XLPE Cable Systems

Users guide

U.S. Standard (rev. 2)

CONTENT

XLPE cable systems

Page

Page

Introduction........................................................................... 3 XLPE cable systems - design, installation and testing. ...... 4 XLPE cables........................................................................ 4 Cable accessories. ............................................................... 4 Installation of XLPE cable systems....................................... 5 Testing of XLPE cable systems. ............................................ 5 XLPE cable and cable system standards. ........................... 6 IEC .................................................................................... 6 ICEA and AIEC. .................................................................... 6 ISO Standards..................................................................... 6 XLPE cable system congurations. ..................................... 7 Trefoil and at formation....................................................... 7 Bonding of metallic screens................................................. 7 Current rating for XLPE cable systems................................ 8 Current rating for single-core cables, amperes .................... 9 Rating factors.................................................................... 11 Rating factor for cross section area of metal screen....... 11 Rating factors for ground temperature. ........................... 11 Example of the use of rating factors............................... 12 Overload............................................................................ 12 Short-circuit currents......................................................... 12 Maximum short-circuit currents due to thermal restrictions..13 Dynamic forces at short circuits......................................... 13

Cable drums........................................................................ 14 Selection of cable drum..................................................... 14 Sizes and weights of cable drums. ..................................... 15 Large and special drums. ................................................... 15 Testing of XLPE cables....................................................... 15 Cable handling. ................................................................... 15 Minimum bending radius. ................................................... 15 Maximum pulling forces..................................................... 15 XLPE cable design. .............................................................. 16 Conductors ......................................................................... 16 Standards - IEC and ICEA. ................................................. 16 Conductor water sealing.................................................... 16 Insulation............................................................................. 16 Conductor screen.............................................................. 16 XLPE insulation.................................................................. 16 Insulation screen................................................................ 16 Metallic screen.................................................................... 17 Copper wire screen, standard design. ................................ 17 Copper wire screen, water tight design.............................. 17 Lead sheath. ...................................................................... 17 Copper tape screen........................................................... 17 Non-metallic outer sheath . ................................................ 18 Conductive outer layer ....................................................... 18 Flame retardant outer layer. ............................................... 18 Fire behavior........................................................................ 18 Technical data for cables in the ABB XLPE cable system......19 Formulas.............................................................................. 21 Support .................................................................................. 22 Checklist for cable inquiry.................................................. 23

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ABB

INTRODUCTION

XLPE Cable Systems

Introduction
Over the past 25 years, cross-linked polyethylene (XLPE) cables have been extensively used in underground transmission circuits at 220 kV and above in Europe, the Middle East and Asia. Indeed, ABB delivered its first commercial 245 kV XLPE cables to the ministry of Electricity in Libya already in 1978 and its first complete 245 kV XLPE cable system (i.e., cables, splices and terminations) to the municipal power company in Stockholm, Sweden, in 1984. To date, ABB has delivered more than 900 kilometers of XLPE cable for system voltages at 220 kV and above. Until recently, new 230 kV and 345 kV underground circuits in the United States and Canada were built almost exclusively with high pressure fluid-filled (HPFF) cable technology. As a result, North-American transmission providers have relatively limited operating experience with XLPE cables at 230 kV and above and, therefore, may not yet fully appreciate the many technical, installation and operational advantages of the XLPE technology. No risk of oil release The insulation system of a HPFF cable includes pressurized oil that circulates inside the steel pipe conduits of the power cables. During failures in the oil handling and processing equipment or in case of a leak in a steel pipe conduit (e.g., due to corrosion or excavation near the cable trench), substantial amounts of oil may inadvertently be released to the environment. The insulation system in an XLPE cable, on the other hand, is based on a solid dielectric and, therefore, there is no risk of oil release to the environment. Excellent reliability performance Due to continuous improvements in material characteristics and manufacturing processes, the in-service reliability performance of modern XLPE cable systems for underground or underwater transmission circuits is equivalent to or better than the reliability performance of HPFF cable systems. Indeed, over the past 30 years XLPE cable system failure rates have dramatically decreased even though the voltage stress per millimeter of insulation has continuously increased. For example, since 1973 ABB has delivered more than 7,400 kilometers of XLPE cable for system voltages of 100 kV and above. The average failure rate reported for these ABB supplied cables between 1990 and 2003 was approximately 0.008 failures per 100 miles per year. Reduced operating costs The power losses on a 230 kV or 345 kV HPFF cable circuit are significantly higher than for an XLPE cable circuit of the same rating especially dielectric losses, charging current losses and losses in reactive power compensation equipment.

Accordingly, the costs of losses over the expected service life of a HPFF cable system is higher than for a XLPE-insulated cable system. Also, XLPE cables need very little maintenance and generally are considered maintenance free. Other technical and economical benefits The per mile capacitance of a 345 kV XLPE cable is only about 60% of the per mile capacitance of a 345 kV HPFF cable. This lower capacitance of the XLPE cables offers numerous technical and economical benefits, including:

Use of lower capacitance XLPE cable reduces the significant voltage variations that may otherwise occur in the integrated transmission network when a large cable circuit is switched in or out of service.

Use of lower capacitance XLPE cable reduces the need for

shunt reactors and other costly equipment for reactive power compensation.

Use of lower capacitance XLPE cable significantly reduces

the charging current flowing in the cable circuit. This results in lower losses and higher load carrying capability in the cable circuit.

Use of lower capacitance XLPE cable reduces the adverse

impacts that large cable circuits may have on transient and temporary overvoltages in integrated transmission networks during contingency conditions and disturbances.

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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 - Copper (Cu) or Aluminum (Al) stranded compacted conductor or - Cu segmented 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 - Cu or Al laminate solidly bonded to outer polyethylene jacket or - 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 ABBs line up of cable accessories for ABB XLPE cable systems includes: Straight splices and splices with integrated screen separation for cross bonding Transition splices for connection of XLPE to uid lled cables Outdoor terminations with porcelain or composite insulators Screened separable connectors for switchgears and transformers Cable terminations for transformers and gas insulated switchgears (GIS) Link boxes for earthing and cross-bonding Distributed Temperature Sensing (DTS) Systems with integrated optical fibre in metallic tube (FIMT) Integrated optical fibre cable for control and communication, as an alternative to separately installed optical fibre cable. Especially suitable for 3-core submarine cables and for cables with a copper wire metallic screen.
More information about our accessories is available on www.abb.com

ABB

XLPE CABLE SYSTEMS DESIGN, INSTALLATION AND TESTING

Installation of XLPE cable systems Installation of cable systems includes trenching, cable pulling, clamping of cable, cable splicing as well as mounting of accessories. High quality installation work performed by ABB certified field personnel is essential for achieving the low failure rates and reliability performance that is expected from modern underground transmission and distribution circuits. ABB has long and extensive experience from different types of cable installations including 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 Standard routine tests, sample tests, type tests and after laying tests are performed according to AEIC CS7-93 for cables 69 kV - 138 kV and above that level, according to IEC 62067. 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 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 AC voltage test of main insulation

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XLPE CABLE AND CABLE SYSTEM STANDARDS

XLPE cable and cable system standards

ABBs XLPE cable systems are designed to meet requirements in international and/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. Some frequently used standards are: IEC 60228 Conductors of insulated cables. IEC 60287 Electric cables - Calculation of the current rating. 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. 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. ICEA and AEIC In North America, cables are often specified according to ICEA (Insulated Cable Engineers Association, Inc.): S-97-682 Standard for utility shielded power cables rated 5-46 kV. S-108-720 Standard for extruded insulated power cables rated above 46 through 345 kV. or AEIC (Association of Edison Illuminating Companies): CS7-93 Specifications for cross-linked polyethylene insulated shielded power cables rated 69 through 138 kV. 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 and ISO 9001 - Certicate of Approval

ABB

XLPE CABLE SYSTEM CONFIGURATIONS

XLPE cable system configurations

Trefoil and flat formation The three cables in a 3-phase circuit can be placed in different formations. Typical formations include trefoil (triangular) and flat formations. The choice depends on several factors like screen bonding method, conductor area and available space for installation. Bonding of the metallic screens The electric power losses in a cable circuit are dependent on the currents flowing in the metallic sheaths of the cables. Therefore, by reducing or eliminating the metallic sheath currents through different methods of bonding, it is possible to incresase the load current carrying capacity (ampacity) of the cable circuit. 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 reduce 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 sectionalized 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.

Trefoil or

at formation

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 of energy losses can be reduced by using a larger conductor. Load losses in XLPE cables are primarily due to the ohmic losses in the conductor and the metallic screen. XLPE cables can be loaded continuously to a conductor temperature of 90C. The dielectric losses in the XLPE insulation system are present also at no load current and depend primarily on the magnitude of the operating voltage. Dielectric losses in XLPE cables are lower than for EPR and fluid-filled cables. Continuous current ratings for single-core cables are given in Tables 1-4. The continuous current ratings are calculated according to IEC 60287 series of standards and with conditions according to Figure 1a, 1b and 2. Rating factors for single-core cables are given in Tables 5 to 7.
Fig.1b Phase location in duct banks Fig.1a

Fig.2

ABB

CURRENT RATING FOR XLPE CABLE SYSTEMS

Current rating for single-core cables, amperes - cables in duct banks Table 1 Rated voltage 138 kV (and 115 kV), aluminum conductor - 180 kcmil screen Load factor 1.0 Conductor crosssection Copper screen Single circuit single point bonding / cross bonding Single circuit bothends bonded Single circuit single point bonding / cross bonding Single circuit bothends bonded 2circuits 2circuits single bothpoint ends bonding bonded / cross bonding Single circuit single point bonding / cross bonding Single circuit bothends bonded Load factor 0.8 Single circuit single point bonding / cross bonding Single circuit bothends bonded 2circuits 2circuits single bothpoint ends bonding bonded / cross bonding

kcmil 750 1,000 1,250 1,500 1,750 2,000 2,500 3,000

kcmil 180 180 180 180 180 180 180 180

A 535 625 700 775 835 885 980 1,060

A 440 495 530 565 590 610 650 675

A 545 635 715 785 850 900 1,005 1,085

A 440 490 530 560 585 605 640 665

A 455 530 595 655 705 745 825 890

A 365 405 435 460 480 495 520 540

A 585 685 770 850 920 975 1,085 1,170

A 485 545 590 630 665 685 730 765

A 590 690 775 855 930 985 1,100 1,190

A 485 540 585 620 650 675 715 750

A 510 595 670 735 795 845 935 1,010

A 415 460 495 525 545 565 595 620

Table 2 Rated voltage 138 kV (and 115 kV), copper conductor - 180 kcmil screen Load factor 1.0 Conductor crosssection Copper screen Single circuit single point bonding / cross bonding Single circuit bothends bonded Single circuit single point bonding / cross bonding Single circuit bothends bonded 2circuits 2circuits single bothpoint ends bonding bonded / cross bonding Single circuit single point bonding / cross bonding Single circuit bothends bonded Load factor 0.8 Single circuit single point bonding / cross bonding Single circuit bothends bonded 2circuits 2circuits single bothpoint ends bonding bonded / cross bonding

kcmil 750 1,000 1,250 1,500 1,750 2,000 2,500 3,000

kcmil 180 180 180 180 180 180 180 180

A 680 790 880 955 1,020 1,165 1,295 1,405

A 515 560 595 625 650 695 730 755

A 690 800 890 970 1,040 1,190 1,325 1,440

A 510 555 590 615 640 685 715 740

A 580 670 745 810 865 985 1,090 1,185

A 420 455 480 500 520 550 575 595

A 740 860 965 1,050 1,125 1,290 1,430 1,550

A 550 625 665 700 730 785 825 860

A 750 870 975 1,065 1,140 1,310 1,465 1,595

A 560 615 655 690 715 770 805 840

A 650 755 840 910 975 1,115 1,240 1,345

A 475 520 550 575 595 635 665 690

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CURRENT RATING FOR XLPE CABLE SYSTEMS

Table 3 Rated voltage 345 kV (and 230 kV), aluminum conductor - 500 kcmil screen Load factor 1.0 Conductor crosssection Copper screen Single circuit single point bonding / cross bonding Single circuit bothends bonded Single circuit single point bonding / cross bonding Single circuit bothends bonded 2circuits 2circuits single bothpoint ends bonding bonded / cross bonding Single circuit single point bonding / cross bonding Single circuit bothends bonded Load factor 0.8 Single circuit single point bonding / cross bonding Single circuit bothends bonded 2circuits 2circuits single bothpoint ends bonding bonded / cross bonding

kcmil 1,000 1,250 1,500 1,750 2,000 2,500 3,000 3,944 4,931

kcmil 500 500 500 500 500 500 500 500 500

A 615 690 760 820 870 965 1,060 1,160 1,245

A 505 545 580 605 630 665 695 730 755

A 625 705 775 835 885 985 1,070 1,175 1,270

A 510 545 580 605 625 665 685 720 745

A 525 585 640 690 730 805 880 960 1,035

A 415 445 470 490 505 530 550 570 590

A 675 760 835 905 960 1,065 1,175 1,290 1,395

A 560 610 650 680 705 750 790 830 865

A 685 770 850 920 975 1,085 1,190 1,310 1,420

A 560 610 650 680 705 745 780 815 850

A 590 660 725 780 830 920 1,000 1,095 1,185

A 470 510 540 565 580 615 635 665 685

Table 4 Rated voltage 345 kV (and 230 kV), copper conductor - 500 kcmil screen Load factor 1.0 Conductor crosssection Copper screen Single circuit single point bonding / cross bonding Single circuit bothends bonded Single circuit single point bonding / cross bonding Single circuit bothends bonded 2circuits 2circuits single bothpoint ends bonding bonded / cross bonding Single circuit single point bonding / cross bonding Single circuit bothends bonded Load factor 0.8 Single circuit single point bonding / cross bonding Single circuit bothends bonded 2circuits 2circuits single bothpoint ends bonding bonded / cross bonding

kcmil 1,000 1,250 1,500 1,750 2,000 2,500 3,000 3,944 4,931

kcmil 500 500 500 500 500 500 500 500 500

A 775 865 940 1,005 1,145 1,270 1,400 1,550 1,680

A 580 620 645 670 715 750 775 810 840

A 790 880 960 1,025 1,170 1,305 1,425 1,590 1,740

A 580 620 640 670 710 745 760 790 825

A 660 730 790 845 960 1,060 1,165 1,290 1,400

A 470 500 520 535 565 590 605 625 645

A 850 950 1,035 1,105 1,265 1,405 1,560 1,730 1,890

A 650 695 730 755 810 850 885 925 970

A 860 965 1,050 1,125 1,295 1,440 1,590 1,775 1,955

A 645 690 725 750 805 840 870 910 945

A 740 825 895 960 1,095 1,215 1,330 1,480 1,615

A 540 575 600 620 655 685 705 730 760

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CURRENT RATING FOR XLPE CABLE SYSTEMS

Rating factors Rating factor for cross section area of metal screen The rating factor is applicable to single-core cables in flat and trefoil formation with the screens bonded at both ends. The rating factor does not apply to single-point bonding or cross-bonded systems.
Table 5, 115-138 kV cable with 180 kcmil screen Rating factor for tables 1 and 2 Conductor kcmil Al 750 1,000 1,250 1,500 1,750 2,000 2,500 3,000 750 1,000 1,250 1,500 1,750 2,000 2,500 3,000 Cu 45 1.06 1.06 1.06 1.10 1.10 1.10 1.12 1.12 1.12 1.15 Copper screen kcmil 90 1.03 1.03 1.03 1.04 1.04 1.04 1.05 1.05 1.05 1.07 180 1 1 1 1 1 1 1 1 1 1 360 1.00 1.00 1.00 1.00 1.00 1.00 0.99 0.99 0.99 0.98 500 1.02 1.02 1.02 1.02 1.02 1.02 1.02 1.02 1.02 1.02 Al 1,000 1,250 1,500 1,750 2,000 2,500 3,000 3,944 1,000 1,250 1,500 1,750 2,000 2,500 3,000 3,944 4,931 Cu Table 6, 230-345 kV cable with 500 kcmil screen Rating factor for tables 3 and 4 Conductor kcmil 90 1.01 1.01 1.01 1.02 1.02 1.02 1.03 1.03 1.03 1.03 1.03 Copper screen kcmil 180 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 360 0.98 0.98 0.98 0.98 0.98 0.98 0.97 0.97 0.97 0.97 0.97 500 1 1 1 1 1 1 1 1 1 1 1

Rating factor for ground temperature

Table 7, 115-345 kV cable with 500 kcmil screen Ground temperature C Rating factor 10 1.11 15 1.07 20 1.04 25 1 30 0.96 35 0.92 40 0.88 45 0.83

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11

CURRENT RATING FOR XLPE CABLE SYSTEMS

Example of the use of rating factors 2 groups of 138 kV cables with copper conductors 1000 kcmil and a copper screen of 90 kcmil, both ends bonded - ground temperature 15C. Table 2 gives a continuous load of 455 A with copper screen 180 kcmil and 25C soil temperature. Rating factor for screen 90 kcmil and copper conductor is 1.03 (table 5). Rating factor for ground temperature 15C (table 7) is 1.07. Adjusted rating per group: 1.03 x 1.07 x 455 = 501 A

Overload capacity 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 impact to the expected service life of 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.

Short-circuit currents During short circuit events 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.

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CURRENT RATING FOR XLPE CABLE SYSTEMS

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.

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 83A/ kcmil during 1s. (Both higher and lower current densities may be allowed if other conditions apply.) Lead sheath temperatures of up to 210oC are permitted in connection with short circuit events. With an initial temperature of 50oC this corresponds to a current density of 14 A/kcmil during 1 s.
Table 9 Max short-circuit current on the screen during 1 s kA Metallic screen cross section kcmil Copper 45 90 180 360 500 750 per kcmil Cu per kcmil Pb Lead 311 621 1,242 2,484 3,450 5,175 Metallic screen temp before the short circuit 50C 3.7 7.5 14.9 30 42 62 0.083 0.0142 70C 3.5 7.0 14.0 28 39 58 0.0776 0.0132

Ish= short-circuit current [kA] during time tsh I1 = short-circuit current rating during 1 second. See the 1second value in Table 8 for the conductor and in Table 9 for the metal screen. tsh= short-circuit duration (sec) For XLPE insulated conductors the maximum allowable short circuit temperature is 250oC.
Table 8 Max short-circuit current on the conductor during 1 s kA Conductor temperature 90C before short-circuit Cross section kcmil 750 1,000 1,250 1,500 1,750 2,000 2,500 3,000 3,944 4,931 per kcmil Cu conductor 54 73 91 109 127 145 181 218 286 357 0.0725 Al conductor 36 48 60 72 84 96 120 144 189 237 0.048

Dynamic forces during short circuit events In addition to the thermal stresses, the dynamic forces in the cables and accessories during a short circuit event must also be considered. The dynamic force between two conductors can be calculated as:

Where; Ipeak = peak current, [kA] = (2.5 Ish ) 1sh = short current [kA] RMS S = centre to centre spacing between conductors, inches F = maximum force Lbf/ft

For three phase systems in flat configuration the force is 0.87F for the middle cable and 0.81F for the outer cables. For three phase systems in triangular configuration the force is 0.87F.

ABB

13

CABLE DRUMS

Cable drums
Wooden drums/reels are standardized. For certain purposes steel drums/ reels are applicable. Both wooden and steel-drums can be obtained for special purposes with other dimensions than stated below.
Table 10 Selection of cable drum Cable lenghts in feet on standard drum K22 - K30 and Steel drum St 28 - St 43 Cable dia. inch 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 5.0 5.1 5.2 K22 1,050 755 755 689 689 689 Wooden drum K24 1,312 1,066 1,066 984 902 902 K26 1,969 1,640 1,542 1,542 1,444 1,444 1,165 1,066 1,066 1,066 K28 2,657 2,657 2,543 2,165 2,018 2,018 1,919 1,919 1,591 1,493 K30 3,970 3,330 3,330 3,330 2,756 2,756 2,625 2,625 2,100 2,100 St 28 2,986 2,986 2,904 2,887 2,067 2,067 2,001 2,001 1,903 1,903 1,837 1,263 1,247 1,247 1,198 1,181 1,132 1,115 1,115 1,066 1,066 1,066 1,001 St 30 3,707 3,707 3,576 3,576 2,690 2,690 2,575 2,575 2,477 2,477 2,379 1,739 1,739 1,739 1,657 1,657 1,575 1,575 1,575 1,476 1,476 1,476 1,001 St 32 5,217 4,462 4,298 4,298 4,003 4,003 3,182 3,182 3,051 3,051 2,953 2,264 2,264 2,264 2,165 2,165 2,051 2,051 2,051 1,952 1,476 1,476 1,411 St 34 6,004 6,004 5,052 5,052 4,692 4,692 4,528 3,871 3,707 3,707 3,543 2,822 2,822 2,822 2,690 2,690 2,575 2,575 2,575 1,952 1,952 1,952 1,837 St 35 6,857 6,037 5,840 5,840 4,692 4,692 4,528 4,528 4,364 3,740 3,543 3,412 3,412 3,412 3,248 2,690 2,559 2,559 2,559 2,428 2,428 2,428 1,837 Steel drum St 36 6,857 6,857 6,660 6,660 5,446 5,446 5,249 4,560 4,364 4,364 4,199 3,412 3,412 3,412 3,248 3,248 3,117 3,117 2,592 2,428 2,428 2,428 2,297 St 37 7,710 7,710 6,660 6,660 6,201 5,479 5,249 5,249 5,052 4,396 4,199 4,035 4,035 4,035 3,248 3,248 3,117 3,117 3,117 2,953 2,461 2,461 2,297 St 38 8,645 7,776 7,530 7,530 6,201 6,201 6,020 6,020 5,052 5,052 4,888 4,035 4,035 4,035 3,871 3,871 3,675 3,117 3,117 2,953 2,953 2,953 2,789 St 39 8,645 8,645 8,399 7,579 7,021 7,021 6,020 6,020 5,774 5,774 4,888 4,692 4,692 4,692 3,871 3,871 3,675 3,675 3,675 2,953 2,953 2,953 2,789 St 40 9,580 9,580 8,399 8,399 7,021 7,021 6,791 6,791 5,774 5,774 5,610 4,692 4,692 4,692 4,495 4,495 3,675 3,675 3,675 3,510 3,510 3,510 2,789 St 43 11,549 11,549 10,302 10,302 8,760 8,760 8,465 7,677 7,349 7,349 6,332 6,102 6,102 6,102 5,151 5,151 4,921 4,921 4,331 4,101 4,101 4,101 3,904

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CABLE DRUMS | TESTING | CABLE HANDLING

Table 11 A Sizes and weights of standard drum K22 - K30 Wooden drum K22 Shipping volume Drumweight incl. battens a Diameter incl. battens b Flange diameter c Barrel diameter d Total width e Spindle hole diameter Table 11 B Sizes and weights of drum St 28 - St 43 Steel drum St 28 Shipping volume Drumweight incl. battens a Diameter incl. battens b Flange diameter c Barrel diameter d Total width e Spindle hole diameter ft3 lbs inch inch inch inch inch 727.5 3,307 115.4 110.2 78.7 94.5 5.9 St 30 829.9 3,748 123.2 118.1 78.7 94.5 5.9 St 32 939.4 4,850 131.1 126.0 78.7 94.5 5.9 St 34 1,020.6 5,732 139.0 133.9 78.7 94.5 5.9 St 35 1,115.9 5,952 142.9 137.8 78.7 94.5 5.9 St 36 1,179.5 6,173 146.9 141.7 78.7 94.5 5.9 St 37 1,243.1 6,614 150.8 145.7 78.7 94.5 5.9 St 38 1,306.6 6,834 154.7 149.6 78.7 94.5 5.9 St 39 1,373.7 7,275 158.7 153.5 78.7 94.5 5.9 St 40 1,444.4 7,716 162.6 157.5 78.7 94.5 5.9 St 43 1,663.3 8,818 174.4 169.3 78.7 94.5 5.9 ft3 lbs inch inch inch inch inch 217.2 1246 89.6 86.6 55.1 46.8 5.2 K24 259.9 1378 97.4 94.5 55.1 47.2 5.2 K26 372.9 2524 106.3 102.4 59.1 57.0 5.2 K28 490.2 3219 114.2 110.2 59.1 65.0 5.2 K30 605.6 4012 122.0 118.1 59.1 70.9 5.2

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 might 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

Table 12 Rated voltages and corresponding test voltages according to AEIC or IEC Rated voltage Type test Impulse BIL (Basic Insulation Level) kV 550 650 1,050 1,175 Routine test AC voltage test Partial discharge measurement at kV Max 10 pC 160 200 190 285 Max 5 pC 135 160 -

Cable handling
Table 13 Minimum bending radius for standard designs Single-core cable At laying When installed 15 De 10 De

kV AEIC CS7-93 IEC 62067 115 138 220 345

kV 160 200 318 420

Duration minutes 30 30 30 30

De is the external diameter of the cable For other cable designs other bending radii may apply.

Maximum pulling forces The following pulling forces should not be exceeded: Aluminum conductors 4 Lbf/kcmil Copper conductors 7 Lbf/kcmil
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CONDUCTORS | INSULATION

XLPE Cable Design

Conductors
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 aluminum. ICEA, Standard Publication No. S-97-682, further specified in ASTM B 400-18 for aluminum, ASTM B 496-81 for copper. 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.

Table 14 ICEA Cross section kcmil 750 1,000 1,250 1,500 1,750 2,000 2,500 3,000 3,944 4,931 Diameter mils 906 1,059 1,189 1,319 1,425 1,496 1,772* 1,929* 2,205* 2,598* Nominal d.c resistance at 25C, ohm/1000 ft aluminum 0.0236 0.0177 0.0141 0.0118 0.0101 0.00885 0.00715 0.00596 0.00463 0.0037 copper 0.0144 0.0108 0.00863 0.00719 0.00616 0.00539 0.00436 0.00363 0.0028 0.00224

*Segmented Cu conductor including tapes

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 good electrical performance. XLPE insulation The XLPE insulation is extruded simultaneously with the conductor screen and the insulation screen, i.e. 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 15 to 18. 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.

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INSULATION | METALLIC SCREEN

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 aluminum. 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.

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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. 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.

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TECHNICAL DATA FOR CABLES IN THE ABB XLPE CABLE SYSTEM

Technical data for cables in the ABB XLPE cable system

Crosssection of conductor kcmil Diameter of conductor Insulation thickness Diameter over insulation Crosssection of screen kcmil Outer diameter of cable Cable weight (Al-conductor) Lb/ft Cable weight (Cu-conductor) Lb/ft Capacitance Charging current per phase at 60 Hz A/ 1000 ft Inductance ** * Surge impedance

mil

mils

inches

inches

F/ 1000 ft

mH/ 1000 ft

mH/ 1000 ft

Table 15 Single core cables, nominal voltage 115 kV 750 1,000 1,250 1,500 1,750 2,000 2,500 3,000 Table 16 Single core cables, nominal voltage 138 kV 750 1,000 1,250 1,500 1,750 2,000 2,500 3,000 906 1,059 1,189 1,319 1,425 1,496 1,673 1,819 850 850 850 850 850 850 850 850 2.67 2.84 2.97 3.10 3.20 3.27 3.53 3.68 180 180 180 180 180 180 180 180 3.21 3.38 3.51 3.64 3.74 3.81 4.07 4.22 5.04 5.60 6.07 6.54 6.96 7.32 8.38 9.14 6.65 7.76 8.77 9.78 10.74 11.63 13.78 15.61 0.039 0.044 0.047 0.050 0.053 0.054 0.061 0.064 1.18 1.31 1.41 1.51 1.59 1.64 1.83 1.93 0.205 0.195 0.188 0.182 0.177 0.174 0.167 0.162 0.212 0.202 0.195 0.189 0.184 0.181 0.174 0.169 44.8 40.9 38.0 35.5 33.7 32.6 31.1 29.3 906 1,059 1,189 1,319 1,425 1,496 1,673 1,819 800 800 800 800 800 800 800 800 2.57 2.74 2.87 3.00 3.10 3.17 3.43 3.58 180 180 180 180 180 180 180 180 3.08 3.25 3.38 3.51 3.61 3.68 3.94 4.09 4.71 5.25 5.71 6.17 6.58 6.93 7.96 8.71 6.33 7.41 8.41 9.41 10.35 11.24 13.36 15.18 0.041 0.045 0.049 0.052 0.055 0.057 0.063 0.067 1.01 1.13 1.21 1.30 1.37 1.41 1.58 1.67 0.205 0.195 0.188 0.182 0.177 0.174 0.167 0.162 0.212 0.202 0.195 0.189 0.184 0.181 0.174 0.169 43.3 39.6 36.7 34.3 32.5 31.4 30.0 28.3

** Inductance trefoil in duct w 9 horisontal and vertical distance *Inductance at formation with distance c/c 9 between cables

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TECHNICAL DATA FOR CABLES IN THE ABB XLPE CABLE SYSTEM

Crosssection of conductor kcmil

Diameter of conductor mil

Insulation thickness

Diameter over insulation inches

Crosssection of screen kcmil

Outer diameter of cable inches

Cable weight (Al-conductor) Lb/ft

Cable weight (Cu-conductor) Lb/ft

Capacitance

Charging current

Inductance ** mH/ 1000 ft * mH/ 1000 ft

Surge impedance

mils

F/ 1000 ft

A/ 1000 ft

Table 17 Single core cables, nominal voltage 230 kV 1,000 1,250 1,500 1,750 2,000 2,500 3,000 3,944 4,931 Table 18 Single core cables, nominal voltage 345 kV 1,000 1,250 1,500 1,750 2,000 2,500 3,000 3,944 4,931 1,059 1,189 1,319 1,425 1,496 1,673 1,819 2,150 2,346 1,000 1,000 1,000 1,000 1,000 1,000 1,000 1,000 1,000 3.14 3.27 3.40 3.50 3.57 3.83 3.98 4.31 4.50 500 500 500 500 500 500 500 500 500 3.75 3.88 4.01 4.11 4.18 4.44 4.59 4.92 5.11 7.64 8.15 8.66 9.10 9.48 10.62 11.43 13.04 14.37 9.80 10.85 11.90 12.88 13.80 16.02 17.90 21.56 25.02 0.039 0.042 0.045 0.047 0.049 0.054 0.057 0.064 0.068 2.95 3.16 3.37 3.55 3.66 4.06 4.28 4.80 5.12 0.195 0.188 0.182 0.177 0.174 0.167 0.168 0.158 0.153 0.202 0.195 0.189 0.184 0.181 0.174 0.175 0.165 0.160 44.7 41.6 39.0 37.1 35.9 34.1 32.3 28.8 26.9 1,059 1,189 1,319 1,425 1,496 1,673 1,819 2,150 2,346 900 900 900 900 900 900 900 900 900 2.94 3.07 3.20 3.30 3.37 3.63 3.78 4.11 4.30 500 500 500 500 500 500 500 500 500 3.55 3.68 3.81 3.91 3.98 4.24 4.39 4.72 4.91 7.06 7.55 8.04 8.46 8.83 9.93 10.71 12.27 13.57 9.22 10.24 11.28 12.24 13.15 15.33 17.19 20.79 24.22 0.042 0.045 0.048 0.051 0.052 0.058 0.061 0.069 0.074 2.01 2.15 2.30 2.42 2.50 2.78 2.94 3.30 3.52 0.195 0.188 0.182 0.177 0.174 0.167 0.168 0.158 0.153 0.202 0.195 0.189 0.184 0.181 0.174 0.175 0.165 0.160 42.2 39.3 36.7 34.8 33.7 32.1 30.4 26.9 25.2

** Inductance trefoil in duct w 9 horisontal and vertical distance (10 from 3,000 kcmil) *Inductance at formation with distance c/c 10,1 between cables (11,2 from 3,000 kcmil)

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FORMULAS

Formulas
Formula for capacitance Formula for dielectric losses

Where

= relative permittivity of the insulation d0 = external diameter of the insulation (inches) di = diameter of conductor, including screen (inches) XLPE = 2.3

Where

U = rated voltage (kV) f = frequency (Hz) C = capacitance (F/1000 ft) tan = loss angle

Formula for inductance

Where

trefoil formation: K = 1 flat formation: K = 1.26 s = distance between conductor axes (inches) r = conductor radius (inches)

Formula for inductive reactance

Where f = frequency (Hz) L = inductance (mH/1000 ft) Formula for electric stress Conductor screen: Ish = I1 = tsh = short-circuit current during time tsh short-circuit current rating during 1 second. See the 1-second value in table 8 for the conductor and in Table 9 for the metallic screen. short-circuit duration (sec) Formula for maximum short circuit currents

Insulation screen:

For XLPE insulated conductors the maximum allowable short circuit temperature is 250oC.
XLPE

ri = radius of conductor screen r0 = radius of XLPE insulation U = voltage across insultaion

r0 ri

Formula for calculation of dynamic forces between two conductors

Where; Ipeak = peak current, [kA] (2.5 Ish) 1sh = short current [kA] RMS S = centre to centre spacing between conductors, inches F = maximum force Lbf/ft For three phase systems in flat configuration the force is 0.87 F for the middle cable and 0.81 F for the outer cables. For three phase systems in triangular configuration the force is 0.87 F
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SUPPORT

Support
The transmission network in most countries is very large and complex. It may incorporate many different types of transmission circuits, including AC and DC over-head lines, fluid-filled cable systems and extruded cable systems, etc. Also, many modern networks contain extensive underground and submarine cable systems for supply of major metropolitan areas and for interconnection with neighboring countries. ABBs experienced project managers, technical specialists and other staff will give their professional support in evaluating 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 localization and cable repair Maintenance of fluid-filled systems Leasing of installation equipment Training NOTE: All data given in this brochure are non-binding and indicative only

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CHECKLIST FOR CABLE ENQUIRY

Checklist for cable inquiry

ABB is always prepared to work closely with our customers to develop optimized and cost effective cable system design solutions. In order for us to identify the best overall design solution for a specific application, we kindly request that the
Commercial information
Name of project Customer Location of site for delivery Inquiry for budget or purchase Tender submission date Do any special conditions apply How long should the tender be valid Required delivery/completion time Terms of delivery (FCA/CPT etc.) Specic requirements on cable length per delivered drum Do any specic metal prices apply Installation: Turnkey by ABB Installation by ABB Supervision by ABB * * * * *Required information * * * * * Installed in air Air temperature, maximum Installed in trough If trough, inside dimension of trough (width height) If trough, lled or unlled Exposed to solar radiation Direct buried installation Soil, ground temperature at laying depth Laying depth Thermal resistivity backll If drying out, thermal resistivity dry backll close to cable Backll material: selected sand, CBS, etc Special requirements for trench Cables in duct bank, pipes * Yes/No inch inch inch C Km/W Km/W Km/W inch *Required information kV kV A/MVA kA/s kA/s ft Cu/Al, kcmil Yes/No Yes/No Material: PVC, PE, Fibre, steel, etc Distance between ducts/pipes Outside duct/pipe diameter Inside duct/pipe diameter Ambient temperature at burial depth Thermal resistivity of ground Thermal resistivity duct bank If drying out, thermal resistivity dry backll close to duct Laying depth Backll material: selected sand, CBS, etc * Yes/No Yes/No C inch Km/W Km/W

below data checklist is submitted with each inquiry (if some of the requested data is not available at the time of the inquiry or does not appear applicable, just insert N/A in the corresponding data cell).
*Required information * Yes/No C Yes/No inch inch

Technical information
Cable system input:

Maximum System Voltage Umax * Nominal System Operating Voltage U * Continuous current capacity * Maximum symmetrical short-circuit * current and duration Maximum earth-fault current and duration * Route length * Conductor: copper/aluminum, cross-section Longitudinal water protection * Radial water protection * Any special cable design requirements Customer specication

Accessories
Termination *Required information Type of termination and quantity. Indoor, outdoor, AIS, GIS, transformer, etc. Special requirements - pollution level, rod gap, polymer insulator, etc. Joints Type of joint and quantity - premoulded, vulcanized, sectionalized, straight etc *Required information Special requirements Link boxes Type of link box Special requirements Other accessories Other relevant information inch Yes/No inch, W/ft inch, W/ft

*Required information

Tests
Routine, sample and after installation test. IEC, other Type test requirements. IEC, other Other test requirements

Type * Qty *

Installation data
Cable conguration: Flat/Trefoil

Type * Qty *

Number of parallel circuits * Distance between parallel circuits Heating from existing cables If yes, distances to and losses of parallel cables Other heat sources, distance to and losses of sources Screen earthing (Both ends, Cross, Single)

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For additional information please contact you local ABB Sales Office
2GM 5007 US.pdf Elanders, Vsters 0610

Brochure issued by: ABBs high voltage cable unit in Sweden Phone +46 455 556 00 Fax +46 455 556 55 E-mail: sehvc@se.abb.com www.abb.com/cables