XLPE Cable Systems

User´s guide

U.S. Standard (rev. 2)

CONTENT

XLPE cable systems

Page

Page 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

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 configurations ...................................... 7 Trefoil and flat 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 .............................. 1 Overload ........................................................................... 1 Short-circuit currents ........................................................ 1 Maximum short-circuit currents due to thermal restrictions..13 Dynamic forces at short circuits ........................................ 13

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 ............................................................................. 1 Support .................................................................................  Checklist for cable inquiry.................................................. 3

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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. Use of lower capacitance XLPE cable significantly reduces the charging current flowing in the cable circuit. The insulation system in an XLPE cable. This results in lower losses and higher load carrying capability in the cable circuit. Excellent reliability performance Due to continuous improvements in material characteristics and manufacturing processes. This lower capacitance of the XLPE cables offers numerous technical and economical benefits. 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. the Middle East and Asia. Indeed. Use of lower capacitance XLPE cable reduces the need for shunt reactors and other costly equipment for reactive power compensation. 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. substantial amounts of oil may inadvertently be released to the environment. Also. To date. North-American transmission providers have relatively limited operating experience with XLPE cables at 230 kV and above and. Accordingly. may not yet fully appreciate the many technical. 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. 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. splices and terminations) to the municipal power company in Stockholm. due to corrosion or excavation near the cable trench). Sweden..INTRODUCTION XLPE Cable Systems Introduction Over the past 25 years. ABB has delivered more than 900 kilometers of XLPE cable for system voltages at 220 kV and above.. For example. since 1973 ABB has delivered more than 7. cross-linked polyethylene (XLPE) cables have been extensively used in underground transmission circuits at 220 kV and above in Europe. Indeed. therefore. the costs of losses over the expected service life of a HPFF cable system is higher than for a XLPE-insulated cable system. installation and operational advantages of the XLPE technology. on the other hand. cables.e. XLPE cables need very little maintenance and generally are considered maintenance free. in 1984. 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. During failures in the oil handling and processing equipment or in case of a leak in a steel pipe conduit (e. 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.400 kilometers of XLPE cable for system voltages of 100 kV and above. there is no risk of oil release to the environment. 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.008 failures per 100 miles per year. The average failure rate reported for these ABB supplied cables between 1990 and 2003 was approximately 0.g. 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. Until recently. • • • ABB 3 . charging current losses and losses in reactive power compensation equipment. is based on a solid dielectric and. therefore.

Halogen free flame retardant .or three-core XLPE cables consist of the following components: • Conductor .com 4 ABB .Copper (Cu) or Aluminum (Al) stranded compacted conductor or . More information about our accessories is available on www.Cu or Al laminate solidly bonded to outer polyethylene jacket or .PE .Lead sheath Longitudinal water sealing of metallic screen • Non-metallic outer sheath .Double wire armour Cable accessories ABB’s 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 fluidfilled 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.Single wire armour . Especially suitable for 3-core submarine cables and for cables with a copper wire metallic screen.PVC . as an alternative to separately installed optical fibre cable. installation and testing XLPE cables Single.Cu segmented conductor or .Co-extruded conductive layer over the sheath for special sheath testing • Armour .Longitudinal water sealing of conductor • Triple extruded and dry cured XLPE insulation system • Metallic screen Copper wire screen Copper tape screen Radial water sealing .XLPE CABLE SYSTEMS .DESIGN. INSTALLATION AND TESTING XLPE cable systems – design.abb.Cu or Al conductor with key-stone shaped profiles .

• 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. INSTALLATION AND TESTING Installation of XLPE cable systems Installation of cable systems includes trenching. type tests and after laying tests are performed according to AEIC CS7-93 for cables 69 kV . ABB has long and extensive experience from different types of cable installations including direct burial. pipe jacking and others. • 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 ABB 5 . sample tests. Routine tests of XLPE cables and accessories • PD-measurement test. Testing of XLPE cable systems Standard routine tests. tunnel and submarine installations. clamping of cable. shaft.138 kV and above that level. but also trenchless technologies like directional drilling.XLPE CABLE SYSTEMS – DESIGN. according to IEC 62067. 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. duct. cable pulling. cable splicing as well as mounting of accessories. trough.

IEC 60287 Electric cables . Test methods and requirements. 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). IEC 60853 Calculation of the cyclic and emergency current rating of cables. or AEIC (Association of Edison Illuminating Companies): CS7-93 Specifications for cross-linked polyethylene insulated shielded power cables rated 69 through 138 kV.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 XLPE cable systems specified according to IEC (International Electrotechnical Commission) are among many other standards accepted.2 kV) up to 30 kV (Um=36 kV). ISO Standards ABB has well-developed systems for quality and environmental management which put the needs and wishes of the customer first. Some of these are listed below. ISO 14001 and ISO 9001 - Certificate of Approval 6 ABB . IEC standards are considered to express an international consensus of opinion. Our systems comply with the requirements of ISO 9001 and ISO 14001 and are certified by Bureau Veritas Quality International. 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. Inc. Some frequently used standards are: IEC 60228 Conductors of insulated cables.XLPE CABLE AND CABLE SYSTEM STANDARDS XLPE cable and cable system standards ABB´s XLPE cable systems are designed to meet requirements in international and/or national standards. S-108-720 Standard for extruded insulated power cables rated above 46 through 345 kV. IEC 60502 Power cables with extruded insulation and their accessories for rated voltage from 1 kV (Um=1. cables are often specified according to ICEA (Insulated Cable Engineers Association. ICEA and AEIC In North America.

by reducing or eliminating the metallic sheath currents through different methods of bonding. but no significant current will flow. In such case. but in general the accepted screen voltage potential limits the length. conductor area and available space for installation. The choice depends on several factors like screen bonding method. which reduce the cable current carrying capacity. This method permits a cable current-carrying capacity as high as with single-point bonding but longer route lengths than the latter. 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. In such case. This induced voltage is proportional to the cable length and current. 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. a voltage will be induced in between screen and earth. Trefoil or flat formation ABB 7 . a voltage will be induced between screens of adjacent phases of the cable circuit and between screen and earth. Single-point bonding can only be used for limited route lengths. it is possible to incresase the load current carrying capacity (ampacity) of the cable circuit. It requires screen separation and additional link boxes. but no current will flow. This will cause losses in the screen. Typical formations include trefoil (triangular) and flat formations.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. The maximum induced voltage will appear at the link boxes for cross-bonding. 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. 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. These losses are smaller for cables in trefoil formation than in flat formation with separation. Therefore.

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.1a Fig. The cost of energy losses can be reduced by using a larger conductor. Continuous current ratings for single-core cables are given in Tables 1-4.1b Phase location in duct banks Fig. Dielectric losses in XLPE cables are lower than for EPR and fluid-filled cables. Fig. Rating factors for single-core cables are given in Tables 5 to 7. XLPE cables can be loaded continuously to a conductor temperature of 90°C. 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. The continuous current ratings are calculated according to IEC 60287 series of standards and with conditions according to Figure 1a. Load losses in XLPE cables are primarily due to the ohmic losses in the conductor and the metallic screen. 1b and 2.2 8 ABB .

8 Single circuit single point bonding / cross bonding Single circuit bothends bonded 2circuits 2circuits single bothpoint ends bonding bonded / cross bonding kcmil 750 1.060 A 440 495 530 565 590 610 650 675 A 545 635 715 785 850 900 1.500 3.90 1.35 1.090 1.085 1.440 A 510 555 590 615 640 685 715 740 A 580 670 745 810 865 985 1.000 kcmil 180 180 180 180 180 180 180 180 A 535 65 700 775 835 885 980 1.190 1.8 Single circuit single point bonding / cross bonding Single circuit bothends bonded 2circuits 2circuits single bothpoint ends bonding bonded / cross bonding kcmil 750 1.185 A 40 455 480 500 50 550 575 595 A 740 860 965 1.085 A 440 490 530 560 585 605 640 665 A 455 530 595 655 705 745 85 890 A 365 405 435 460 480 495 50 540 A 585 685 770 850 90 975 1.165 1.010 A 415 460 495 55 545 565 595 60 Table 2 Rated voltage 138 kV (and 115 kV).750 .CURRENT RATING FOR XLPE CABLE SYSTEMS Current rating for single-core cables.405 A 515 560 595 65 650 695 730 755 A 690 800 890 970 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 0.500 3.430 1.180 kcmil screen Load factor 1.500 1.005 1.40 1.000 .95 1.465 1.50 1.140 1.50 1. amperes .190 A 485 540 585 60 650 675 715 750 A 510 595 670 735 795 845 935 1.cables in duct banks Table 1 Rated voltage 138 kV (and 115 kV).345 A 475 50 550 575 595 635 665 690 ABB 9 .500 1.040 1.550 A 550 65 665 700 730 785 85 860 A 750 870 975 1.310 1.170 A 485 545 590 630 665 685 730 765 A 590 690 775 855 930 985 1. copper conductor .180 kcmil screen Load factor 1.115 1.050 1.000 kcmil 180 180 180 180 180 180 180 180 A 680 790 880 955 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 0.000 1.00 1.750 .000 .065 1. aluminum conductor .15 1.000 1.100 1.595 A 560 615 655 690 715 770 805 840 A 650 755 840 910 975 1.

955 A 645 690 75 750 805 840 870 910 945 A 740 85 895 960 1.105 1.40 A 560 610 650 680 705 745 780 815 850 A 590 660 75 780 830 90 1.175 1.500 kcmil screen Load factor 1.160 1.730 1.750 .185 A 470 510 540 565 580 615 635 665 685 Table 4 Rated voltage 345 kV (and 230 kV).500 kcmil screen Load factor 1.95 1.070 1.085 1.000 1.060 1.480 1.000 3.145 1.095 1.90 1.750 .70 1.560 1.035 1.310 1.590 1. copper conductor .8 Single circuit single point bonding / cross bonding Single circuit bothends bonded 2circuits 2circuits single bothpoint ends bonding bonded / cross bonding kcmil 1.944 4.170 1.165 1.70 A 510 545 580 605 65 665 685 70 745 A 55 585 640 690 730 805 880 960 1.05 1.944 4.305 1.400 1.65 1.005 1.000 .500 1.90 1.060 1.45 1.500 3.0 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 0.405 1.000 .615 A 540 575 600 60 655 685 705 730 760 10 ABB .095 1.000 3.50 1.50 1.45 A 505 545 580 605 630 665 695 730 755 A 65 705 775 835 885 985 1.000 1.CURRENT RATING FOR XLPE CABLE SYSTEMS Table 3 Rated voltage 345 kV (and 230 kV). aluminum conductor .680 A 580 60 645 670 715 750 775 810 840 A 790 880 960 1.050 1.175 1.590 1.15 1.500 1.065 1.395 A 560 610 650 680 705 750 790 830 865 A 685 770 850 90 975 1.931 kcmil 500 500 500 500 500 500 500 500 500 A 615 690 760 80 870 965 1.740 A 580 60 640 670 710 745 760 790 85 A 660 730 790 845 960 1.500 3.400 A 470 500 50 535 565 590 605 65 645 A 850 950 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 0.190 1.440 1.890 A 650 695 730 755 810 850 885 95 970 A 860 965 1.035 A 415 445 470 490 505 530 550 570 590 A 675 760 835 905 960 1.330 1.15 1.775 1.550 1.000 1.8 Single circuit single point bonding / cross bonding Single circuit bothends bonded 2circuits 2circuits single bothpoint ends bonding bonded / cross bonding kcmil 1.931 kcmil 500 500 500 500 500 500 500 500 500 A 775 865 940 1.

98 0.1 1.944 1.03 1.03 1.98 0.000 .500 3.10 1.50 1.1 1.98 500 1.000 1.0 1.99 0.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.0 1.500 3.05 1.000 .01 1.0 1.500 1.11 15 1.750 .000 1.98 0.50 1.99 0.0 1.000 3.01 1.931 Cu Table 6.0 1. Table 5.98 0.98 0.1 1.88 45 0.03 1.05 1.750 .750 .04 5 1 30 0.000 Cu 45 1.98 0.00 1.000 1.06 1.98 0.500 1.99 0.03 1.9 40 0.500 3.10 1.000 .0 1.0 1.07 180 1 1 1 1 1 1 1 1 1 1 360 1.83 ABB 11 .04 1. 115-138 kV cable with 180 kcmil screen Rating factor for tables 1 and 2 Conductor kcmil Al 750 1.03 1.50 1.944 4.98 0.97 0.03 1.0 1.000 .000 1.00 1.04 1.07 0 1.98 0.0 Al 1.98 0.04 1.98 0.97 0.10 1.98 0.15 Copper screen kcmil 90 1.96 35 0.98 0.97 500 1 1 1 1 1 1 1 1 1 1 1 Rating factor for ground temperature Table 7.50 1. The rating factor does not apply to single-point bonding or cross-bonded systems.00 0.03 1.0 1.000 750 1.01 1.06 1. 115-345 kV cable with 500 kcmil screen Ground temperature °C Rating factor 10 1.03 Copper screen kcmil 180 0.97 0.98 0.500 1.00 1.0 1. 230-345 kV cable with 500 kcmil screen Rating factor for tables 3 and 4 Conductor kcmil 90 1.0 1.97 0.500 3.500 1.98 360 0.98 0.750 .98 0.05 1.00 1.0 1.06 1.00 1.000 3.

both ends bonded . Cyclic and emergency ratings can be calculated according to IEC publication 60853. Adjusted rating per group: 1. 1 ABB . This is specified in IEC 61443 “Short circuit temperature limits of electric cables with rated voltage above 30 kV (Um=36 kV). 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.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. Singular emergency overloads are not expected to produce any significant impact to the expected service life of the cable.03 x 1. Rating factor for screen 90 kcmil and copper conductor is 1. an XLPE-cable may be overloaded above 90°C and the conductor temperature may reach up to 105°C. Table 2 gives a continuous load of 455 A with copper screen 180 kcmil and 25°C soil temperature. However both occurrence and duration of these overloads should be kept at a minimum.ground temperature 15°C.07 x 455 = 501 A Overload capacity As infrequently as possible.03 (table 5).07. The dynamic forces between the conductors must be taken into account for cable installations. Rating factor for ground temperature 15°C (table 7) is 1.

50 1.7 7. 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 61 1. See the 1second value in Table 8 for the conductor and in Table 9 for the metal screen.750 .075 Al conductor 36 48 60 7 84 96 10 144 189 37 0.5 7.5 14.0 14.450 5.048 Dynamic forces during short circuit events In addition to the thermal stresses.5 Ish ) 1sh = short current [kA] RMS S F = centre to centre spacing between conductors.014 70°C 3. With an initial temperature of 50oC this corresponds to a current density of 83A/ kcmil during 1s.944 4.000 . tsh= short-circuit duration (sec) For XLPE insulated conductors the maximum allowable short circuit temperature is 250oC. The dynamic force between two conductors can be calculated as: Where. For three phase systems in triangular configuration the force is 0.000 1. Ipeak = peak current. For design purposes.87F for the middle cable and 0.0 8 39 58 0.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.2 to 5.484 3. inches = maximum force Lbf/ft For three phase systems in flat configuration the force is 0. an equivalent short-circuit current with a duration of 1 sec is used according to formula below.) Lead sheath temperatures of up to 210oC are permitted in connection with short circuit events. the dynamic forces in the cables and accessories during a short circuit event must also be considered.0 sec.9 30 4 6 0.500 3.4 .000 3. This formula is valid for a short-circuit duration of 0.81F for the outer cables. (Both higher and lower current densities may be allowed if other conditions apply.013 Ish= short-circuit current [kA] during time tsh I1 = short-circuit current rating during 1 second. [kA] = (2.931 per kcmil Cu conductor 54 73 91 109 17 145 181 18 86 357 0. With an initial temperature of 50oC this corresponds to a current density of 14 A/kcmil during 1 s.87F. Copper screens may reach a temperature of 250oC without damaging adjacent insulating material. Table 8 Max short-circuit current on the conductor during 1 s kA Conductor temperature 90°C before short-circuit Cross section kcmil 750 1. ABB 13 .0776 0.175 Metallic screen temp before the short circuit 50°C 3.500 1.083 0.

59 .035 3.54 1. 4.165 1.01 6.645 7.575 .789 St 40 9.776 7.660 6.165 .657 .13 1.364 4.066 1.677 7.48 .65 . Table 10 Selection of cable drum Cable lenghts in feet on standard drum K22 .591 1.100 St 28 .98 4.117 3.165 .791 6.710 6.887 .330 .330 3.549 10.117 .48 .64 .510 3.461 .575 1.645 8.051 .117 3.48 3.477 .970 3.066 K28 .575 1.8 .69 4.48 3.69 4.495 3.30 8.066 1.10 5.151 4.5 3.003 3.066 1.101 4.01 7.05 5.117 .871 3.001 .774 5. inch 3.64 .857 6.904 .760 8.543 .St 43 Cable dia.69 4.446 5.4 4.576 .476 1.64 .657 1.035 4.919 1.6 3.6 4.610 4.30 10.549 11.330 3.004 5.051 .037 5.018 1.510 .1 4.495 4.066 984 90 90 K26 1.837 St 35 6.399 7.018 .117 3.675 3.69 3.690 .690 .789 St 39 8.871 3.660 5.46 4.199 4.98 4.051 1.95 1.41 3.CABLE DRUMS Cable drums Wooden drums/reels are standardized.050 755 755 689 689 689 Wooden drum K24 1.396 4.690 .399 8.31 1.01 5.739 1.789 St 43 11.117 3.756 .8 3.001 St 30 3.465 7.580 8.051 3.91 4.510 3.953 .888 4.01 6.001 St 32 5.919 1.986 .00 5.48 .47 1.47 1.476 1.675 3.17 4.035 4.903 1.41 3.953 .198 1.543 3.10 6.58 4.151 5.871 3.660 6. K22 1.18 3.199 3.33 6.49 5.1 5.41 3.101 3.65 .953 .675 3.871 3.904 14 ABB .69 4.1 3.675 3.710 7.774 5.840 4.740 3.575 .066 1.576 3.58 3.461 .69 4.476 1.857 6.95 1.640 1.69 4.035 4.41 3.100 .579 7.707 3.559 .63 1.8 4.101 4.48 3.675 .476 1.953 .49 5.379 1.01 7.657 1.543 .3 3.707 3.760 8.067 .690 .575 1.364 4.035 4.349 6.7 3.69 4.8 .181 1.580 9.837 Steel drum St 36 6.95 1.115 1.066 1.446 5.00 6.K30 and Steel drum St 28 .444 1.675 3.48 .01 6.690 .10 6.001 1.657 .8 .69 4.739 1.165 .97 St 38 8.364 3.48 .986 .00 5.117 .953 .49 4.004 6.953 .559 .066 1.48 .774 5.00 6.411 St 34 6.9 4.857 6.530 7.48 3.0 5.791 5.888 4.58 4.97 St 37 7.54 1. Both wooden and steel-drums can be obtained for special purposes with other dimensions than stated below. For certain purposes steel drums/ reels are applicable.559 .115 1.0 3.476 1.05 5.48 1.05 4.707 3.399 7.003 4.035 3.575 .707 3.645 8.05 4.560 4.871 3.530 6.051 .69 4.575 1.840 5.95 1.675 3.18 3.479 5.9 5.4 3.331 4.493 K30 3.756 .067 .774 4.953 .41 3. 3.953 .444 1.575 .969 1.477 .05 4.349 7.5 4.01 6.903 1.91 4.0 4.837 1.41 3.660 6.739 1.7 4.3 4.

7 94.9 5.818 174.7 94.179.5 5.7 153.173 146. 59.9 5.5 6.4 4.9 78.1 65.8 145.0 5. Steel drums with larger outer diameters are available.7 94.6 78.7 94.9 141.9 St 38 1.3 8.9 ft3 lbs inch inch inch inch inch 17.373.306. battens a Diameter incl.6 6.716 16.4 7.7 94. Maximum pulling forces The following pulling forces should not be exceeded: Aluminum conductors 4 Lbf/kcmil Copper conductors 7 Lbf/kcmil 15 ABB . 110.748 13.St 43 Steel drum St 28 Shipping volume Drumweight incl. 319 114.95 14.9 St 34 1.00.663.3 10.CABLE DRUMS | TESTING | CABLE HANDLING Table 11 A Sizes and weights of standard drum K22 .5 5.9 St 36 1.5 5.5 5.5 55.4 94.9 St 30 89.75 158. K26 37.7 94. but transport restrictions have to be considered.614 150.0 133.7 78.8 5.1 78. battens a Diameter incl.9 St 35 1.9 St 39 1.834 154.175 Routine test AC voltage test Partial discharge measurement at kV Max 10 pC 160 00 190 85 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 6067 115 138 0 345 kV 160 00 318 40 Duration minutes 30 30 30 30 De is the external diameter of the cable For other cable designs other bending radii may apply.850 131.6 86.7 94.6 157. Special wooden drums with larger barrel diameter or larger width are also available.050 1. 118.1 6.9 3. battens b Flange diameter c Barrel diameter d Total width e Spindle hole diameter Table 11 B Sizes and weights of drum St 28 .6 401 1.7 149.5 5. Large and special drums.0 78.7 78.1 16.1 46.5 5.115.K30 Wooden drum K22 Shipping volume Drumweight incl.5 5.9 1378 97. 78.73 139.4 110. battens b Flange diameter c Barrel diameter d Total width e Spindle hole diameter ft3 lbs inch inch inch inch inch 77.5 5.307 115.5 5.7 94. 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 1.5 78.9 St 40 1.1 70.5 5. K30 605. 146 89. 5.5 78. K24 59.4 59.43.9 54 106.1 59.9 137.5 3.0 5.8 78.3 78.1 47.9 St 37 1.7 94.7 94.9 St 43 1.5 5.0 118.1 57.6 55.7 94.7 7.444.4 169.9 St 32 939. Special lowloading trailers and permits from traffic authorities might be needed depending on local regulations and conditions.6 5. K28 490.

The interface surfaces between insulation and conductive screens are not exposed at any stage of the manufacturing. Class 2: Stranded circular or shaped conductors of copper or aluminum.00539 0. 16 ABB . . High quality material-handling systems.Swelling material between the conductor strands.000 1.CONDUCTORS | INSULATION XLPE Cable Design Conductors Standards – IEC and ICEA Conductors are manufactured according to the following standards: IEC (International Electrotechnical Commission) Standard Publication 60228.00463 0.944 4.45 1. S-97-682. the conductor can be water sealed by: .598* Nominal d.500 3.00885 0. ohm/1000 ft aluminum 0. A very smooth material is used to obtain good electrical performance. triple extrusion. The interface between the screen and the insulation is smooth.008 0.189 1.750 .0177 0. further specified in ASTM B 400-18 for aluminum.00715 0.0144 0.99* . i.059 1.00436 0. XLPE insulation The XLPE insulation is extruded simultaneously with the conductor screen and the insulation screen.004 *Segmented Cu conductor including tapes Insulation Conductor screen The conductor screen consists of an extruded layer firmly bonded to the XLPE insulation. The actual thickness for different voltage levels and conductor sizes is given in Tables 15 to 18. dry curing and super-clean XLPE materials guarantee high quality products.00719 0.50 1.496 1.036 0.77* 1. The material is a high quality conductive compound.0141 0.000 3. Conductor water sealing If required. Table 14 ICEA Cross section kcmil 750 1. ASTM B 496-81 for copper.0118 0.c resistance at 25°C.00363 0. The insulation thickness is determined by the design electrical stresses for AC or impulse.0108 0.931 Diameter mils 906 1.00596 0.00863 0.e.05* . This material turns into jelly when in contact with water. Standard Publication No.0037 copper 0. ICEA. triple extrusion.0101 0. Insulation screen This screen consists of an extruded layer firmly bonded to the XLPE insulation.319 1.500 1.000 .Filling compound between the conductor strands.00616 0.

which gives excellent mechanical properties. Longitudinal water sealing is achieved by using a water swelling material applied under the lead sheath. Copper may also be used.INSULATION | METALLIC SCREEN Metallic screen Copper wire screen. The laminate is bonded to the polyethylene. standard design A polymeric sheath covers the copper wire screen. water tight design Radial water sealing is achieved by using a metal-PE laminate. Longitudinal water sealing is achieved by using a water swelling material at the copper wires or swelling powder between the screen wires. Copper wire screen. Copper tape screen Cross section defined by the geometrical cross section of the copper tapes. Lead sheath Radial water sealing achieved by a corrosion resistant lead sheath. The metal is normally aluminum. ABB 17 .

18 ABB . Cables having a PVC sheath are considered as flame retardant. directly after laying. However. after transportation. This gas is highly corrosive and irritating to inhale. However. Experience shows that cables seldom initiate fires.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. Conductive outer layer A conductive outer layer facilitates testing of the nonmetallic outer sheath. PE is the first choice for most applications. upon completion of the installation. Special polyolefines with flame retardant properties but without chlorine or any other halogenes are optional for the outer sheath. Cables with a standard PE outer sheath do not generate any corrosive HCl but are not flame retardant. either in factory. 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. it generates hydrochloric acid fumes (HCl) acid. PVC is used when there are high requirements on fire retardation behaviour. Several serious fire accidents have focused attention on the fire behaviour of cables. once PVC is on fire. A conductive outer layer obtained by simultaneous extrusion with the non-conductive outer sheath presents superior electrical and structural properties. 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. This testing is important to ensure the physical integrity of the cable from time to time. or periodically thereafter.N O N .

1 1.055 0.77 9.189 1.3 906 1.18 1.500 1.83 1.16 0.169 43.3 39.061 0.041 0.8 40.63 13.45 1.18 0.78 10.93 0.96 7.10 3.74 .08 3.41 9.3 ** Inductance trefoil in duct w 9” horisontal and vertical distance *Inductance flat formation with distance c/c 9” between cables ABB 19 .00 3. nominal voltage 115 kV 750 1.78 15.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 μF/ 1000 ft mH/ 1000 ft mH/ 1000 ft Ω Table 15 Single core cables.053 0.50 1.45 1.81 4.189 0.68 180 180 180 180 180 180 180 180 3.38 3.3 3.05 0.18 0.68 3.6 36.41 1.195 0.673 1.5 3.58 6.184 0. nominal voltage 138 kV 750 1.41 8.181 0.050 0.3 8.36 15.58 180 180 180 180 180 180 180 180 3.189 0.71 5.14 6.000 906 1.7 3.174 0.7 34.181 0.177 0.76 8.500 3.496 1.4 30.054 0.71 6.58 1.30 1.7 3.1 3.0 35.673 1.1 0.000 1.33 7.0 3.16 0.67 .17 6. 5.750 .37 1.13 1.1 0.4 13.74 11.819 800 800 800 800 800 800 800 800 .05 0.5 5.05 0.41 10.174 0.41 1.64 1.51 3.04 5.71 6.51 1.0 0.059 1.750 .74 3.047 0.319 1.000 1.6 31.049 0.044 0.500 1.94 4.188 0.07 4.819 850 850 850 850 850 850 850 850 .54 6.64 3.064 1.045 0.38 3.177 0.61 0.0 8.59 1.5 33.61 3.169 44.17 3.184 0.18 0.000 .195 0.53 3.195 0.0 0.1 9.057 0.000 .07 6.188 0.500 3.65 7.57 .93 7.063 0.67 0.059 1.496 1.96 8.000 Table 16 Single core cables.189 1.84 .35 11.87 3.167 0.60 6.09 4.97 3.195 0.039 0.319 1.067 1.174 0.01 1.9 38.51 3.38 9.5 31.174 0.43 3.167 0.50 1.10 3.31 1.

0 0.88 13.37 3.673 1.55 3.83 9.195 0.195 0.7 3.30 3.346 900 900 900 900 900 900 900 900 900 .68 3.04 0.40 3.79 4.150 .000 1.7 34.188 0.319 1.0 37.496 1. 0.048 0.153 0.8 33.37 3.064 0.56 5.500 1.90 1.5 0.061 0.174 0.39 4.64 8.78 .4 11.174 0.045 0.000 3.91 7.11 4.50 .55 3.7 4.058 0.30 500 500 500 500 500 500 500 500 500 3.11 4.1 35.50 1.000 1.8 6.174 0.673 1.000 1.189 0.01 .000 3.189 1.7 3.93 10.181 0.174 0.95 3.346 1.50 1. 10.069 0.000 kcmil) 0 ABB .195 0.45 1.000 1.3 8.04 14.4 .819 .189 0.1 30.057 0.049 0.931 1.9 34.158 0.000 kcmil) *Inductance flat formation with distance c/c 10.944 4.71 1.184 0.931 Table 18 Single core cables.750 .819 .500 3.000 1.57 9.9 5.59 4.8 4.4 13.500 3.50 3.30 .068 .98 4.160 44.18 0.000 1.45 1.168 0.000 .01 4.16 3.06 7.160 4.158 0.496 1.181 0.30 3.78 4.195 0.37 9.4 6.045 0.90 1.50 500 500 500 500 500 500 500 500 500 3.175 0.188 0.81 3.0 0.0 0.57 3.3 36.167 0.94 3.167 0.15 15.10 9.04 0.88 4.31 4.63 3.000 1.150 .1 0.6 11.48 10.66 9.0 3.06 4.059 1.9 5.75 3.177 0.500 1.85 11.059 1.000 1.15 8.18 4.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 Ω mils μF/ 1000 ft A/ 1000 ft Table 17 Single core cables.43 13.7 13.1” between cables (11.319 1. nominal voltage 230 kV 1.7 41.07 3.80 5.184 0.80 16.15 .14 3.19 0. 39.153 0.94 3.04 8.189 1.000 .91 3.168 0.9 1.074 .165 0.11 7.46 8.4 4.051 0.165 0.944 4.66 4.8 1.55 8.000 1.054 0.6 39.000 3. nominal voltage 345 kV 1.” from 3.05 0. ** Inductance trefoil in duct w 9” horisontal and vertical distance (10” from 3.175 0.177 0.750 .33 17.047 0.039 0.83 3.80 10.000 1.0 17.44 4.1 3.18 0.98 4.

81 F for the outer cables. tsh = short-circuit duration (sec) For XLPE insulated conductors the maximum allowable short circuit temperature is 250oC. For three phase systems in triangular configuration the force is 0.3 Where U = f = C = tan δ = rated voltage (kV) frequency (Hz) capacitance (µF/1000 ft) loss angle Formula for inductance Where trefoil formation: K = 1 flat formation: K = 1. inches F = maximum force Lbf/ft For three phase systems in flat configuration the force is 0.FORMULAS Formulas Formula for capacitance Formula for dielectric losses Where ε d0 di ε XLPE = = = = relative permittivity of the insulation external diameter of the insulation (inches) diameter of conductor. [kA] (2. including screen (inches) 2.26 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 = short-circuit current during time tsh I1 = short-circuit current rating during 1 second. XLPE Formula for maximum short circuit currents Insulation screen: 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.5 Ish) 1sh = short current [kA] RMS S = centre to centre spacing between conductors.87 F for the middle cable and 0. Ipeak = peak current. See the 1-second value in table 8 for the conductor and in Table 9 for the metallic screen.87 F ABB 1 .

including AC and DC over-head lines. fluid-filled cable systems and extruded cable systems.SUPPORT Support The transmission network in most countries is very large and complex. Also. technical specialists and other staff will give their professional support in evaluating suitable solutions. It may incorporate many different types of transmission circuits. 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. ABB’s experienced project managers.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  ABB . etc. many modern networks contain extensive underground and submarine cable systems for supply of major metropolitan areas and for interconnection with neighboring countries.

ground temperature at laying depth Laying depth Thermal resistivity backfill If drying out. vulcanized. transformer. other Other test requirements Type * Qty * Installation data Cable configuration: Flat/Trefoil Type * Qty * Number of parallel circuits * Distance between parallel circuits Heating from existing cables If yes. etc. just insert N/A in the corresponding data cell). other Type test requirements. IEC. inside dimension of trough (width • height) If trough. PE. 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. 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. Single) ABB 3 . rod gap. pipes * Yes/No inch inch inch °C K•m/W K•m/W K•m/W inch *Required information kV kV A/MVA kA/s kA/s ft Cu/Al. distance to and losses of sources Screen earthing (Both ends. cross-section Longitudinal water protection * Radial water protection * Any special cable design requirements Customer specification Accessories Termination *Required information Type of termination and quantity.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. outdoor. CBS.) Specific requirements on cable length per delivered drum Do any specific metal prices apply Installation: Turnkey by ABB Installation by ABB Supervision by ABB * * * * *Required information * * * * * Installed in air Air temperature. In order for us to identify the best overall design solution for a specific application. IEC. Cross. filled or unfilled Exposed to solar radiation Direct buried installation Soil. etc. Joints Type of joint and quantity - premoulded. sample and after installation test. W/ft *Required information Tests Routine. thermal resistivity dry backfill close to cable Backfill material: selected sand. *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. CBS. polymer insulator. GIS. distances to and losses of parallel cables Other heat sources. etc * Yes/No Yes/No °C inch K•m/W K•m/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. steel. Indoor. kcmil Yes/No Yes/No Material: PVC. maximum Installed in trough If trough. sectionalized. etc Special requirements for trench Cables in duct bank. straight etc *Required information Special requirements Link boxes Type of link box Special requirements Other accessories Other relevant information inch Yes/No inch. Special requirements - pollution level. W/ft inch. Fibre. AIS. thermal resistivity dry backfill close to duct Laying depth Backfill material: selected sand.

com www.abb. Västerås 0610 Brochure issued by: ABB’s high voltage cable unit in Sweden Phone +46 455 556 00 Fax +46 455 556 55 E-mail: sehvc@se.abb.pdf Elanders.com/cables .For additional information please contact you local ABB Sales Office GM 5007 US.

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