable. Additional copper wires s creen is necessary t o carry earth fault current. Larger delivery length and hence les s number of joints .
4.
T H E M AN U F AC T U R I N G P R O C E S S
For bulk power transmission, in addition to using higher voltages, higher ampacity is equally Cable Corporation of India Ltd. Offers two distinct technologies, both systems XLPE employing for the dry curing of The
necessary. To meet this need, use of conductor with higher crosssections is imminent. For
production cables.
insulated
extruded core in the Continuous Catenary Vulcanising (CCV) line is subject to gravitational force which handling poses cores limitations having a in
conductor construction is suitable. However, above for conductor sq mm, sizes use of
1000
larger
segmental conductor construction (also called Milliken conductor) is recommended skin effect. to overcome has the the
with finished cores which many not have a fully concentric shape after cross-linking particularly for large cross-sections, thereby
CCI
resulting
in
installation
and
larger cores, the MDCV process is known worldwide for making highquality 400-500 XLPE kV cables range, even with upto no
limitations of conductor size upto 2000 sq.mm. W ith this technology, CCI has joined a select group of international manufacturers in the field of super tension XLPE
conventional CCV line may not be adequate. It is for this reason that CCI has adopted MDCV a special process
patented
cables.
Unique
features
of
the
Continuous Vulcanising (MDCV) line for EHV cables, which is the first of its kind in Asia, outside Japan. The heart of the system is a unique Long Land Die (LLD), inside carried which out cross-linking under is 2)
specially
MDCV Process The plant has a horizontal layout, as a result of which the conductor as well as the extruded core can remain in a straight line without
bending or sagging, thereby permitting manufacture cables. Cross-linking in Long Land Die under strict process of stabilised large-sized
at
elevated
temperatures, void-free,
special constitute
techniques the
which of
ensures
hallmark
the process. The conductor and insulation (core) is fully supported in the LLD, and as such, the tendency of the core to sag is avoided inside the straight and horizontal LLD. is of
conductor screen, insulation and insulation screen in one single operation ensures
perfect bonding without any surface irregularities. 4) Further achieved perfection by the use
T E S T I N G AN D Q U AL I T Y C O N T R O L
satisfactorily run through the tests conducted Netherlands at (an NV KEMA,
independent
testing laboratory and a research organisation repute), successfully Super Tension XLPE Cables from CCI are manufactured in-process with quality CCI EHV cables have also passed rigorous tests conducted at the Central Power Research Institute (CPRI) with satisfactory results. CCI has to sophisticated undertake basic and care of commissioned Board in India. and of international has installed at an been and
Electricity
stringent
requirements in accordance with the latest like international IEC:840/1988 Standard and our own
specification and
Swedish
research to take
specification
3)/1993. are
Reference in
voltages no.1.
indicated
development work in the field, the Company has set up ultramodern test facilities which permit long term performance evaluation and
Our 220 kV cable, the first ever to be made in the country, has
equipment are listed below. High Voltage and Discharge Equipment Capacity : 400 kV System Type Features Room, : Double Shielded graphic : Series Resonance Partial
Features
Suitable
for
lightning impulses 1.2/50 micro seconds. Heat Cycle Equipment Capacity : 30 V, 4000 Amps, 120 kVA Current transformer Features : Can perform Heat Cycle test as per IEC:840 in combination with High Voltage Test. DC High Voltage Equipment Capacity Generator Features : Suitable for after tests on cables : 400 kV DC
Facilitates
recording of PD.
Companys is
electrical as a
laboratory testing
accredited by
laboratory
NABL
Laboratories), Govt. of India. Our in-house R & D unit is recognized by the Department of Scientific & Industrial Research, Ministry of
1994.
E H V C AB L E AC C E S S O R I E S
normally
Joints
and
termination
are
Taped type : Currently applied this upto techniques 132 kV. is Self
transformer
outdoor power distribution. Straight Through Joints : This could be normal or insulated type depending on whether is
amalgamating tapes are used for both insulation steps the and followed cable. shield; are to
basically
metallic
sheath/screen
Purity, are
interrupted or not for bonding purposes. Link Boxes : These are used at terminations or joints for
homogeneity
factors.
W orkmanship
carried out in a clean controlled environment. From 170 kV to 245 kV however, to achieve proper homogeneity & pressure at interface, field
arrangement
for
stress
control
electrodes, the field strengths are kept below the working level. Premoulded stress cone for
termination and sleeve for joints have embedded electrodes. These prefabricated parts are placed on cable insulation The to with an
expansion. ensures
pressure of
rapidly come into use; precision, factory pretested finished quality products, and rapid,
cable
surface. parts
prefabricated
also take care of expansion of cable during load cycle and under short circuit this is due to the elasticity of elastomeric
simple installation being distinct features. Termination have been developed and are in use upto 400 kV; joints are in use upto 245 kV. For 400 kV test is going on. The accessories are designed for 3 main stresses and electrical, Large
prefabricated stress cone / joint body. For the stress cone / joint body either silicon or EPDM
thermal
mechanical.
for stress grading. For outdoor cable terminations, a new type of is insulator now in besides The
field non-homogenates and high field strengths occur at interface of cable & accessories; by
porcelain
use.
composite insulator is an epoxy tube reinforced with fibre glass and fitted with elastomeric sheds. The chief advantages are. Light W eight, not prone to
Creepage
distance
can
be
increased as required. Does not blow apart even in case of inner flashover.
damage, sabotage.
T E C H N I C AL P AR T I C U L AR S
The EHV cable system has to be considered in its totality, and viewed from both design and installation considerations so as to serve the end use effectively and in an optimum manner. More often than not, the installation parameters, suitably selected, provide the guiding principle for working out design solutions. Installation conditions such as depth of laying, laying formation, screen bonding systems and the environment, all play an important role in determining the current carrying capacity vis-vis economical selection of the conductor size. The EHV cable system is generally custom designed to suit the application. As a result, the cable construction is mutually agreed upon by the customer and the
manufacturer. EHV cable design is not restricted to the design of the EHV cable as a product; a system perspective has to be adopted and as such EHV orders are invariably handled as turnkey assignments. The key technical features are shown in Tables 2 to 5. The current ratings for various conductor sizes and voltage grades are shown in Tables 6 to 8. These are based on standard conditions of installation as mentioned below.
1) 2) 3) 4) 5) 6) Maximum continuous operating conductor temperature : 90 o C Standard ground temperature : 30 o C Ambient air temperature : 40 o C Thermal resistivity of soil : 150 o C cm/W att Depth of laying : 150 cm Trefoil f ormation : For Cables in close touching, Transposition not applicable
Flat formation : Cables laid with gap, centre to centre spacing being 2D, where D = overall diameter of cable without transposition in case of both end bonding. Transposition not applicable in case of single end bonding.
In selecting the starting conductor size of different voltage grades of super tension cables, Bureau of Indian Standards (BIS) guidelines which specify the corresponding minimum conductor cross sections have been followed. All current ratings have been computed considering screen cross-sections suitable for short circuit current of 31.5 kA for one second duration. The assumptions is in accordance with the general engineering practice
employed in the country for electrical systems which are solidly earthed. For any other short circuit rating of screen, corresponding values of current rating can be furnished on request. Rating Factors For installation conditions other than standard, rating factors will apply as given in Tables 9 to 14. Short Circuit Rating Thermally admissible short circuit current ratings for TROPOTHEN-S Cables are given in Table 3. The computations are based on full load conductor temperatures of 90 o C at the inception of short circuit, and build up to maximum temperature of 250 o C at the end of short circuit. For any other duration t second/s divide the value given in respective table by t.
SCREEN BONDING METHODS 1. The Both End Bonding system and depicted earthing involves of cable 2. Special Bonding Systems bondign developed systems to have keep
Special been
bonding
screens at both ends to form part of a closed loop which linked by a is with the
circulating current losses to the minimum. follow are : a) Economical conductor size Advantages which
conductors.
system, b)
ciruclating currents are set up in the cable screen, resulting in heat loss and consequent derating of current carrying capacity. Such
losses are minimized when cables are laid in trefoil close-touching formation, but increase with the spacing between cables.
Special
bonding
is
generally
cable circuits. In such a system, standing voltages will appear in the cable screen which needs to be adequately insulated. Further, from the safety angle, a limiting value of such voltages becomes important. For the purpose,
screen
circulating
specially designed Sheath Voltage Limiters restrict particularly (SVL) the which serve to
limited
lengths to keep the standing voltage to the minimum and render the cable installation safe voltage. b) Cross Bonding Cross bonding of essentially against touch
voltage under
rise, transient
consists the
screens are connected and earthed at one end of the route. At all other points, the screen being insulated from earth will have a
cable
elementary minor
sections
connecting them so as to neutralise the total induced voltage in three consecutive sections. sections Three together minor make a
standing voltage which will be proportional to the circuit length, conductor current
major section.
the three geometrical positions in the laying formation. This results In cross bonding system, the in balancing of induced voltages in the screen because of equal relative proximity of each single core cable with respect to the other.
route is split up into groups of three screens drum lengths and with the
bounded
earthed
connected in series at all other points. The purpose is to allow a standing voltage between screen and earth in each major section but eliminate circulating currents. W ith such an arrangement, the current carrying capacity can be considerably particularly for large enhanced conductor
Laying Methods
As
dicussed
in
the
preceding
paragraphs, cables can be laid in trefoil or flat formation, depending upon end design use requirements and
suitability.
Installation
conditions play a major role in optimising the performance of an EHV cable circuit, as also
rendering it safe for long term reliability and utmost in usage. care For is an to the be
W hen
cable
are
lain
in
flat is
purpose, exercised
formation,
transposition
handling
EHV
resorted to, so that each phase cable is arranged to occupy over equal lengths of the route, each of
cable installation so that it can serve its useful life to the fullest extent.
Standard
methods
of
laying
guidelines for which are available from Codes of Practice formulated by the BIS. Attention in particular needs to be paid to the
consolidation of the surrounding soil environment in direct burial conditions for improvement of
Bending Radius W hile cables, bending installing TROPOTHEN-S the following minimum be
radius
should
observed for single core cables, so that the cable and especially the insulation are not unduly
T O T AL C A B L E S E R V I C E
oversee installation the work. entire CCI is cable also
execution of a cable installation project starting with route survey, subsequent jointing CCIS responsibility does not end with supply of cables and jointing accessories only, but extends to assisting customers in installing maintenance-free cable network. and cable final of has laying testing the a and and
installed team of
The
Company
is
committed
to
The
importance
of
synergy
between
and an
installation
parameters
apart from design, selection and supply of cables, installation of the cable system as a whole,
EHV cable system involves the application of integrated Project Engineering solutions for from finding concept total to
including
pre-commissioning
tests. In its simplest from, this may mean the presence of CCIs Service Engineer at site, to
commissioning. CCI has a Special Cell looking into this aspect to render all necessary assistance in
of
all
aspects A with
of
and
installation. installation
typical cables
CCIs Total Cable Service concept means total responsibility for a project so as to offer a
alongwith
protection
measures
Ra t ed vo l t a ge of c ab l es
I mpu l s e wi t hs t and t es t
1. 5 Uo kV 57 96 114 190
Uo kV 38 64 76 122
A pp. A. C . r es i s t anc e of c on duc t or at 90 D eg. Ce nt i gr ade Co pper c on duc t or ohm/ k m 0. 2 460 0. 1 960 0. 1 590 0. 1 270 0. 0 972 0. 0 780 0. 0 618 0. 0 491 0. 0 393 0. 0 322 0. 0 236 0. 0 207 0. 0 163 0. 0 138
A l umi ni u m c on duc t or ohm/ k m 0. 3 200 0. 2 530 0. 2 060 0. 1 640 0. 1 250 0. 1 000 0. 0 778 0. 0 605 0. 0 469 0. 0 367 0. 0 291 0. 0 247 0. 0 186 0. 0 149
Co pper c on duc t or ohm/ k m 0. 1 930 0. 1 530 0. 1 240 0. 0 991 0. 0 754 0. 0 601 0. 0 470 0. 0 366 0. 0 283 0. 0 221 0. 0 176 0. 0 151 0. 0 113 0. 0 090
A l umi ni u m c on duc t or ohm/ k m 0. 4 110 0. 3 250 0. 2 640 0. 2 110 0. 1 610 0. 1 290 0. 1 010 0. 0 791 0. 0 622 0. 0 497 0. 0 380 0. 0 326 0. 0 251 0. 0 207
95 120 150 185 240 300 400 500 630 800 1000 1200 1600 2000
S hor t C i r c ui t Ra t i n g f or 1 S ec . Cu k A ( r ms )
A l k A( r ms )
95 120 150 185 240 300 400 500 630 800 1000 1200 1600 2000
8. 9 3 11. 30 14. 10 17. 40 22. 60 28. 20 37. 60 47. 00 59. 20 75. 20 94. 00 112. 80 150. 40 188. 00
13. 58 17. 16 21. 45 26. 45 34. 32 42. 90 57. 20 71. 50 90. 10 114. 40 143. 00 171. 60 228. 80 286. 00
No mi nal Thi c k ne s s o f I ns ul a t i o n
0. 1 35 0. 1 40 0. 1 50 0. 1 65 0. 17 5 0. 1 90 0. 2 05 0. 2 25 0. 2 45 0. 2 70 0. 2 95 0. 3 25
0. 1 30 0. 1 40 0. 1 50 0. 1 65 0. 1 75 0. 1 90 0. 2 05 0. 2 25 0. 2 45 0. 2 70 0. 3 00
0. 1 25 0. 1 35 0. 1 45 0. 1 55 0. 1 70 0. 1 85 0. 2 00 0. 2 20
95 120 150 185 240 300 400 500 630 800 1000 1200 1600 2000
Both End Bonding Trefoil Formation In Ground Aluminium Amp 191 215 239 267 305 339 380 424 471 516 554 587 639 678 Copper Amp 242 272 301 334 378 417 461 507 554 595 631 660 704 736 In Air Aluminium Amp 267 307 345 391 456 516 593 678 772 866 961 1048 1176 1285 Copper Amp 341 390 437 494 571 642 728 821 920 1013 1115 1198 1317 1415 In Ground Aluminium Amp 189 211 231 255 284 309 337 365 391 415 437 453 474 490 Copper Amp 234 258 281 305 335 359 384 407 429 447 465 477 493 505 Flat Formation In Air Aluminium Amp 284 324 362 408 469 524 591 662 737 806 884 946 1030 1101 Copper Amp 357 404 449 501 570 629 697 767 837 900 976 1032 1105 1166
95 120 150 185 240 300 400 500 630 800 1000 1200 1600 2000
Not e : The abov e c urrent ratingsc orrespond t o a m etallic sheat h/ sc reen short c irc uit current capability of 31. 5 kA For one second durat ion. For any v ariation f rom this v alue of s hort circ uit current and duration, k indly refer to us.
185 240 300 400 500 630 800 1000 1200 1600 2000
Both End Bonding Trefoil Formation In Ground Aluminium Amp 268 306 341 383 428 475 522 559 593 645 685 Copper Amp 336 381 421 466 513 561 605 639 668 713 746 In Air Aluminium Amp 390 455 516 593 679 775 871 970 1057 1190 1303 Copper Amp 494 574 646 735 830 933 1030 1138 1222 1347 1449 In Ground Aluminium Amp 256 286 312 341 369 396 420 443 459 480 496 Copper Amp 308 338 363 389 414 436 454 473 485 500 512 Flat Formation In Air Aluminium Amp 403 465 521 591 664 741 815 897 961 1050 1123 Copper Amp 499 570 632 705 778 853 920 1003 1060 1137 1200
185 240 300 400 500 630 800 1000 1200 1600 2000
Not e : The abov e c urrent ratingsc orres pond to a met allic s heath/ sc reen short c ircuit c urrent c apabilit y of 31.5 kA For one second durat ion. For any v ariation f rom this v alue of s hort circ uit current and duration, k indly refer t o us.
Both End Bonding Trefoil Formation In Ground Aluminium Amp 384 429 478 525 562 595 643 670 Copper Amp 469 518 566 612 646 674 713 728 In Air Aluminium Amp 589 674 770 869 971 1059 1188 1286 Copper Amp 734 831 935 1038 1152 1237 1358 1440 In Ground Aluminium Amp 344 373 400 425 448 465 493 537 Copper Amp 394 419 442 461 480 493 516 561 Flat Formation In Air Aluminium Amp 585 660 740 818 904 971 1071 1186 Copper Amp 706 784 862 935 1024 1085 1174 1288
Not e : The abov e c urrent ratingsc orrespond t o a m etallic sheat h/ sc reen short c irc uit current capabilit y of 31.5 k A For one second durat ion. For any v ariation f rom this v alue of s hort circ uit current and duration, k indly refer t o us.
Table No. 11 Rating factors for grouping of single core cable laid direct in ground in horizontal formation
D i s t a n c e b e t we e n centres of circuits mm 100 200 400 600 800 2000 1 1 1 1 1 1 1 2 0.76 0.81 0.85 0.88 0.90 0.96 3 0.67 0.71 0.77 0.81 0.84 0.93 Number of c ircuit s in group 4 0.59 0.65 0.72 0.77 0.81 0.92 5 0.55 0.61 0.69 0.74 0.79 0.91 6 0.51 0.58 0.66 0.72 0.77 0.91 7 0.49 0.56 0.64 0.71 0.76 0.91 8 0.47 0.53 0.63 0.70 0.75 0.90 9 0.46 0.52 0.62 0.69 0.75 0.90
200 0.88
250 0.78
300 0.73
160 0.99
170 0.99
180 0.98
190 0.98
200 0.97
D+400 1.10