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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 XLPE CABLE SYSTEMS

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

CURRENT RATING FOR XLPE CABLE SYSTEMS

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

CURRENT RATING FOR XLPE CABLE SYSTEMS

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

CURRENT RATING FOR XLPE CABLE SYSTEMS

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

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.

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
Single-core cables, nominal voltage 20 kV (Um = 24 kV)
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

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 25
Single-core cables, nominal voltage 30 kV (Um = 36 kV)
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
Single-core cables, nominal voltage 45 kV (Um = 52 kV)
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

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 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

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 29
Single-core cables, nominal voltage 110 kV (Um = 123 kV)
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
Single-core cables, nominal voltage 132 kV (Um = 145 kV)
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

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 31
Single-core cables, nominal voltage 150 kV (Um = 170 kV)
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
Single-core cables, nominal voltage 220 kV (Um = 245 kV)
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
Single-core cables, nominal voltage 275 kV (Um = 300 kV)
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

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

8.3

0.43

0.57

38.2

Table 34
Single-core cables, nominal voltage 330 kV (Um = 362 kV)
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
Single-core cables, nominal voltage 400 kV (Um = 420 kV)
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
Single-core cables, nominal voltage 500 kV (Um = 550 kV)

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

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

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