Академический Документы
Профессиональный Документы
Культура Документы
ER 381
TITLE:
REPORT No:
ER 381
CUSTOMER:
AESO
AUTHORS:
DATE:
18 February 2010
INTRODUCTION
CCI has been engaged to perform a feasibility study into the use of 500 kV underground cables for the
Edmonton region of Alberta. The design requirements used within this study are generic and based on
those of the 500 kV 3,000 MW system known as the Heartland Project.
This document contains a description of the available cable technology, recommendations on the
feasibility of the cable technology and how underground cable technology needs to be developed so as
to be suitable for use in the Edmonton region.
Also included are:
Definitions and glossary (Section 16) for words that have been Capitalised.
An appendix recording individual studies, including:
Total cost estimates (in 2009 Canadian dollars) for nine scenarios comprising
different proportions of underground cable and overhead line, which were
provided by the Heartland Project Team (HPT) based on estimated cable system
costs provided by cable manufacturers and estimated civil cable installation costs
provided by HPT. HPT also provided the estimated costs of the overhead line and
all of the other equipment required for each scenario.
Preliminary project schedules, which were provided by HPT.
Distribution:
ER 381
CONTENTS
INTRODUCTION .................................................................................................................................... 1
1
EXECUTIVE SUMMARY............................................................................................................. 13
1.1
Introduction............................................................................................................................. 13
1.2
Method of approach ................................................................................................................ 14
1.3
Technical feasibility findings.................................................................................................. 16
1.3.1
Choice of cable technology............................................................................................. 16
1.3.2
500 kV XLPE cable system: supply capability and experience...................................... 17
1.3.3
Choice of installation technology ................................................................................... 18
1.3.4
500 kV Study Project size............................................................................................... 19
1.3.5
Project specific requirements .......................................................................................... 19
1.3.6
Low ambient temperatures.............................................................................................. 20
1.3.7
Proving the performance of the cable system before it is supplied ................................ 21
1.4
Estimates of reliability ............................................................................................................ 22
1.5
Estimates of capital cost.......................................................................................................... 24
1.5.1
Scenarios considered for costing..................................................................................... 26
1.5.2
Estimated capital cost: comparison between scenarios................................................... 28
1.5.3
Estimated Net Present Value: comparison between scenarios........................................ 29
1.5.1
Summary of cost estimates ............................................................................................. 30
1.5.2
Cost differences between cable and overhead line ......................................................... 31
1.6
500 kV Study Project duration................................................................................................ 32
1.7
Power losses............................................................................................................................ 33
1.7.1
Relationship of power loss to power transfer for the 500 kV Study Project .................. 34
1.7.2
Cumulative power losses for the 500 kV Study Project ................................................. 36
1.7.3
Estimated NPV of cumulative power losses ................................................................... 37
1.8
Recommendations for next steps ............................................................................................ 38
1.8.1
Study of end to end reliability and availability ............................................................... 39
1.8.2
System and design studies............................................................................................... 39
1.8.3
Carry out additional engineering studies, as required..................................................... 39
2
REQUIREMENTS FOR UNDERGROUND POWER TRANSMISSION SYSTEM FOR THE
500 KV STUDY PROJECT.................................................................................................................... 44
2.1
Functional requirement: .......................................................................................................... 44
2.1.1
Functional requirement: power transmission.................................................................. 44
2.1.1
Functional requirement: ambient temperatures............................................................... 46
2.2
Scenarios considered............................................................................................................... 48
3
BASIC DESCRIPTION OF 500 KV AC UNDERGROUND TECHNOLOGY ........................... 56
3.1
Alternating current transmission system................................................................................. 56
3.2
Voltage, current and power..................................................................................................... 56
3.2.1
Voltage ............................................................................................................................ 56
3.2.2
Power .............................................................................................................................. 58
3.2.3
Current ............................................................................................................................ 58
Page 2 of 310
ER 381
3.3
Component parts of the cable.................................................................................................. 59
3.4
Cable system ........................................................................................................................... 61
3.4.1
Component parts of the cable system ............................................................................. 65
3.4.2
Cable spans ..................................................................................................................... 65
3.4.3
Cable Terminations ......................................................................................................... 66
3.4.4
Cable Joints ..................................................................................................................... 68
3.4.5
Bonding equipment. ........................................................................................................ 69
3.5
Ancillary equipment................................................................................................................ 71
3.6
Hydraulic system for SCFF cable systems only ..................................................................... 72
3.7
Thermal design........................................................................................................................ 72
3.8
Thermomechanical design ...................................................................................................... 72
3.9
Installation design ................................................................................................................... 73
3.9.1
Cable installation............................................................................................................. 73
3.9.2
Assembly of joints and terminations............................................................................... 76
3.10 Route protection and identification......................................................................................... 78
3.11 Forced cooling......................................................................................................................... 79
3.12 Operation, maintenance and repair ......................................................................................... 81
3.13 Testing..................................................................................................................................... 81
3.13.1 Proving tests.................................................................................................................... 82
3.13.2 Quality tests..................................................................................................................... 85
3.14 Permissible length of an AC underground cable circuit ......................................................... 87
4
STATE OF THE ART FOR 500 KV UNDERGROUND POWER TRANSMISSION ................ 90
4.1
Introduction............................................................................................................................. 90
4.2
Self-Contained Fluid Filled Cables (SCFF)............................................................................ 91
4.3
Cross-Linked Polyethylene Cable (XLPE) ............................................................................. 94
4.4
Advantages of extruded cross-linked polyethylene cables ..................................................... 96
4.4.1
XLPE cable has the advantage over the SCFF type of : ................................................. 96
4.4.2
XLPE cable technology .................................................................................................. 97
4.5
Accessories for XLPE cable systems...................................................................................... 98
4.6
Cumulative service experience of XLPE cable systems ....................................................... 105
4.7
Electrical tests for XLPE cable systems ............................................................................... 111
4.7.1
Importance of prequalification tests for EHV XLPE cables......................................... 112
4.7.2
Prequalification test recommendations for the 500 kV Study Project .......................... 113
4.8
Low temperature operation ................................................................................................... 115
4.8.1
Ambient temperature levels for the Edmonton region of Alberta ................................ 115
4.8.2
Low temperature risks................................................................................................... 118
4.9
Types of cable installation .................................................................................................... 123
4.9.1
Direct Buried Installation.............................................................................................. 123
4.9.2
Duct-manhole system.................................................................................................... 126
4.9.3
Tunnel Installation ........................................................................................................ 128
4.9.4
Service experience with different methods of installation at 400 kV and 500 kV ....... 129
4.9.5
Service experience with forced cooled systems............................................................ 130
Page 3 of 310
ER 381
Page 4 of 310
ER 381
Page 5 of 310
ER 381
9.4.7
SCFF cable designs....................................................................................................... 226
9.4.8
GIL design..................................................................................................................... 226
9.4.9
Cable design types proposed......................................................................................... 227
9.5
Cable electrical values provided by suppliers....................................................................... 237
9.6
Splice designs proposed by prospective suppliers ................................................................ 238
10
TRANSITION STATION......................................................................................................... 240
11
POWER LOSSES ..................................................................................................................... 242
11.1.1 Relationship of power loss to power transfer for the 500 kV Study Project ................ 242
11.1.2 Cumulative power losses for the 500 kV Study Project ............................................... 244
11.1.3 Estimated Net Present Value of Losses ........................................................................ 246
12
GENERIC COST STUDY FOR THE 500KV STUDY PROJECT ......................................... 248
12.1 Cable system unit costs ......................................................................................................... 248
12.2 End-to-end estimated capital costs for the 65 km route length............................................. 249
12.3 Capital cost estimates: comparison of components in each scenario.................................... 250
12.4 Estimated Net Present Value of the life cycle costs for the 65 km route length................... 255
12.5 Comparison of the cost of each scenario ............................................................................ 256
12.6 Differences between the estimated cost of underground cable and overhead line ............... 257
12.7 Sensitivity studies on the estimated capital cost of the cable system ................................... 261
12.7.1 Sensitivity: Effect on cost of SCFF cable ..................................................................... 261
12.7.2 Sensitivity: Canadian Dollar value falls against other currencies by 20% ................. 261
12.7.3 Sensitivity: Metal prices change by 50%...................................................................... 263
13
500 kV STUDY PROJECT DURATION................................................................................. 265
13.1 Cable ..................................................................................................................................... 266
13.2 Transition station................................................................................................................... 266
14
UNDERGROUNDING THE ENTIRE 65 KM ROUTE LENGTH......................................... 267
14.1 Scenarios considered............................................................................................................. 267
14.2 Technical limitations............................................................................................................. 267
14.2.1 Voltage control.............................................................................................................. 267
14.2.2 Reduction in useful power transmission capacity because of cable charging current .. 267
14.3 Supplier capability ................................................................................................................ 268
14.4 Cost estimates ....................................................................................................................... 269
14.5 Cable system fault statistics for 65 km underground route length........................................ 269
15
500 kV STUDY PROJECT RISKS .......................................................................................... 271
15.1 Technical risks ...................................................................................................................... 271
15.1.1 Inability of the accessories to meet the required minimum winter design temperatures.
271
Remedial Action: .......................................................................................................................... 271
15.1.2 Uncertainty of the winter minimum design temperature .............................................. 271
15.1.3 Failure of the joints to demonstrate reliability in the Proving Tests............................. 272
15.1.4 Failure of the cable system to achieve reliable service performance............................ 272
15.1.5 Inability to repair the circuit at winter minimum ambient temperature:....................... 273
15.2 Contractual risks ................................................................................................................... 274
Page 6 of 310
ER 381
Page 7 of 310
19
20
21
22
23
24
25
26
ER 381
TABLE OF FIGURES
Figure 1. 500 kV Study project estimated capital cost main components ........................................... 25
Figure 2 Comparison of scenario trench cross sections.......................................................................... 27
Figure 3. Estimated capital costs in 2009 dollars.................................................................................... 29
Figure 4 Estimated NPV of the life cycle costs for each scenario .......................................................... 30
Figure 5. Power losses for selected scenarios at different levels of transmitted power.......................... 35
Figure 6. Overhead line: Normal operation ............................................................................................ 45
Figure 7. Overhead line: Contingency operation .................................................................................... 46
Figure 8 Comparison of scenario trench cross sections.......................................................................... 50
Figure 9 Scenario 1A.10 and 1B.20........................................................................................................ 52
Figure 10 Scenario 2A.10 and 2B.20...................................................................................................... 52
Figure 11 Scenario 3A.10 and 3B.20...................................................................................................... 53
Figure 12 Scenario 4A.10 and 4B.20...................................................................................................... 53
Figure 13 Scenario 5A.65 ....................................................................................................................... 54
Figure 14 Scenario 5B.65........................................................................................................................ 54
Figure 15 Scenario 6 : No cable.............................................................................................................. 55
Figure 16 Key to scenario diagrams ....................................................................................................... 55
Figure 17. Three parallel lines or cables are required to form an AC circuit ......................................... 56
Figure 18. Relative voltages of a 500 kV system ................................................................................... 57
Figure 19. Voltages between individual 500 kV cables.......................................................................... 57
Figure 20. Voltage across the insulation of a 500 kV cable ................................................................... 58
Figure 21. Component parts of a 500 kV XLPE cable ........................................................................... 59
Figure 22. The component parts of a cable system................................................................................. 61
Figure 23. Two circuits comprising four groups of underground cables................................................ 62
Figure 24. 400 kV transition station with terminal gantry..................................................................... 63
Figure 25. 400 kV transition station with terminal tower ....................................................................... 64
Figure 26. Two overhead line circuits connect to four groups of underground cable ............................ 64
Figure 27. Delivery with cable reel axle cross-wise ............................................................................... 65
Figure 28. Delivery with cable reel axle length-wise ............................................................................. 65
Figure 29. Loading cable reels in ships hold ......................................................................................... 66
Figure 30. Outdoor cable terminations ................................................................................................... 67
Page 8 of 310
ER 381
Page 9 of 310
ER 381
Figure 72: Construction and dimensions of Scoping Study 500 kV, 2500 mm, XLPE cable............. 164
Figure 73 Scenario 1 ............................................................................................................................. 167
Figure 74: Preliminary duct block arrangement ................................................................................... 169
Figure 75: Preliminary direct burial arrangement................................................................................. 172
Figure 76: Trench with sloped sides ..................................................................................................... 174
Figure 77: Spacing between Groups of Cables ..................................................................................... 176
Figure 78: Arrangement of circuits and construction Swathe.............................................................. 177
Figure 79: Photograph of construction swathe for four trenches.......................................................... 178
Figure 80: Sample ampacity calculation ............................................................................................... 179
Figure 81: Required phase spacing at increased laying depth .............................................................. 182
Figure 82: Requirement for cable installed by trenchless method........................................................ 183
Figure 83: Typical directional drill arrangement, plan view ................................................................ 183
Figure 84: Typical naturally ventilated tunnel ...................................................................................... 184
Figure 85: Compound containing two headhouses for naturally ventilated tunnels............................. 185
Figure 86: Typical reel dimensions and weight .................................................................................... 186
Figure 87: Conventional delivery ......................................................................................................... 187
Figure 88: Longitudinal reel on lowboy ............................................................................................... 187
Figure 89: Plan of typical joint bay....................................................................................................... 188
Figure 90: Longitudinal elevation of typical joint bay ......................................................................... 189
Figure 91: Elevation cross section across typical joint bay .................................................................. 189
Figure 92:Tunnel temperatures over a 10 year period .......................................................................... 191
Figure 93: Typical tunnel cable clamp (cleat) for a sagged system...................................................... 192
Figure 94:Tunnel cross section: deep tunnel......................................................................................... 193
Figure 95:Tunnel cross section: cut and cover...................................................................................... 193
Figure 96 Scenario 2, one group per circuit installed initially (black), the second later ...................... 194
Figure 97: Staging summary ................................................................................................................. 195
Figure 98: Scenario 2, staging for the duct-manhole system................................................................ 196
Figure 99:Scenario 2, staging for cables direct buried in the ground ................................................... 198
Figure 100: Scenario 2, staging for cables installed in deep tunnels .................................................... 199
Figure 101: Scenario 2, staging for cables installed in cut and cover tunnels ...................................... 201
Figure 102: Alternative SCFF 500 kV cable ........................................................................................ 204
Figure 103. Underground cable: design requirement............................................................................ 220
Figure 104 Cable spacing...................................................................................................................... 221
Figure 105. Cross bonding schematic ................................................................................................... 223
Figure 106. Detail of cross bonding components ................................................................................. 223
Figure 107: Proposed 500 kV design: extruded lead sheath ................................................................. 228
Figure 108: Proposed 500 kV design: welded aluminium sheath......................................................... 229
Figure 109: Proposed 500 kV design: corrugated aluminium sheath ................................................... 230
Figure 110: Proposed 500 kV design: copper wire screen and corrugated stainless steel sheath......... 231
Figure 111: Proposed 500 kV design: copper wire screen and lead sheath.......................................... 232
Figure 112: Proposed 500 kV design: wire screen and smooth aluminium sheath .............................. 233
Figure 113: Proposed 500 kV design: copper wire screen and aluminium laminate............................ 234
Page 10 of 310
ER 381
Figure 114: Proposed 500 kV design: self contained fluid filled ......................................................... 235
Figure 115: Proposed 500 kV design: GIL ........................................................................................... 236
Figure 116 One piece prefabricated joint (OPJ) ................................................................................... 239
Figure 117. Prefabricated composite joint (PJ)..................................................................................... 239
Figure 118. Indoor GIS switchgear....................................................................................................... 240
Figure 119. Power losses for selected scenarios at different levels of transmitted power.................... 243
Figure 120. Power losses for an average load of 457.3 MW ................................................................ 245
Figure 121. Estimated capital cost components in $M for 4 groups of Cables, 10 km long ................ 251
Figure 122. Estimated capital cost components in $M for 3 groups of Cables, 10 km long ................ 252
Figure 123. Estimated capital cost components in $M for 4 groups of Cables, 20 km long ................ 253
Figure 124. Estimated capital cost components in $M for 3 groups of Cables, 20 km long ................ 254
Figure 125. Estimated capital cost components in $M for all overhead line (Scenario 6) ................... 255
Figure 126. Historic variation in the value of Canadian dollar............................................................. 262
Figure 127. Historic variation in copper price (USD) .......................................................................... 264
TABLES
Table 1. Description of Scenarios ........................................................................................................... 26
Table 2. Table of Scenarios..................................................................................................................... 27
Table 3. 500 kV Study Project costs, cost differences and cost ratios compared to all-overhead line... 31
Table 4. Ratio of cost of underground cable and transition stations to an equal length of overhead line
.......................................................................................................................................................... 32
Table 5. Duration of cable supply and installation for each scenario ..................................................... 33
Table 6. Power losses for each scenario at an average load of 457.3 MW............................................. 36
Table 7. Power losses per circuit for each scenario at an average load of 1,000 MW ........................... 37
Table 8. PV of losses and of revenue requirement ................................................................................. 38
Table 9. Number of suppliers for each undergrounding scenario........................................................... 43
Table 10. Minimum design temperatures for cable ................................................................................ 47
Table 11. Minimum design temperatures for splices (joints) ................................................................. 47
Table 12. Maximum and minimum design temperatures for air insulated terminations ........................ 48
Table 13. Maximum and minimum design temperatures for gas insulated terminations ....................... 48
Table 14. Scenarios considered............................................................................................................... 51
Table 15 Cumulative quantities of underground cables of all types in each country ........................... 106
Table 16 Commercial applications of large conductor XLPE cable with joints by voltage,
conductors size, and circuit length ................................................................................................. 109
Table 17 Summary of the cumulative lengths at each voltage of major XLPE circuits with large
conductors, long lengths and joints ............................................................................................... 109
Table 18 XLPE Cable system component statistics: 315 kV to 500 kV............................................... 110
Table 19 SCFF Cable system component statistics: 315 kV to 500 kV ............................................... 110
Table 20 Total cable system components installed up to end 2005: 315 kV to 500 kV....................... 111
Table 21 Comparison of statistics of XLPE circuit from three sources................................................ 111
Page 11 of 310
ER 381
Table 22 EHV installation types, three phase cable lengths and number of projects ........................... 129
Table 23. Details of significant GIL applications ................................................................................. 135
Table 24. Details of some HTSC cables and applications .................................................................... 147
Table 25 CIGRE failure rates of components in 220 kV to 500 kV XLPE cable systems................... 154
Table 26 Failure rates of components in 220 kV to 500 kV XLPE cable systems by cause ................ 155
Table 27 Conditioned failure rates of components in 220 kV to 500 kV XLPE cable systems ........... 156
Table 28 Unconditioned cable system failure rates for the study scenarios for one year in-service .... 156
Table 29 Conditioned cable system failure rates for the study scenarios for one year in-service ........ 157
Table 30 Unconditioned cable system failure rates for the study scenarios for 40 years in-service .... 158
Table 31 Conditioned cable system failure rates the study scenarios for 40 years in-service .............. 158
Table 32 Numbers of faults in all types of 220 kV-500 kV AC land circuits by installation type....... 159
Table 33 OHL failure rates for the study scenarios for one year in-service ......................................... 160
Table 34 OHL failure rates for the study scenarios for forty years in-service...................................... 160
Table 35 Tunnel dimensions for scoping study .................................................................................... 190
Table 36. Magnetic field from EMF report (Appendix, Section 13) .................................................... 213
Table 37 Supplier responses: Average capacitance and dielectric losses for XLPE cable................... 237
Table 38 Supplier responses: Average capacitance and dielectric losses for SCFF cable ................... 237
Table 39 Supplier responses: Average capacitance for GIL................................................................. 237
Table 40 Combined conductor and sheath losses: XLPE cable mean and maximum ....................... 238
Table 41 Conductor and enclosure losses of GIL ................................................................................. 238
Table 42. Power losses for each scenario at an average load of 457.3 MW......................................... 245
Table 43. Power losses per circuit for each scenario at an average load of 1,000 MW ....................... 246
Table 44. Estimated NPV of power losses over a forty year period. .................................................... 247
Table 45. Capital cost estimates for each scenario (2009 dollars)........................................................ 250
Table 46. Estimated NPV of the life cycle cost for each scenario........................................................ 256
Table 47. Effect on estimated cost of number of Groups of Cables ..................................................... 257
Table 48. Effect on estimated cost of staging ....................................................................................... 257
Table 49. 500 kV Study Project Estimated costs, cost differences and cost ratios compared to alloverhead line .................................................................................................................................. 258
Table 50. Ratio of estimated installed cost of underground cable to an equal length of overhead line 259
Table 51. Ratio of estimated cost of underground cable and transition stations to an equal length of
overhead line .................................................................................................................................. 259
Table 52. Estimated capital cost increase if SCFF cable is used .......................................................... 261
Table 53. Estimated capital cost change if Canadian dollar value should vary by 20% ...................... 263
Table 54. Estimated capital cost change if cable metal prices should vary by 50%............................. 264
Table 55. Duration of cable supply and installation for each scenario ................................................. 265
Table 56 Unconditioned failure rates for a 65 km cable route length for one year in-service ............. 269
Table 57 Conditioned failure rates for a 65 km cable route length for one year in-service ................. 270
Table 58 Unconditioned failure rates for a 65 km cable route length for forty years in-service .......... 270
Table 59 Conditioned failure rates for a 65 km cable route length for forty years in-service .............. 270
Page 12 of 310
1
1.1
ER 381
EXECUTIVE SUMMARY
Introduction
CCI has been engaged to perform a study into the feasibility of using 500 kV underground cable for a
transmission system in the Edmonton region of Alberta. The example used for the 500 kV Study
Project is generic and based on the two 3,000 MVA circuits known as the Heartland Project, with the
understanding that the findings could be applied to other 500 kV transmission applications in the
Edmonton region of Alberta. This report does not include an economic optimisation of the design as
this would be performed at some future stage should it be decided to proceed with an underground
option.
The scope of the feasibility study also includes the identification of the next steps to be taken if it is
decided to proceed with a detailed evaluation of an option that includes underground cable.
While the AESO and others have provided information to CCI relevant to the study, the findings and
recommendations are those of CCI alone.
The main issues that have been addressed are:
Reliability
Reliability of the 500 kV cable system is summarised in Section 1.4 and is discussed within
Section 5.2.1.
Reliability of the 500 kV overhead line systems is discussed within Section 5.3 and
information is given in Appendix, Section 1.
Estimated costs
These are summarised in Section 1.5 and is discussed in Section 12, with detailed
information being given in the Appendices, Sections 2 and 3.
Power losses
This is summarised in Section 1.7 and discussed in Section 11, with detailed information
being given in Appendix, Section 5.
Page 13 of 310
1.2
ER 381
Method of approach
This report is based on the prospective requirement to use underground cable for all or part of two
500 kV Transmission circuits in the Edmonton region of Alberta. This is referred to as the 500 kV
Study Project. The example upon which the design parameters and the terrain of the route of the
500 kV Study Project have been based is the proposed Heartland Project, which consists of two parallel
500 kV, 3,000 MVA circuits with a route length of 65 km per circuit.
A summary of the division and sequence of work between CCI, HPT and AESO is given below:
CCI
Page 14 of 310
HPT
AESO
ER 381
Selected preliminary routes for indicative civil and installation costing purposes, comprising
installation of a) cable laying in normal conditions and b) cable crossings of route
obstructions.
Selected the installation type, i.e. that the cable should be direct buried in the ground. This
being considered to be the lowest cost option.
Compiled a project schedule.
Compiled the total estimated capital costs of nine scenarios comprising a) different
proportions of underground cable to overhead line and b) transition stations.
Studied the effect of the underground cable on the operation of the system.
Studied the effect of reactive compensation on the operation of the transmission system
containing underground cable.
Compiled the lifecycle costs of nine different scenarios.
Calculated the cost of losses of the cable, reactors and overhead line.
In order to obtain information for the 500 kV Study Project on the availability of 500 kV cable systems
and the estimated costs for cable systems, a number of prospective manufacturers were contacted and
technical proposals and budgetary prices were requested. The request was based on the requirements
for the Heartland Project, with a generic underground route length of nominally 10 km. The ambient air
and ground temperature information given to suppliers was based generally on the design parameters
that had been used for the 240 kV Downtown Edmonton Supply and Substation (DESS) underground
cable project.
The estimated cost provided by each prospective cable supplier was given on the basis that, for
commercial reasons, it would remain confidential. The estimated cost and design information have
therefore been presented in this report a non attributable manner. A summary of the designs proposed
by prospective suppliers is given in Section 9.
Different scenarios, which each include some underground cable, were agreed for study; Figure 9,
Figure 10, Figure 11 and Figure 12. Each scenario comprises different combinations of underground
cable length, overhead line length and numbers of parallel Groups of Cables. These scenarios include
options for undergrounding the following generic lengths in a nominal 65 km route:
The estimated costs of the scenarios containing either a 10 km or 20 km length of underground cable
were compared with the estimated cost of a 65 km all-overhead line scenario, with no underground
cable. Some consideration was also given to the engineering implications of undergrounding the entire
65 km route, Section 14, although the costs were not estimated.
Page 15 of 310
ER 381
To obtain representative costs for installation conditions, indicative routes in the Edmonton
Transportation Utility Corridor (TUC) were chosen by the HPT. The lengths of these indicative routes
do not necessarily correspond with the generic 10 km and 20 km lengths chosen for the study. These
are shown in Appendix, Sections 6 and 7. The work by the HPT is acknowledged with thanks.
Indicative installation designs were prepared by CCI so that the feasibility of undergrounding could be
evaluated and to determine the civil cost and practicability. These were based on the ground conditions
through which the cable system would have to be installed and the types of obstruction which would
have to be crossed. Details of these indicative designs are given in Section 7.
Information was collected and compiled for inclusion in this report by CCI from information supplied
a) on the cable system by the cable manufacturers and b) on the type of civil works installation supplied
by the HPT.
The estimated costs given in this feasibility study were expected to be within a range of plus or minus
thirty percent.
1.3
Accelerated aging conditions at elevated voltage and high current loading for one year to
IEC 62067[1]
Simulated low ambient temperature for a representative period, this being a special
requirement for this 500 kV Study Project.
The reasons for the choice of this technology and the need to demonstrate performance are given
below.
1.3.1
Page 16 of 310
ER 381
XLPE cable is preferred to the alternative pre-existing design of cable, which is the selfcontained fluid-filled (SCFF) type insulated with polypropylene paper laminate (LPP) tape.
The numbers of applications and suppliers of SCFF cable are presently falling to a level
where it is foreseen that it will soon become obsolete for land cable applications. The
suitably trained and experienced personnel and specialist equipment which would be
required for a SCFF cable system for the 500 kV Study Project will consequently become
increasingly difficult to obtain. There are also environmental concerns regarding possible
leakage of insulating fluid from SCFF cable systems.
1.3.2
Other technologies of Gas Insulated Line (GIL) and High Temperature Superconducting
(HTS) cable have also been evaluated. GIL is a possible alternative for a tunnel application,
but is not recommended for a long length buried application. (No proposals for buried GIL
systems have been received from any prospective suppliers.) GIL has the advantages of a
high power carrying capacity and reduced need for reactive compensation. A long length
GIL circuit contains large volumes of Sulphur Hexafluoride (SF6) insulating gas and there
are some environmental concerns regarding possible leakage. HTS cable has not been
sufficiently developed for use in a high power, long length application with joints, such as
the 500 kV Study Project and so is not considered further.
The typical design of direct buried XLPE cable system proposed by prospective
manufacturers to meet the requirement to transmit 3,000 MW comprised two cables per
phase each having a copper conductor with a cross sectional area of 2,500 mm. This
conductor size is at the top end of the range that has been installed to date. Conductor sizes
of up to 3,500 mm have been developed for 500 kV cable.
The majority of the prospective manufacturers who were contacted were willing to offer a
500 kV XLPE underground cable system for the Heartland Project. From a supplier
perspective a 500 kV XLPE underground cable system is thus indicated to be technically
feasible. The cables and joints are prospectively suitable for installation either in the ground
(buried or in ducts), or in tunnels.
A fully tested and service proven off the shelf design of 500 kV XLPE cable system
(cables, accessories and ancillaries) does not exist for the 500 kV Study Project. Suitable
designs of proven 500 kV XLPE cables and terminations exist, but the analysis of
Page 17 of 310
ER 381
Three suppliers have commercial experience with the manufacture and installation of large
conductor 500 kV cable and joints. There are many 400 kV cable systems in operation that
contain XLPE insulated cables having the same 2,500 mm conductor size that would be
needed for the 500 kV Study Project. Many of these include the prefabricated joint types
proposed for the 500 kV Study Project. However, the 400 kV cables and joints operate at a
lower electrical stress than is required for the 500 kV Study Project. The existence of these
400 kV circuits is a good indicator that there are several more manufacturers who have the
right level of capability and experience to develop, manufacture and install a long length,
high power 500 kV cable system.
It is normal for manufacturers to custom-design underground EHV transmission circuits for
each particular application, including the necessary supporting development work and
Proving Tests.
1.3.3
The most appropriate cable installation technology for the 500 kV Study Project is direct
buried, naturally cooled, in terms of simplicity and anticipated total costs. A forced cooled
system is more complex than a naturally cooled cable system. Because of the need for
planned or unplanned outages to maintain the cooling equipment, it is less likely to be
available for service. A naturally cooled system has no cooling equipment.
Prospective cable system suppliers provided designs and cost estimates for cable systems
suitable for installation in naturally cooled direct buried, naturally cooled duct-manhole and
forced ventilated tunnel arrangements. The HPT have provided installation cost estimates
for the direct buried, naturally cooled, method.
The layout proposed by most manufacturers comprised four trenches each containing one
Group of Cables. This is shown in Figure 23 and with installation dimensions typically as
Page 18 of 310
ER 381
shown in Figure 78. This arrangement consists of two circuits, each comprising two Groups
of Cables. Each Group of Cables has three individual single core cables installed in one
trench. For the purpose of this feasibility study a total of eleven layout scenarios was
considered in varying levels of detail. The scenarios have either different lengths of
underground cable, different numbers of Groups (trenches) and different phased installation
time Stages. The scenarios are described in Section 2.2.
1.3.4
An underground cable system for the 500 kV Study Project would be one of the largest in
the world to date. If the route length were to be 20 km, and if two circuits, each consisting
of two Groups of Cable were to be selected, the quantities of cable would be equal to those
in the only very long 500 kV circuit in commission to date (in Tokyo). The Tokyo tunnel
circuit was supplied by four cable manufacturers and commissioned nine years ago. (Since
the installation of the Tokyo project, there has been a consolidation in the number of
Japanese cable makers from four to two). The quantities required for the 500 kV Study
Project are within the supply capabilities of cable manufacturers.
This would be the first application of direct buried, long length, large conductor 500 kV
XLPE cable.
The 500 kV Study Project has the combination of the highest system voltage of 500 kV and
one of the highest power ratings of 3,000 MVA, which results in a large conductor area of
2,500 mm and a large diameter cable. The large cable size poses challenges to the
manufacture, delivery and installation of worthwhile drum lengths of cable and in particular
to the designs and performance of the accessories (joints and terminations) required.
1.3.5
Page 19 of 310
1.3.6
ER 381
The winter air and ground temperatures that occur in the vicinity of Edmonton are lower
than those previously reported for any other 400 kV and 500 kV applications of XLPE cable
systems. Some manufacturers submitted their experience lists for transmission voltages of
less than 400 kV. These showed that some long length, large conductor cable systems have
been supplied into locations in which the minimum winter ambient temperature is possibly
less than zero degrees Celsius. However, no evidence of recorded minimum ambient
temperatures was provided. For the 500 kV Study Project cable system to be acceptable it
is necessary to demonstrate the operational reliability at low temperature of the cables and
accessories. The cable accessories are prospectively the most vulnerable, because the
elastomeric insulation would be operating closer to the glass transition temperature at
which the properties of high elasticity, believed to be essential for reliable electrical
performance, are lost.
Temperature records from the 240 kV DESS duct-manhole project in Edmonton, show that:
240 kV elastomeric joints and XLPE cable installed at 1.3 m depth have been
exposed to a winter ground temperature of -8oC.
To give an adequate margin of safety for the 500 kV Study Project, design
temperatures are recommended of:
500 kV joints in a direct buried installation: -15oC
500 kV joints in a duct-manhole installation: -20oC
-50oC
The winter design temperatures can be raised to higher and more acceptable temperatures at
which more service and test experience exists. Joint temperatures could be raised by burial
at greater depths, for example to a depth of 2.5 m, at which depth the minimum ground
temperature may be above 0oC, thus allowing the design temperature to be raised to, say,
-5oC. Cable termination temperatures can be increased by installation within a specially
Page 20 of 310
ER 381
constructed and temperature controlled building. This should allow the minimum air
temperature to be maintained above, say, 0oC and the design temperature to be raised to,
say, -5oC. (It is recommended that these alternatives be investigated in the next steps)
A consequence of installing the cable system at greater depths is that system ampacity is
reduced under the limiting summer rating condition. To ensure that the cable at greater
depth does not exceed its maximum design temperature in summer the following studies are
recommended to be performed:
1.3.7
It is recommended that the cable systems must pass the following proving tests before they
are supplied to the 500 kV Study Project:
Page 21 of 310
1.4
ER 381
Type test: a six week long series of high voltage laboratory tests to prove the
suitability of the cable system design selected for the study project.
Special proving tests: tests to demonstrate the reliability of the cable systems at
Edmonton cold winter temperatures. It is recommended that a specific series of
tests be specified and performed.
Most of the manufacturers expressed an interest in supplying the 500 kV cable systems for
this Project and in performing the necessary tests. Some manufacturers provided details of
the 500 kV proving tests that they had already commenced or completed, or are planning,
for 2,500 mm conductor cables and joints. None have yet completed a full series of tests
on the size of cable, type of joints and type of direct buried installation that would be used
for the Study Project. This is not considered to be an obstacle to them performing the
required 500 kV prequalification tests.
Estimates of reliability
Expectations of reliability
Utilities throughout the world are now purchasing XLPE cable systems at voltages up to the
highest EHV levels, which demonstrates their confidence in the reliability of this
technology.
Page 22 of 310
ER 381
present. Any faults detected are repaired, or replaced, before the cable system is accepted
into service.
Statistics show that a significant proportion of cable failures are due to third party dig-ins.
Adequate protection measures must be incorporated into the design of the installation.
Adequate surveillance and maintenance must be conducted throughout the service life. The
incidence of third party damage can then be expected to be low.
Repair times
The average estimated time to repair the 500 kV XLPE cable system is 29 days, with a
variation between minimum and maximum times of 14 days. This estimated time is based
on data collected from a survey of 220 kV to 500 kV XLPE cable installations. This time
includes an allowance of four days for delays resulting from the extremes of weather and
ambient temperature expected to be encountered in the Edmonton region of Alberta.
Page 23 of 310
ER 381
reason a direct comparison with published failure rates for overhead lines has not been
presented. For information purposes, the published overhead line failure rates for sustained
outages [79] have been presented separately in Section 5.3.
Based on the published data [49] the estimated numbers of faults per year that occur in the
500 kV Study Project are given below for different numbers of Groups of Cables.
10 km
0.04 to 0.05
0.08 to 0.11
0.13 to 0.16
0.17 to 0.21
20 km
0.08 to 0.10
0.17 to 0.21
0.25 to 0.31
0.33 to 0.42
The above fault numbers include external damage (third party dig-ins, subsidence, etc).
Approximately 25% of the faults reported were as a result of external dig-in damage. This
demonstrates the importance of providing robust protection and surveillance systems for the
underground cable in the 500 kV Study Project.
The majority of internal failures were attributed to accessories. This demonstrates the
importance of robust design, stringent Proving Tests, quality control in manufacture, a high
level of jointer proficiency in their assembly and the use of stringent on-site after-laying
tests and in-service monitoring.
The above failure data only includes the cable system (cable, joints and terminations).
1.5
(Note: all costs in this report are in Canadian dollars, unless otherwise stated. All capital cost estimates
are in 2009 dollars).
The estimated capital cost for the underground part of the 500 kV Study Project has been derived from
anticipated price level information from prospective suppliers of 500 kV XLPE cable together with
estimates of the civil construction costs, which were supplied by the HPT. For the total route length of
65 km, the estimated costs also include the overhead line and the associated transmission equipment,
such as sub-stations, transition stations and reactive compensation, where required as depicted
diagrammatically in Figure 1.
Page 24 of 310
Substation
Overhead Line
(OHL)
ER 381
Transition
Station
Transition
Station
Overhead Line
(OHL)
Substation
Underground
Cable System
65 km
Substations (two)
The equipment necessary for the new 500 kV Study Project transmission line additional to the
existing substation equipment. This includes telecommunication equipment and other items as
detailed in Appendix, Section 2.
The construction of the, double circuit, 500 kV overhead line for the 500 kV Study Project
including diversions of existing lines as detailed in Appendix, Section 2.
The construction of the new 500 kV transition stations between the overhead line and
underground cable. This includes telecommunication equipment, reactors, switchgear and other
items as detailed in Appendix, Section 2.
The supply and installation of the new 500 kV underground cable system as detailed in
Section 12.1.
Page 25 of 310
1.5.1
ER 381
Owners costs
Distributed cost:
Contingency
Engineering and Supervision (E&S)
Allowance for funds used during Construction (AFUDC)
Estimates were prepared for eight scenarios for undergrounding either 10 km or 20 km of the 65 km
route, plus, for reference, an all-overhead line. The scenarios have (a) different proportions of
underground cable and overhead line lengths, (b) different numbers of groups of cables in parallel and
(c) different installation time stages in which not all of the Groups of Cables are installed initially.
These are shown schematically in Section 2.2, Figure 9, Figure 10, Figure 11, Figure 12 and Figure 15
Figure 2 gives a comparison of the cross section for each scenario, showing:
The number of Groups of Cables.
Whether they are installed in stage 1 or stage 2.
Scenario
1A.10
and
1B.20
2A.10
and
2B.20
3A.10
and
3B.20
4A.10
and
4B.20
6
Description
4 Groups of Cables (2 cables per phase),
all installed together
4 trenches
4 Groups of Cables (2 cables per phase),
2 installed initially and 2 later.
4 trenches total
3 Groups of Cables (2 circuits shared between 3 Groups of Cables),
all installed together
3 trenches
3 Groups of Cables (2 circuits shared between 3 Groups of Cables),
2 installed initially and 1 installed later
3 trenches total
All-overhead
Table 1. Description of Scenarios
Page 26 of 310
ER 381
10
OHL
km
55
No. of
Groups
of cable
4
3
65
20
45
4
3
65
(all
overhead)
Staged
Scenario
No
Yes
No
Yes
No
Yes
No
Yes
No
1A.10
2A.10
3A.10
4A.10
1B.20
2B.20
3B.20
4B.20
65
Page 27 of 310
ER 381
Note: Scenarios with three Groups of Cables (3A.10, 3B.20) have less substantial n-1 redundancy
margins than Scenarios with four Groups of Cables (1A.10 1B.20) in meeting the contingency
condition of 3,000 MW, as there is one spare Group of Cables available, compared with two spare
Groups.
Details of the cost estimates are given in Section 12, and in Appendices, Section 2 and Section 3. These
are summarised below for convenience.
The estimated costs in this feasibility study are expected to be representative to within a tolerance
of 30%.
1.5.2
The estimated capital costs of the scenarios considered are given in Table 45 in Section 12.2 and are
shown diagrammatically in Figure 3.
In Figure 3:
- The total estimated capital cost for each scenario is the sum of the stage 1 and stage 2 costs.
- The group of four columns on the left hand side represent the costs of the 10 km underground
scenarios.
- The group of four columns on the right hand side represent the costs of the 20 km underground
scenarios.
- In each pair of columns:
o The left hand column represents the estimated capital cost if all the cables are installed
at one time.
o The right hand column represents the estimated capital cost if the cable is installed in
two stages.
- The blue sections of the columns represents the estimated capital cost of either:
o The total of the un-staged scenarios
or
o Stage 1 only.
- The red sections of the columns represent the estimated capital cost of the stage 2 costs of
staged scenarios.
- The column on the far right represents an all overhead line estimated capital cost for
comparison.
Page 28 of 310
ER 381
1.5.3
The estimated Net Present Values (NPV) of the life cycle costs for each scenario over a period of
forty years are given in Section 12.4, Table 46, and are shown diagrammatically in Figure 4. The
estimated NPV of life cycle costs includes all the capital costs, the cost of losses and the costs of spares
and maintenance. The NPV takes into account when the costs are incurred and brings them forward to
the present value of money. The methodology of calculating the life-cycle costs is described in
Appendix, Section 3. NPV is a single number that expresses the estimated 40 year stream of costs in
terms of an equivalent lump sum paid today. In Figure 4:
- The four columns on the left hand side represent the estimated NPV of life cycle costs of the 10
km underground scenarios.
- The four columns on the right hand side represent the estimated NPV of life cycle costs of the
20 km underground scenarios.
Page 29 of 310
ER 381
Figure 4 Estimated NPV of the life cycle costs for each scenario
1.5.1
The comparison of the estimates of capital costs and NPV of life cycle costs in Figure 3 and Figure 4
show:
- The all overhead line scenario with no underground cable has the lowest cost
- The 65 km route scenarios with 10 km of underground cable have lower cost than those with
20 km underground.
- The scenarios with three groups of cable are lower in cost than with 4 groups. This is true even
though more costly switching equipment is required in the transition stations.
(Note, if three groups of cables are used instead of four then the cable system will have less
operating margin in contingency situations).
Page 30 of 310
ER 381
- The staged scenarios have the lowest estimated capital cost, but only in stage 1. When the
estimated cost of the stage 2 installation is added, the staged scenarios are higher in estimated
cost than the un-staged scenarios. This is because of the need to re-mobilize the installation
workers and equipment.
- The staged scenarios have a lower estimated NPV of life cycle costs than the un-staged
equivalent. The estimated NPV of life cycle costs for staged scenarios are 0.4% to 7.0% less
than the estimated NPV of life cycle costs of the un-staged scenarios.
The effect on cost of the number of Groups of Cable and of staging is shown in more detail in
Section 12.5.
1.5.2
Details of comparisons between scenarios are given in Sections 12.5 and 12.6, Table 49, Table 50 and
Table 51. The cost differences and ratios summarised in Table 3. Table 3 compares the estimated
capital cost and the estimated NPV of the life-cycle costs as:
348
1.9
757
345
1.8
959
577
2.5
977
565
2.4
382
412
Table 3. 500 kV Study Project costs, cost differences and cost ratios
compared to all-overhead line
Page 31 of 310
ER 381
The estimated NPV of the life cycle costs are greater than the estimated capital costs;
however the average cost ratio for each scenario compared to the all-overhead line scenario
is not significantly changed.
Increasing the length of underground cable from 10 km to 20 km, increases the average
estimated NPV of life cycle costs ratio from 1.8 to 2.4 and the average difference in
estimated NPV of life cycle costs compared to all-overhead line scenario from 345 $M to
565 $M.
Table 4 compares the average estimated capital cost per unit length of underground cable, both with
and without the transition stations, to that of overhead line:
Table 4. Ratio of cost of underground cable and transition stations to an equal length of overhead line
1.6
Details of the 500 kV Study Project duration are given in Section 13 and Appendix, Section 4 and are
summarised below.
The total times to procure, test and install the 500 kV Study Project were compiled by AltaLink and
EPCOR a) from times supplied by the suppliers for cable manufacture and b) for the civil installation
and construction durations. The work items are listed in Section 13.1 and 13.2 and the AltaLink &
EPCOR schedule basis is given in Appendix, Section 4.
The estimated duration and ISD (in service dates) are given in Table 55. The dates and durations for
the staged options refer only to stage 1 of each scenario. Each of the dates given are for the supply and
installation of all the equipment required for the particular scenario, including both cable and overhead
line.
The schedule was based on activities starting on February 01, 2010. As this date regresses, the ISD
will also regress.
Page 32 of 310
Cable
Length
ER 381
Number of
Groups of Cables
km
4/2
10
Un-staged
Time
Scenario
November 1, 2014 1A.10
57 months
November 1, 2014
57 months
November 1, 2014
4/2
57 months
November 1, 2014
3/2
57 months
All Overhead Line
March 29, 2013
3/2
20
3A.10
1B.20
3B.20
-
Staged
Time
December 1, 2013
46 months
December 1, 2013
46 months
November 1, 2014
57 months
November 1, 2014
57 months
-
Scenario
2A.10
4A.10
2B.20
4B.20
-
1.7
The two 10 km long scenarios with two Groups of Cables to be installed in stage 1 have a
cable supply and installation time of 46 months.
All other scenarios have a cable supply and installation time of 57 months.
Power losses
Some power loss is expended as heat during the transmission of electrical power.
The power losses as a percentage of the transmitted power for the 65 km 500 kV Study Project at the
design average load of 2,000 MW are:
- 0.44% for the scenario having 20 km of four groups of underground cable.
- 0.35% for the all-overhead line scenario.
The losses in an underground cable and overhead line are comprised of two parts:
A fixed part of constant magnitude that is independent of load current. The fixed losses are
a function of the applied system voltage which is constant irrespective of the loading.
The fixed loss of a cable system is higher than that of an overhead line. The fixed losses
associated with a cable are:
Insulation losses in the XLPE insulation
Page 33 of 310
ER 381
Losses in the conductor due to the flow of charging current into the XLPE
insulation
Insulation and conductor losses in the reactors
A variable part that is dependent upon load current, this being the heating of the conductor
by the flow of load current.
The variable loss of a cable system is lower than that of an overhead line, as the overhead
line possesses higher conductor resistance than a cable. .
A cross over load exists at which the losses in the cable are equal to the losses in the same length of
overhead line.
1.7.1
Relationship of power loss to power transfer for the 500 kV Study Project
Teshmont performed a system study for AESO, Appendix Section 5, and compared the losses for each
of the scenarios. Each scenario has different lengths of overhead line and cable connected in series and
has reactors connected in parallel. In consequence the scenarios have a modified ratio of variable to
fixed losses.
A comparison of one circuit of a 65 km all-cable scenario with an all-overhead-line scenario in Figure
5 shows:
The cross-over load occurs at 1,700 MW at which the overhead line and underground
cable scenarios have equal losses.
For transmitted loads up to 1,700 MW, the all-overhead line Scenario 6 has lower losses.
For transmitted loads greater than 1,700 MW, the underground cable scenario has lower
losses. However, a single circuit will only experience loads in excess of 1,500 MW in
contingency situations in which the other circuit is un-available. Thus the prospective power
loss benefits of XLPE underground cables are unlikely to be realised in the 500 kV Study
Project.
Page 34 of 310
ER 381
Figure 5. Power losses for selected scenarios at different levels of transmitted power
At loads less than the 1,700 MW cross over load, the scenarios containing a portion of cable have a
higher loss than Scenario 6, which is all-overhead line. The difference in losses compared to the
overhead line Scenario 6 is lowest in those scenarios that contain a) the shortest length of cable and b)
the fewest number of Groups of Cables. Figure 5 shows that:
Scenario 2A.10 has slightly higher losses than the overhead line Scenario 6. This is because
Scenario 2A.10 contains the smallest quantity of cable. It is the first stage of a staged
option and comprises one group of cables (per circuit) instead of two. Note that the losses
for Scenario 2A.10 are only plotted up to 1,500 MW as this is the limiting load for a single
Group of Cables.
Page 35 of 310
ER 381
Scenario 1A.10 comprises two Groups of Cables and so has a load capability under
contingency operation of 3,000 MW. The losses in Scenario 1A.10 above 1,700 MW are
less than those of the overhead line Scenario 6 because variable losses in the overhead line
conductor are greater than those in the underground cable conductor.
Scenario 5.B.65 comprises two Groups of Cables of 65 km length. The two Groups of
Cable, under contingency operation, have a load capability of 3,000 MW:
At 3,000 MW the losses in the cable Scenario 5B.65 are 16 MW compared to
28 MW in the overhead line Scenario 6.
At a nominal low load of, say, 400 MW the losses in the cable Scenario 5B.65 are
6 MW, compared to 0.5 MW in the overhead line Scenario 6.
1.7.2
Teshmont calculated the losses for each scenario for 40 years based on the forecast average loads as
follows:
Up to and including 2026:
2027 and beyond:
457.3 MW
1,000.0 MW
For the average load of 457.3 MW in the period up to and including 2026, the average power losses for
the relevant scenario Stages are presented in Table 6.
Scenario condition for the
loss calculation
2 Groups of Cables per circuit (Un-staged)
1 Group of Cables per circuit (Stage 1 only)
1 Group of Cables per circuit (Un-staged, with two Groups out of three in operation)
1 Group of Cables per circuit (Stage 1 only)
Total loss
1A.10
2A.10
3A.10
4A.10
Length
km
10
10
10
10
1B.20
2B.20
3B.20
4B.20
20
20
20
20
2.4
1.7
1.7
1.7
5A.65
5B.65
65
65
3.4
6.5
65
1.0
Scenario
Page 36 of 310
MW
1.7
1.4
1.4
1.4
ER 381
For the average load of 1,000 MW for the period 2027 and beyond, the average power losses for the
relevant scenario Stages are presented in Table 7.
Scenario
Total loss
1A.10
2A.10
3A.10
4A.10
Length
km
10
10
10
10
MW per circuit
3.9
3.7
-
1B.20
2B.20
3B.20
4B.20
20
20
20
20
4.4
4.0
-
5A.65
5B.65
65
65
Not applicable
2 Group of Cables per circuit
7.1
65
3.5
Table 7. Power losses per circuit for each scenario at an average load of 1,000 MW
1.7.3
The estimated Net Present Value (NPV) cost of the energy losses taken over the forty year analysis
period is given in Appendix, Section 3 and is summarised in Table 8, which and shows that:
The total NPV of the power losses for all scenarios ranges from 33 $M for all-overhead line
Scenario 6 to 52 $M for Scenario 1.B.20.
The NPV of the power losses is 7.3% of the NPV Revenue Requirement* for Scenario 6,
all-overhead line, and between 4.2 and 4.7% of the NPV Revenue Requirement for the
scenarios that include cable. (*The NPV revenue requirement is the present value of capital
and maintenance costs, etc, as detailed in Appendix, Section 3.)
The Net Present Value (NPV) of the differences in losses between those of the scenarios containing
cable and the all-overhead line Scenario 6 are also given in Table 8, which shows that:
The difference in NPV of the power losses for all scenarios ranges from 5 $M
(Scenario 3A.10) to 19 $M (Scenario 1.B.20).
The difference in NPV of the losses as a percentage of the NPV Revenue Requirement
ranges from 0.6% (Scenario 3A.10) to 1.6% (Scenario 1.B.20).
Page 37 of 310
Underground
cable length
OHL
length
ER 381
No of Groups
of Cable
4
10
55
3
4
20
45
3
None
65
None
Staged
Scenario
PV
Revenue
Requirement
$M
PV of
losses
PV Loss difference
from OHL
No
Yes
No
Yes
1A.10
2A.10
3A.10
4A.10
756
727
696
691
$M
42
40
38
39
%
4.7%
4.5%
4.6%
4.7%
$M
9
7
5
6
%
1.0%
0.8%
0.6%
0.7%
No
Yes
No
Yes
1B.20
2B.20
3B.20
4B.20
1,020
951
886
865
52
47
43
44
4.3%
4.0%
4.1%
4.2%
19
14
10
11
1.6%
1.2%
1.0%
1.0%
No
380
33
7.3%
0.0%
1.8
The work described in this report has been the first step in evaluating 500 kV underground cables for
use in the Edmonton region of Alberta. The next step would be to enact this reports recommendations
to quantify the risks associated with key items and further refine and optimise the cable system design.
One key item is the minimum winter temperature that occurs in the Edmonton region of Alberta.
500 kV XLPE cable accessories have not been proven at these low temperatures. It is recommended as
mandatory that proving tests be performed to demonstrate low temperature performance and identify
whether any further development is necessary. The project risk can be reduced by installing the joints
deeper in the ground to provide thermal protection.
If a decision is taken to continue the study of undergrounding for any particular project, then the next
steps are to perform:
Study of end to end reliability and availability
System and design studies
Additional engineering studies, as required
Salient points relating to these steps are listed below:
Page 38 of 310
1.8.1
ER 381
Study the reliability and availability of each scenario and select the optimum. The following
should be taken into account:
The combined reliability and availability of all the equipment, e.g.:
Overhead lines
Underground cables
Switchgear
Reactors
The level of n-1 redundancy required.
1.8.2
Establish the actual current carrying requirements for the particular identified application.
Perform a system design study under one or more of the following conditions:
Continuous loading
Emergency (short time) loading
Peak cyclic loading
The cable system would be designed and optimised to fulfil the particular requirements. For
example, if the peak load is only required for one or two hours in each period of twenty four
hours, with a lower load for the rest of the time, then the resulting maximum conductor
temperature would be less than that calculated for a continuous load. In this case a cyclic
ampacity calculation is recommended to be performed in place of the continuous ampacity
calculation with the objective of quantifying which of the following would benefit the
application most:
Installation of the 2,500 mm2 cable size at a greater depth.
Reduction in the likelihood that three cables per phase would be required for the
whole cable route to allow for a deep crossing under one or more major route
obstructions.
Installation of the 2,500 mm2 cable in a narrower width of trench and swathe at the
proposed depth of 1.3 metres.
Selection of a smaller conductor size than 2,500 mm2.
1.8.3
Two of the key items for study are the low ambient temperatures and the small amount of service
experience with 500 kV joints.
Page 39 of 310
ER 381
More detailed experience lists including those at lower system voltages and lower
ambient temperatures.
The minimum ambient temperatures that their cable systems have encountered.
The types and numbers of accessories that they have supplied over a wider range
of lower system voltages (i.e. 220-500 kV) for use at lower ambient temperatures.
Any national or special tests that have been undertaken, which demonstrate low
temperature performance.
Any private developments that they have undertaken, which demonstrate low
temperature performance (e.g. tests performed on 345 kV XLPE cable systems[3][4]
in Montreal at the IREQ laboratory).
From utility companies, particularly those operating in regions of low ambient temperature:
If test houses have performed tests at low temperature on cable joints (e.g. tests
performed on 345 kV XLPE cable systems in Montreal at the IREQ laboratory).
Whether they have low temperature test facilities.
Whether they would be interested in performing low temperature tests.
Page 40 of 310
ER 381
If the time and uncertainties associated with proving the performance of the joint designs for low
winter temperature operation are deemed to be unacceptable, then consider alternative actions:
Seek from the manufacturers further supporting evidence, if available, on electrical service
and test experience for joints at 500 kV.
If insufficient electrical service and test experience is available upon which to make a
decision, then either:
Sponsor a long term prequalification test.
Await results of the first two years of service experience from the 500 kV
Shanghai project, following its (proposed) commissioning date in 2010.
Install one or more short cable lengths, including at least one set of joints, on the
Alberta 500 kV network.
Page 41 of 310
ER 381
Evaluate the feasibility and quantify the anticipated repair time following a cable fault in a
direct buried installation at the winter ambient temperatures of the Edmonton region of
Alberta.
Instigate discussions with cable manufacturers with regard to possible future development
tests to demonstrate 500 kV operation and low temperature performance:
Draft new test schedules to prove low temperature performance for consultation
with the manufacturers.
Draft detailed schedules which would form the basis for enquiries to be sent to
prospective suppliers at the project bidding stage, comprising a) special low
temperature proving tests and b) pre-qualification (PQ) proving tests and type
approval tests (TAT) based on the IEC 62067[1] specification.
Draft and agree detailed specifications for manufacturing and jointing quality
control (QC) tests, noting that IEC (International Electrotechnical Commission)
and AEIC (Association of Edison Incorporated Companies) specifications do not
give complete coverage for all QC aspects.
Page 42 of 310
ER 381
Detail
Stage Number of trenches Number of suppliers
1A.10
10km
4
2
2A.10
10km
1
2
2
2
2
2
3A.10
10km
3
2
4A.10
10km
1
2
2
2
1
1
1B.20
20km
4
4
2B.20
20km
1
2
2
2
2
2
3B.20
20km
3
3
4B.20
20km
1
2
2
2
1
1
Table 9. Number of suppliers for each undergrounding scenario
The above is only typical; in the project schedule (Appendix, Section 4) a maximum of two suppliers
was assumed. The eventual number of suppliers used would depend on their technical capability and
ability to supply and install the volume of cables and accessories needed. One advantage of using
multiple suppliers is the reduction in the likelihood of multiple outages because of common mode
failure. The disadvantages are the difficulties of managing multiple subcontractors on the same project
and the need to hold a wider range of spares.
Auditing the factory prior to bidding and after awarding the work.
Monitoring design progress.
Witnessing the proving tests, prequalification tests, type approval tests and routine
HV (high voltage) and material tests
Observing the full-scale prototype jointing trials and jointer training.
Page 43 of 310
ER 381
The following summarizes the functional requirements taken in this feasibility study for 500 kV AC
underground cables for use in the Edmonton region of Alberta.
These parameters were advised to us by the AESO. Where additional parameters were required, CCI
provided information.
2.1
Functional requirement:
2.1.1
Two circuits
For the purposes of calculating cable ampacity in this feasibility study, peak loading is
defined as meaning constant, or substantially constant, loading for a period of time long
enough for the cable to reach its design operating temperature.
Average power transmission per circuit requirement for cost of loss calculations:
Up to and including 2026:
2027 and thereafter:
457.3 MW
1,000.0 MW
Page 44 of 310
ER 381
Notes:
The peak load at any time during each year is expected to be some 1.5 times the
average load during the year. e.g. if the average load is 1,000 MW, then the peak
load is 1,500 MW.
To allow for contingency operation (i.e. when one of the circuits is out of service)
the remaining circuit is required to be capable of carrying the combined peak load
of both circuits. i.e. For two circuits, each with a peak load of 1,500 MW, the
maximum combined peak load is 3,000 MW. Each circuit must therefore be
capable of carrying 3,000 MW.
Page 45 of 310
ER 381
2.1.1
- Winter:
Ground at: 1.3 metres depth: 0oC
The above temperatures are based on those used in the design of the cable system for the recently
installed Downtown Edmonton Supply and Substation 240 kV cable system.
The minimum design temperatures for components are given in the following tables:
Cable
Splice (joint)
Air insulated termination
SF6 termination
Table 10
Table 11
Table 12
Table 13
Page 46 of 310
ER 381
Cable
Minimum ground temperature at 1.3 m depth for direct buried cable design
(expected temperature is 0C)
Minimum air temperature for manhole cable design
(expected temperature is -10C)
Minimum air temperature within deep tunnels for cable design
(expected temperature is 0C)
Minimum air temperature within cut and cover tunnels for cable design
(expected temperature is -10C)
Minimum outdoor air temperature for cable design
(expected temperature is -30C)
Minimum indoor air temperature for cable design
(expected temperature is 0C)
Design temperature
-15C
-20C
-10C
-20C
-50C
-10C
Page 47 of 310
Design
temperature
-15C
-20C
-10C
-20C
ER 381
-10C
36C
Table 12. Maximum and minimum design temperatures for air insulated terminations
SF6 termination
Design
temperature
-50C
-10C
36C
Table 13. Maximum and minimum design temperatures for gas insulated terminations
Notes on Table 10, Table 11, Table 12 and Table 13:
2.2
There is a margin of safety between the expected minimum temperatures and the design
temperatures
These temperatures supersede those which were provided to potential suppliers of cable
systems as listed in Section 9.2 and Appendix, Section 15. They were revised following a
study of Edmonton temperature records, which are detailed in Appendix, Section 9.
For the purposes of this feasibility study, the minimum indoor ambient air temperature is
assumed to be -10C. Alternative temperatures could be considered if required as the
indoor design temperature would be dependent upon the heating system within the building.
Scenarios considered
The following scenarios were studied for compilation of cost estimates, voltage studies and loss
comparisons. These scenarios have different combinations of:
Page 48 of 310
ER 381
- Staging of installation
Stage 2:
A comparison of the cross section for each scenario of the Groups of Cables is shown in Figure 8 and a
description of each of the scenarios considered is given in Table 14.
Page 49 of 310
ER 381
Page 50 of 310
Scenario
Staged
1A.10
1B.20
2A.10
2B.20
3A.10
3B.20
4A.10
4B.20
5A.65
No
No
Yes
Yes
No
No
Yes
Yes
N/A
5B.65
N/A
No
ER 381
65
65
65
Figure 9,
Figure 10,
Figure 11,
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
The cable group cross sections X-X in Figure 9, Figure 10, Figure 11 and Figure 12 are shown in
Figure 8.
Page 51 of 310
ER 381
The switching arrangement is indicative only; more representative arrangements are given in drawing
number 47DD-0001 in Appendix, Section 26.
Scenario Number
1A.10 (10km route length). Un-staged
1B.20 (20km route length). Un-staged
Figure 9 Scenario 1A.10 and 1B.20
The switching arrangement is indicative only; more representative arrangements are given in drawing
number 47DD-0001 in Appendix, Section 26.
Scenario Number
2A.10
2B.20
(Staged)
(10km route length)
(20km route length)
Stage 1
Stage 1
Page 52 of 310
Stage 2
Stage 2
ER 381
The switching arrangement is indicative only; more representative arrangements are given in drawing
number 47DD-0004 in Appendix, Section 26.
Scenario Number.
3A.10 (10km route length) Un-staged
3B.20 (20km route length) Un-staged
Figure 11 Scenario 3A.10 and 3B.20
The switching arrangement is indicative only; more representative arrangements are given in drawing
number 47DD-0004 in Appendix, Section 26.
Scenario Number
4A.10
4B.20
(Staged)
(10km route length)
(20km route length)
Stage 1
Stage 1
Page 53 of 310
Stage 2
Stage 2
ER 381
Scenario Number
Scenario Number
Page 54 of 310
ER 381
Scenario Number
6
Page 55 of 310
ER 381
This Section is an introduction to the components that form the cable system, the purpose of which is to
guide the reader in the terminology used in later sections.
3.1
Three conductors are necessary to form an alternating current (AC) transmission system. In North
America the current alternates, (flows to and fro) at a rate of sixty times per second.
Figure 17 shows different transmission circuits; an underground circuit of three cables, an overhead
line circuit of three conductors and a gas insulated line circuit of three pipes. Each of the three cables
and conductors must be in operation for the AC circuit to work.
Figure 17. Three parallel lines or cables are required to form an AC circuit
3.2
3.2.1
Voltage
The transmission system voltage for the Study Project is 500 kV, where kV is the symbol for 1,000
Volts, thus 500 kV is 500,000 Volts. The voltage is the force that, in electrical terms, drives the flow of
load current from the generating station along the conductors to the consumer.
Page 56 of 310
ER 381
Page 57 of 310
ER 381
3.2.2
Power
The unit of power is a Watt. A more useful unit used for power transmission is the Megawatt ( symbol:
MW). One Megawatt is equal to 1,000,000 Watts.
Power is calculated by multiplying the voltage (in Volts) by the current (in Amps).
3.2.3
Current
The current is the rate of flow of the electricity and is measured in Amps (symbol: A). When one
circuit of a 500 kV overhead line is transmitting 3,000 MW of power, each of the three conductors is
carrying 3,448 Amps. The power carried by a group of three 500 kV overhead line conductors is (3 x
290,000 V x 3,448 A) = 3,000,000,000 W, or 3,000 MW.
It is normal for two or more groups of underground cables to be provided to carry a power of the level
of 3,000 MW. In the case of two groups of 500 kV cables, each of the conductors carries 1,724 Amps.
The power carried by one of the groups of 500 kV underground cable conductors is (3 x 290,000 V x
1,724 A) = 1,500,000,000 W, or 1,500 MW.
Page 58 of 310
3.3
ER 381
Figure 21 shows the component parts of a 500 kV XLPE cable in more detail. The cable is a single
core design, having one insulated conductor inside it.
The conductor. The conductor carries the load current. The larger the conductor, the higher the
current that can be carried. The conductor in Figure 21 has a cross sectional area of high
conductivity, annealed copper wires of 2,500 mm2. An alternative measure of conductor area
used in North America is the unit kcmils (thousands of circular thousandths of an inch). The
2,500 mm2 conductor size, Figure 21, is approximately 5,000 kcmils.
The triple extrusion. The triple layer is extruded onto the conductor in one manufacturing
operation. The layers are:
The conductor screen (or shield). This is a layer of carbon loaded conducting
rubber. The purpose of it is to cover the irregularities in the outer surface of the
conductor and to form an electrically smooth interface with the overlaying
insulation. The material of the semiconducting shield in a 500 kV cable is a
super smooth grade.
Page 59 of 310
ER 381
The insulation screen (or shield). In a 500 kV cable this is usually the same grade
of super smooth, semiconducting material as the conductor screen. The purpose of
it is to cover the insulation with a smooth conducting layer. The insulation shield
may be considered to be electrically connected to ground for the purpose of this
explanation. The shield entirely contains the 290 kV voltage within the XLPE
insulation.
The purpose of the triple extrusion is to achieve a fully bonded smooth interface
between the insulation and the shields. When the conductor carries load and
becomes hot, the insulation and shields will expand and contract as one solid
whole.
Cushioning layers. These permit the extruded cable and core to thermally expand without
becoming damage by contact with the outer metallic layers. The layers must be electrically
conducting to transmit the insulation charging current to the metallic ground conductor.
Metal sheath and ground conductor. This may be formed of one or two separate layers. In
Figure 21 one thick walled aluminium sheath performs the dual roles of safely carrying
longitudinal current of high magnitude in the case of a system short circuit and of providing
a water-tight radial water barrier to water. Other cables may have a thinner metallic water
barrier with a copper wire shield conductor (also called a neutral conductor in North
America) to carry the short circuit current. The ground conductor also carries the insulation
charging current in normal service operation back along the cable to a ground connection. In
a long cable circuit this current may be of high magnitude.
Page 60 of 310
ER 381
cushioning tape. In the case of a cable with a copper wire shield conductor, the DTS tube is
laid between two of the helically wrapped wires, as shown in Figure 110.
3.4
Jacket. The jacket (also named an oversheath) is the outer extruded polymeric layer. The
function is threefold a) to protect the inner metallic water barrier from corrosion, b) to
electrically insulate the metallic barrier and ground conductors from ground and c) to be
sufficiently robust to protect the cable during installation. High power carrying cable
systems circuits such as that proposed for the 500 kV Study Project utilise special sheath
bonding. The connections between the link boxes and the cable joints are made in such a
way as to prevent the induced voltage from being able to drive a circulating current around
the integral ground conductors. The downside of these special connections is that a voltage
difference exists across the jacket to ground. If the jacket suffers undetected damage during
installation or in-service the voltage difference will promote rapid corrosion and puncture of
the metallic barrier. During routine maintenance work a test voltage is applied across the
jacket to check that it has not become damaged. The manufacturer applies a conducting
layer to the outside of the jacket to form a ground electrode and facilitate this test. The layer
is either a conducting varnish or a bonded thin semiconducting elastomeric extrusion.
Cable system
The underground part of the transmission circuit for the 500 kV Study Project is named a cable
system. The component parts of a short transmission system comprising two cable section lengths is
shown in Figure 22.
Page 61 of 310
ER 381
A 500 kV cable system or overhead line must always have a minimum of three single core cables in
parallel. In this report the three single core cables are named a Group of Cables, and is shown in
Figure 23.
The three cables in each group are each connected to a separate phase conductor of the AC
transmission system. The phases are usually identified by letters as Phase A, Phase B and Phase C, or
visually by colour, for example, as Red Phase, Black Phase and Blue Phase.
The electrical connection to the AC transmission system is either made to other equipment within a
substation, or to overhead lines within a transition station. Figure 24 shows a 400 kV transition
station (also named a terminal compound) with the overhead line ending in a terminal gantry. Figure
25 shows the overhead line ending in a terminal tower. The terminal tower supports two separate 400
kV circuits, one to the left of the tower, Circuit 1, and one to the right, Circuit 2.
Each overhead line circuit comprises just three conductors each being one phase. (To improve
efficiency each overhead line conductor comprises three wires that are electrically connected
together, being named a bundled conductor. )
Page 62 of 310
ER 381
The bundled conductor is brought down to connect onto the end of the underground cable at the top of
a cable outdoor termination. At the terminal tower in Figure 24 there are three cable terminations on
each side of the terminal gantry, such that one overhead line bundle is connected to one underground
cable termination. At the terminal tower in Figure 25 there are six cable terminations on each side of
the tower, such that one overhead line bundle is connected to two underground cable terminations, this
is shown diagrammatically in Figure 26.
Page 63 of 310
ER 381
Page 64 of 310
ER 381
The underground cable cannot dissipate heat directly to the air so readily as it is surrounded both by a
layer of insulation and by the depth of ground. Design measures are taken by the cable system designer
to limit the temperature by a) to choosing a large conductor of high conductivity copper to reduce the
amount of heat, b) spacing each cable wider apart and c) surrounding cable with a special backfill
material to assist the flow of heat. If the current to be carried is too high for the cable size selected and
it is not possible to manufacture a larger cable, then a second group of cables as shown in Figure 23
must be installed to share the current that each carries. The latter is the case for the un-staged scenarios
of the 500 kV Study Project underground cables. Finally if sufficient heat cannot be dissipated by
natural cooling, a forced cooled design would be considered as described in Section 3.11.
3.4.1
The component parts of the cable system are shown in Figure 22 and are described below:
3.4.2
Cable spans
The length of the cable span is the length of the cable that is delivered to site on a cable reel, also
named a cable drum. For reasons of circuit reliability and economy, the cable supplier normally strives
to deliver the maximum cable length that can be transported, this being limited by the height of road
bridges, the maximum width of the road and the maximum permitted road weight or wheel loading. For
a given route length, the installation of long spans reduces the number of joints needed to connect them
together. The joints are the most sensitive part of the cable system and so increasing the cable delivery
lengths increases the prospective reliability of the cable system. Two methods of transporting large
cable reels by road are shown in Figure 27 and Figure 28 and by sea in Figure 29.
Page 65 of 310
ER 381
3.4.3
Cable Terminations
The terminations are also named Potheads in North America and Sealing Ends elsewhere. The
terminations are fitted to the end of the cable. The cable conductor has a connector (sometimes called a
stalk) that protrudes into open air through the top of the insulator. The stalk permits electric current to
flow into and out of the cable circuit. It is connected to other equipment in the substation or transition
station. Figure 30 shows outdoor terminations fitted with long conical insulators. The stalk is at the
high voltage of 290 kV and the insulator provides the long distance to insulate it from ground. Within
the insulator is the means to control the electrical stress distribution such that there is a smooth
transition from the very small thickness of the cable insulation to the very long length of the insulator.
The top and bottom of the insulator are fitted with corona shields, whose function is to electrically
shield the sharp edges of the top and bottom metalwork, and so prevent low level sparking in the
adjacent air, named corona.
Page 66 of 310
ER 381
Page 67 of 310
ER 381
3.4.4
Cable Joints
Joints connect each cable span together. Joints in North America are frequently named splices. The
three joints are always installed next to each other, either in single file, for example in a tunnel, or in
line abreast, in the ground as shown in Figure 32 or in a vault as shown in Figure 33. It is covered
overall with an electrically insulated joint protection box that serves the same function as the cable
jacket.
For high power circuits the joints would generally also include sheath sectionalising insulation
(interrupted shield gaps) to eliminate the flow of current in the cable sheaths from one side of the joint
to the other.
Page 68 of 310
ER 381
Figure 33. Part assembly of a joint on 240 kV XLPE cable inside a vault in Edmonton
3.4.5
Bonding equipment.
The equipment comprises link boxes and bonding leads. It is required that the cable system be
installed with a parallel ground conductor. In a long length 500 kV cable this ground conductor is built
into the cable construction usually in the form of a metallic sheath or shield wires. At each end of the
cable the ground conductor is connected solidly to a set of electrical ground electrodes.
Bonding cables. The connections are named bonds and the act of connecting is named bonding.
Page 69 of 310
ER 381
Link boxes. To permit maintenance tests to be performed on the cable jacket it is necessary to have
electrical access to it by disconnecting the bonding cables at each end. Disconnecting is performed by
unlocking the link box and removing the connections (sometimes known as links) contained within,
Figure 34. Different types of link boxes exist for above and below ground installation and for different
methods of bonding. Diagrams for a cross-bonded cable system, the type that would be expected for a
high power 500 kV circuit are shown later in this report (Figure 105 and Figure 106).
Underground link boxes would be installed in an underground pit with only the (typically cast iron)
manhole cover visible. Underground link boxes are commonly used in urban areas.
In a specially bonded circuit, current flow is prevented by interrupting the cable integrated ground
return conductors and shields at the accessories. The interrupted shield gaps experience unacceptably
high transient voltages during circuit switching and lightning strikes and must be protected by
connecting across them suitably rated nonlinear resistors called SVLs (sheath voltage limiters). The
SVLs are voltage sensitive and short the insulated gap to limit the magnitude of the transient voltage.
When the transient has passed, the SVL returns to high resistance and effectively becomes an opencircuit. Three cylindrically shaped SVLs can be seen at the top of Figure 34.
Figure 34. An above-ground link box housing the components for a cross bonded position
Figure 35 shows link pillars (also known as kiosks and pedestals) in a field near to the positions of
buried joints. The fences are the indicator that twelve buried 400 kV transmission cables cross the land.
Page 70 of 310
ER 381
The fenced enclosures are to protect the link boxes from damage by cattle. Robust pillars and fences
are fitted if mechanical harvesters are to be used.
Figure 35. Above ground link kiosks connected to 400 kV underground cable
Courtesy CCI
3.5
Ancillary equipment
*Note: A partial discharge (PD) is the occurrence of an electrical spark within a small air or gas-filled void (gap or split) in
the insulation. The spark is formed by the liberation of the capacitive charge stored in the void when it breaks down. The
name partial discharge distinguishes the event from the complete electrical failure of the cable, in which all of the energy
in the insulation is discharged.
Page 71 of 310
3.6
ER 381
The hydraulic system ensures that SCFF cables are provided with dielectric fluid to achieve their
designed dielectric strength during heating and cooling without experiencing extremes of pressure.
Pressure ensures that contraction voids can never form in an SCFF cable. The designer calculates the
size of external fluid reservoirs to absorb the volume of fluid thermal expansion when the cable is
heated and to re-supply the fluid volume when the cable contracts.
SCFF cables are described in Section 4.2.
3.7
Thermal design
The system thermal design ensures that the maximum possible current is carried by the cable system
without exceeding the specified continuous operating temperature of the conductor and insulation. The
designer selects the conductor size, the spacing between cables to limit mutual heating, and a stabilized
backfill (as shown in Figure 74, Figure 75 and Figure 76) with low thermal resistivity. The stabilised
backfill may be either compacted cement bound sand or a fluidised thermal backfill. The thermal
properties of the material above the backfill and to either side of the trench must also be measured and
approved. If the thermal resistivity of the native material is too high, then it will require to be replaced
with an approved imported material. The thermal backfill and the trench filling materials must be
compacted achieve to a specified value.
3.8
Thermomechanical design
The system thermomechanical design protects the cable and accessories from experiencing any
excessive forces and movements that are generated when the cable is heated, cooled, and load cycled.
Design solutions are selected to suit the method of cable installation. For example, in direct-buried or
closely clamped (sometimes known as close-cleated) systems, the cable is rigidly constrained. In
tunnels or on trays, the cable is unconstrained in wave or snake patterns. In a pipe or duct-manhole
system, the cable is semi-constrained and is allowed to expand laterally. In duct-manhole installations,
methods of constraint are required in joint vaults to protect the joints from movement. If the differential
thermomechanical forces cannot be withstood by constraining the adjacent cable, either the cable
system must be redesigned, or special accessories, such as anchor joints, must be installed to replace
the conventional straight joints.
Page 72 of 310
3.9
ER 381
Installation design
Installation design covers all aspect of laying the cable and assembling the accessories to form the
cable system.
3.9.1
Cable installation
Installation design specifies the methods and equipment necessary to install the cable into pre-laid
ducts, Figure 36, or directly into the ground, Figure 37, to protect the cable from third-party damage by
laying the ducts at depth and encasing them in concrete, and to cross obstructions such as roads, rivers,
and other services, using solutions such as cable bridges, horizontal directional drilling (HDD), thrustbores, or tunnels.
Page 73 of 310
ER 381
C
B
Trefoil touching
Triangular
Page 74 of 310
ER 381
Page 75 of 310
ER 381
are also generally laid a flat, horizontal formation rather than a trefoil arrangement. With a trefoil
arrangement, the lower two of the three cables would be further from the ground surface than
uppermost cable. Because of this increased distance, less heat could be dissipated and less power could
be carried.
Cables in flat spaced formation are also easier to access should a repair be required.
Consideration is sometimes given to the installation of a spare cable to permit the circuit to be quickly
returned to service in the event of damage to one of the phase cables. This is unusual. Most cable
laying configurations have symmetrical geometries, this being important if a specially bonded sheath
system is employed to prevent circulating sheath currents. In such configurations an asymmetrically
located fourth cable would unbalance the special bonding system and would require that the circuit be
de-rated. The presence of a fourth specially bonded joint introduces complexity into the sheath
bonding connections. The exception is a configuration which is initially designed such that a fourth
cable can be located symmetrically, as shown as the right angled triangular formation in Figure 38 for
duct-manhole systems. Such configurations are not appropriate for direct buried systems because they
are difficult to install and difficult to repair without damaging the adjacent cables. For these reasons, if
n-1 redundancy is required for a circuit, it is usual to provide an additional Group of Cables that shares
the load in normal operation and which alone can carry full load in contingency operation.
3.9.2
A temporary building called a joint bay is constructed over the cable ends. The bay is made clean and
dry. For high voltage cables the joint bay is well lit, heated and when necessary is air conditioned.
Different manufacturers joints are shown during assembly, Figure 41, and after assembly, Figure 42.
Page 76 of 310
ER 381
Courtesy LS Cable
The outer joint metal casing (joint shell or joint can) shown in Figure 41 form both a water-tight
enclosure and an electrical continuation of the ground return conductor within the cable (formed by the
metal sheath or shield wire conductor). In the special sheath bonded system normally used for
transmission class cables, both the cable sheath and joint shell experience an induced voltage. To
prevent this voltage causing accelerated corrosion of the metal water barrier, the joint shell is encased
within the joint protection box shown in Figure 42. The joint protection box must retain its watertightness and its electrical insulation integrity throughout the life of the circuit. At intervals of typically
one to two years the cables are taken out of service and a DC high voltage test is applied to confirm
that the insulating and hence anti-corrosion protecting properties of the joint protection and cable jacket
are sound. As part of the type approval process the joint protection is submitted to a combined water
immersion, temperature cycling and voltage test, which is as equally searching as the high voltage type
test applied to the primary cable and joint insulation.
Outdoor cable terminations are assembled under similar clean conditions within the temporary structure
shown in Figure 43.
Page 77 of 310
ER 381
The cable system operator should put in place a policy with regard to any
excavations which is communicated to all his own employees, to other utilities
(including local authorities) and to all landowners along the route. This policy
should give requirements as to how to notify the owner prior to commencing any
excavations in the vicinity. It should also give requirements of any investigative
work which must be conducted before excavations are permitted to take place.
This can include the use of cable avoidance tools, ground radar, etc. The Damage
Prevention Process in Alberta is recorded in Appendix, Section 10.
The route should be clearly marked on the ground surface with robust markers that
clearly identify the location, owner and type of the cable.
Page 78 of 310
ER 381
Routine surveillance should be conducted throughout the life of the cable system to
check that the route markers are in place and that that there is no present or
pending ground disturbance in the vicinity.
To give visual warning to any persons who might conduct excavations then a
brightly coloured and labelled warning tape should be placed in the ground above
the cables along the complete length of the route.
To give warning and protection to the cables and joints, rigid cover tiles should be
placed immediately above the backfill surrounding the cables. The cover tile
should be marked with wording to identify the owner and the presence of the
electric cables. These should be rigid, robust and non-biodegradable.
To give warning and protection to the cables they are encased in a robust, hard
backfill material such as cement bound sand or fluidised backfill. It is good
practice to add a distinguishing colour to the backfill such as bright red.
The cable jacket which is usually extruded from HDPE/MDPE should be identified
with embossed wording which as a minimum should include the words Electric
Cable and the voltage.
If the cable system is installed with a DTS system, this can also be configured to
give an alarm and a location if a fibre is broken. The optical fibres may be position
close to the surface of the cable or within the cable, the former prospectively
providing earlier warning.
Should the cable suffer an electrical short circuit due to dig in damage (or internal
faults) then the cable must be disconnected automatically from the supply. Unlike
overhead line, faults on underground cables do not clear themselves, so any autoreclose system should be inhibited from operating on the cable.
Page 79 of 310
ER 381
Lateral pipe cooling, in which the cables are laid in the ground at a sufficiently
close spacing that a cooling pipe can be laid between adjacent cables. Water is
pumped under pressure and circulated along one of the pipes and returned back
along another parallel pipe. Depending upon the particular configuration, inlet
temperature of the water and length of the cooling pipes, up to typically 80% of the
heat that would otherwise flow to the ground surface is absorbed by a rise in the
water temperature. Lateral pipe cooled systems have been used in special
locations in which the width available to locate a cable trench is restricted. A
typical example being under a road in a downtown location.
Integral sheath cooling, in which each single core cable is laid within a water filled
pipe. Water is pumped under pressure and circulated along one of the pipes and
returned back along another parallel pipe. 100% of the heat that would otherwise
flow to the ground surface is absorbed by a rise in the water temperature. This
system can be used for cables laid in the ground or in tunnels but has only been
used for a very small number of special applications.
Trough and weir, in which the group of three cables is laid within a series of
descending horizontal open water filled troughs, each separated by weirs to
control the water flow.
A forced ventilated tunnel, in which the cables are supported by clamps (cable
cleats) or laid on racks. Air is drawn from ground surface down a shaft and along
the tunnel. A high proportion of the heat emitted by the cable is absorbed by a rise
in the air temperature. A smaller proportion of the heat emitted by the cable is
dissipated through the wall of the tunnel to the surrounding ground. The hot air is
exhausted to atmosphere through a second shaft. This is the normal method for
cooling cables installed in long tunnels. A forced ventilated tunnel system is less
complex to design, operate and maintain than a water cooled direct buried system.
In closed water cooling systems, the heat from the hot water outlet pipe is extracted via a heat
exchanger usually to air. If a high ambient air temperature is present in summer it may be necessary to
also refrigerate the return water. If a sub-zero ambient air temperature is present in winter is necessary
to protect the cooling pipes, pumps, and heat exchangers from damage by freezing.
The disadvantages of a forced cooling system are:
Availability of the circuit to carry load throughout its service life is dependent
upon the operational condition of the cooling equipment, whereas a naturally
cooled cable is not dependent upon such equipment and is always available to
carry load.
Page 80 of 310
ER 381
It is more difficult to extract heat from the joints than from the cable due to the
increased thickness of electrical insulation. The means to increase heat extraction
from the joints may increase the complexity of the joint design.
For applications in which a naturally cooled system can be used, the cost of a
forced cooled system is higher than a naturally cooled system.
3.13 Testing
The test standards that include 500 kV are IEC 62067 (2001)[1], IEEE Std 404-2006[6] and IEEE Std 482009[7]. Standards for lower voltage cables are ICEA-S-108-720-2004[8], AEIC CS2-97[9], AEIC CS906[10], IEC 60840[11].
Testing of cable systems can be grouped into three major categories:
Proving tests
Quality tests, consisting of factory (or shipping) tests and commissioning (after
laying) tests
In service maintenance tests and measurements
In the event of a failure then diagnostic tests would be performed to investigate the cause and extent of
a malfunction.
Typical durations are given below for some of the tests, in planning of tests, allowance also has to
made for manufacture of the components, erection of the test assembly, setting up of the measuring
equipment, dismantling, and formal forensic inspection of samples.
Page 81 of 310
ER 381
Clause 3.2.4, IEC 62067. Definition: Test made before supplying on a general
commercial basis a type of cable system covered by this standard, in order to demonstrate
satisfactory long term performance of the complete cable system. The Prequalification
Test need only be carried out once unless there is a substantial change in the cable system
with respect to material manufacturing process, design, and design levels. Note: A
substantial change is defined as that which might adversely affect the performance of the
cable system. The supplier should provide a detailed case, including test evidence, if
modifications are introduced, which are claimed not to constitute a substantial change.
Clause 13.1, IEC 62067: When a Prequalification Test has been satisfactorily performed
on a cable system, it qualifies the manufacturer as a supplier of cable systems with the
same or lower voltage ratings as long as the calculate electrical stresses at the insulation
screen are equal to or lower than for the cable system tested. Note: It is recommended to
carry out a prequalification test using a cable of a large conductor cross-section in order to
cover thermomechanical aspects.
The test assembly must include each design of accessory and the test arrangement shall be
representative of the installation design conditions. Figure 44 shows a 400 kV cable system being
prepared for test. A one year test is performed, comprising 180 thermal load cycles and 8,760 hours on
voltage. This is then followed by lightning impulse voltage tests and an examination of the
components to demonstrate that no damage has occurred. The overall duration of the testing will this
be in excess of one year.
Page 82 of 310
ER 381
Figure 44: 400 kV cable system being prepared Figure 45: A Cable being prepared for type approval
for long term testing
testing
Courtesy Nexans
Page 83 of 310
ER 381
Item 2.4, page 27, TB 303. A simplified long term test (80) cycles called Extension of
Prequalification (EQ) test in case of:
Purpose of EQ, Item 2.3.2, page 24, TB 303. The 60 daily heat cycles without voltage plus the
20 heat cycles of the type test applied to the test loop are intended to allow relaxation of most of
the mechanical stresses trapped in the cable insulation during manufacture.
o Authors: this is the full IEC 62067 type test procedure, (Item12, page 31, therein) with
amendments including:
Clause 3.2.4, IEC 62067. Definition: Test made before supplying on a general
commercial basis a type of cable system covered by this standard, in order to demonstrate
satisfactory performance characteristics to meet the intended application. Once
successfully completed, these tests need not be repeated unless changes are made in the
cable or accessory materials, or design or manufacturing process which might change the
performance characteristics.
Page 84 of 310
ER 381
The tests include a range of material and electrical tests on cables and accessories, but do not require
that they be installed in a way which is representative of how they are to be installed in service. The
tests do not therefore simulate the thermomechanical forces that would be encountered in service. The
Type Tests specified in IEC 62067 has a typical duration of six weeks, including 20 daily loading
cycles.
Page 85 of 310
ER 381
Page 86 of 310
ER 381
These are not covered by international specifications. A customer would specify the in-house
requirements and specifications to which the supplier must comply. The customer would also require
that the cable system supplier should provide operating and maintenance instructions as a contractual
stage.
A transmission class cable does not have a significant length limit due to voltage drop,
because the conductor resistance is high and the inductance is low (a property arising from
the geometry of the cable spacing and the magnetic field).
A power cable does have a length limit due to a reduction in the useful power that can
delivered because of the increase in charging current with circuit length.
The circuit length limit caused by capacitive charging current can be substantially eliminated by
installing items of equipment called reactors at intervals along a long route. The purpose of the
reactors is twofold; to increase the power carrying efficiency of the cable and to limit voltage increases
on the transmission system. A photograph of three reactors in a substation is shown in Figure 47.
Page 87 of 310
ER 381
Thin insulation thickness; a cable has thin insulation and so will draw a higher charging
current than an overhead line.
The type of insulation; solid cable insulation draws a higher current than the air insulation
around an overhead line, or the gas insulation around a gas insulated line. XLPE insulation
draws about 130% more charging current than the same thickness of air. XLPE draws the
least charging current of the types of available conventional cable.
The length of the circuit; a 20 km length will draw twice as much charging current as
10 km.
The system voltage; the same insulation thickness and length connected to a supply
voltage of 500 kV compared to one of 24 kV will draw twice the charging current.
The frequency of the AC supply voltage; insulation experiencing the North American
frequency of 60 cycles per second, compared to the European 50 cycles per second
frequency, will draw 20 % more charging current.
The distance between reactors is calculated for each individual application and may vary widely. In the
500 kV Study Project, reactors were located at the transition substations at each end of the
underground cable for both the 10 km and 20 km long underground cable scenarios.
In lower voltage cables of lengths less than approximately 20 km, the charging current is small in size
and so only a small reduction of the cables rated current results (i.e. less than 4%) and is usually
accepted. The charging current can be halved in magnitude by positioning an inductive reactor at the
load end of the cable. The reactor may be positioned at a transition station or a substation. If a longer
length of underground cable is required it may be necessary to consider installing reactors at regular
distances along the route, however in practice this is unusual, one reactor is normally sufficient. In
some circumstances the natural inductive reactance of the overhead line at the load end can be helpful
in reducing the cable charging current. Conversely the presence of the cable capacitance can be helpful
to offset the inductance of some overhead line circuits. In a long length submarine cable it is not
physically possible to locate intermediate reactors on the seabed and so the size of the cable conductor
is increased to carry the charging current without exceeding its design temperature. It is not usually
Page 88 of 310
ER 381
economic or possible to do this with high power, land transmission cables as they tend to be already at
the maximum size that can be manufactured.
The property of the insulation material and geometry which defines its ability to draw charging current
is called capacitance. The presence of the capacitance of the cable insulation at the end of an overhead
line, (which has the property of inductance) can, under certain conditions, produce an undesirable
increases in voltage. The location of a reactor at the end of the cable beneficially reduces this effect.
Page 89 of 310
4
4.1
ER 381
An underground 500 kV AC cable system is feasible for the 500 kV Study Project in the
context of achieving and maintaining a reliable transmission of power for a 40 year design
life.
Technology exists to design and supply the type and number of components necessary to
fabricate the cable system.
The required power level is 3,000 MVA, which is either a) shared between two parallel circuits in
normal operation, or b) is carried by a single circuit in a contingency situation. The ampacity rating
studies (Sections 7 and 9) have shown that:
A conductor size of 2,500 mm2 is needed for an XLPE cable, but for an SCFF LPP cable,
3,000 mm would be required. Proven service experience exists with 2,500 mm conductors
at both 400 kV and 500 kV AC system voltages with both XLPE and SCFF insulated
cables. 3,000 mm conductors have been used in DC LPP cables, which can utilise a
different design of conductor to that required for AC cables.
Each AC circuit needs a minimum of two cables per phase, comprising a total of six parallel
cables (3 phases and two cables per phase). The two circuits require 12 cables arranged in
four groups, each group having three single phase cables.
Large numbers of cable lengths and joints are needed. The generic circuit lengths of 10 km
and 20 km considered in the 500 kV Study Project (Scenarios 1 and 2) study require:
Total cable lengths of 120 km and 240 km respectively.
Total numbers of delivery reels, each holding up to 700 metres, of 180 reels and
360 reels for 10 km and 20 km respectively.
Total numbers of joints of 168 and 348 for 10 km and 20 km respectively.
(The average reel length in the responses from prospective suppliers was less than
700 metres, requiring, say, 30% more reels and splices)
The design ambient temperature limits determined for the 500 kV Study Project are:
Summer:
36oC
20oC
Page 90 of 310
Winter:
ER 381
-50oC
-15oC
-20oC
0oC
The following review considers the technology of EHV cables (extra high voltage), which is defined as
the transmission voltages within the range of 215 kV up to and including 500 kV. Numerically there
are more 400 kV transmission systems in the world than 500 kV. Applications of 400 kV underground
cable are therefore a good indicator of the availability of technology to be applied to the 500 kV Study
Project
4.2
SCFF cable is the type that preceded XLPE (cross-linked polyethylene) cable. SCFF cable is insulated
with layers of lapped paper or laminated polypropylene paper (LPP) tapes and is completely
impregnated with a low viscosity dielectric fluid (a synthetic, low viscosity hydrocarbon). SCFF cables
were originally impregnated with a blend of mineral oil and were then called low pressure, oil-filled
cables. The first 400 kV 2,000 mm2 large conductor, long length cable circuits containing joints were
installed in the UK in the late 1960s in direct buried applications. A 400 kV 2,600 mm2 long length
tunnel circuit was installed in the early 1970s[12].
Page 91 of 310
ER 381
Figure 48. SCFF 525 kV 1,000 mm2 cable commissioned in Grand Coulee Dam in 1976
Notable applications of SCFF cable at 500 kV and above are:
Grand Coulee Dam, Washington, in tunnels. Two manufacturers supplied the
paper insulated 525 kV cables, Figure 48, which were installed in tunnels. The
conductor sizes are 1,000 mm2 and 1,250 mm2. The circuits were commissioned in
1976. Long term Proving Tests were performed[13] [14] [15].
Page 92 of 310
ER 381
installed in two stages in 1987 and 1993 and were commissioned in 1994. An LPP
cable is shown in Figure 49.
Canada, IREQ, long term tests on 800 kV LPP cable with accessories. The
conductor size was 2,000 mm2. The tests were performed in 1991.
On technical grounds SCFF cable is a prospective second choice to XLPE for the Edmonton region of
Alberta as it has proven 500 kV and low temperature operating capabilities. SCFF cable is more
forgiving of short term high temperatures than XLPE even though it may suffer shortened life in the
longer term.
The low temperature capabilities are limited only by the temperature limit of the O-ring rubber seals in
the accessories and by the temperature at which the standard hydrocarbon impregnant begins to
thicken, this being around -40oC. The paper and LPP tapes are capable of operating at cryogenic
temperatures (e.g. -270oC) in combination with a liquid helium or liquid nitrogen impregnant.
Figure 49. SCFF LPP 2,500 mm2 cable, similar to that commissioned in Japan in 1994
The substitution from SCFF cables to XLPE cables at 400 kV and 500 kV first began in the late 1980s
for short cable circuits with small conductor sizes (less than 1,000mm2) and without joints and in the
mid 1990s for long cable circuits with large conductors (1,200mm2 and greater) and with joints. The
number of SCFF cable systems selected by utilities for new applications fell worldwide to minimal
proportions during the period 2000-2005 due to their preference for XLPE cables. Since 2000 some
SCFF manufacturing facilities have been closed. The surviving manufacturers with an SCFF capability
have all switched to XLPE cable manufacture and at the present time have effectively mothballed their
SCFF equipment. The expectation is that these manufacturers will dispose of their SCFF manufacturing
and repair capabilities well within the 40 service life of the 500 kV Study Project.
Page 93 of 310
ER 381
The maintenance of SCFF cable requires specialist equipment as skills. On grounds of maintainability
SCFF cable is not recommended for the 500 kV Study Project.
4.3
XLPE cable is the recommended first choice for the 500 kV Study Project.
Although deceptively simple in construction, modern EHV XLPE cables have only been made possible
by major developments in dielectrics science[20] [21], polymer chemistry, clean materials, manufacturing
equipment and accessories[22] .
Page 94 of 310
ER 381
cooled to return to its original solid, white, semi-crystalline state. The cross-linking process permits the
safe operating temperature of the cable insulation to be raised to 90oC, so that it can competitively carry
similar levels of power to the SCFF cable. Additionally, some of the electrical properties of XLPE are
superior to those of SCFF insulation, such as low power loss, which further improves its power
carrying efficiency.
The main thrust of the development of EHV XLPE cable has been to increase the design stress of such
that thickness of insulation, overall cable diameter, cable span length, and most importantly, service life
reliability are competitive with those of the highly evolved paper and LPP cables. The development of
high stress XLPE cable systems is described by Attwood et al in 1998[23]. Figure 51 shows how the
cable design stress at the conductor shield (screen) and insulation shield have been increased at higher
system voltages. A key design parameter for the accessories is the stress at the cable insulation shield.
Different manufacturers select different design stresses, the value in Figure 51 for a 500 kV cable,
being approximately 7.5 kV/mm. This is similar to the average of the design stress values proposed by
the manufacturers who participated in the 500 kV Study Project.
Page 95 of 310
ER 381
1996
400 kV Metropolitan Power Project in Copenhagen[24], comprising a 12 km and a 9 km
circuit length with a conductor size of 1,600 mm2. The circuits were installed direct buried.
This is the first long length circuit of 400 kV cable with joints to be installed in Europe. A
third 12 km circuit was installed in 1999. Two types of prefabricated joints were installed.
2000
500 kV Shinkeiyo-Toyosu Project in Tokyo [27] [28] [29], comprising a 40 km long double
circuit length with a conductor size of 2,500 mm2. The circuits were installed in a tunnel
and commissioned in 2000. This is the first 500 kV XLPE circuit with joints and is still the
longest EHV cable circuit in the world.
2004
400 kV Barajas Airport[30] in Madrid, comprising a 12.8 km double circuit length with a
conductor size of 2,500 mm2. The circuits were installed in a tunnel.
2005
400 kV Elstree-St Johns Wood [31] [32] [33], London comprising a 20 km single circuit length
with a conductor size of 2,500 mm2. The circuit was installed in a tunnel.
Progress in the adoption of 400 kV XLPE cable projects in Europe is recorded in Jicable technical
papers in 2003[34] and 2007[35].
4.4
4.4.1
Page 96 of 310
4.4.2
ER 381
The electrical strength of the cable is dependent upon minimising the number and size of a)
particulate contaminants in the insulation and b) surface protrusions from the semiconducting shields23[36]. The design and manufacture of the high stressed insulation
necessary for EHV cable applications requires careful QC (quality control) management of
contaminant levels at the front end of manufacture i.e. the incoming insulation and shielding
materials, the materials handling equipment and the extrusion equipment.
XLPE has a low resistance to partial discharging (low level electrical sparking in gas filled
voids in, or on, the insulation). In manufacture the cable insulation must be kept completely
free of voids and surface damage. Joints and terminations must be designed and assembled
in such a way that air gaps are excluded and cannot reform during service life.
XLPE insulation is vulnerable to loss of electrical strength in-service due to the growth of
water trees. The rate of growth is accelerated if a) water is present, b) the insulation and
shields contain defects and c) if the electrical design Stress is greater than 2 kV/mm. The
design stress in a 500 kV cable is approximately five times greater than this limit and so
trees would rapidly grow. As yet no accepted means exists of continuously monitoring and
detecting water entry into a cable through damaged outer coverings. It is accepted industry
practice that EHV cable should have :
Insulation that is subject to a factory drying process to remove traces of the
moisture that are chemically produced as a by-product of the cross-linking
reaction.
A water tight metallic sheath and around accessories a completely water tight
enclosure.
A longitudinally water blocked construction to prevent the flow of water along a
complete span length should the outer coverings be punctured either by third party
damage or by primary electrical failure. The spaces between the wires in the
conductor are filled and the gaps under the metallic sheath are filled, typically by a
water swellable tape.
A robust outer jacket to withstand abrasion during the cable installation process
and puncture by stone/rock damage in-service. A robust, thick layer of extruded
high density polyethylene jacket is normally applied for buried and duct
applications.
A protected environment such as being laid in specially sieved or strained layers of
backfill material (sometimes called bedding and blinding), or into a duct with
clean, smooth walls and joints.
Regular maintenance checks on the integrity of the jacket during service life. The
purpose is to detect and repair damage before the metallic sheath is punctured by
corrosion. At intervals of typically no greater than one to two years a 5 kV DC
voltage is applied between the metallic sheath and ground for 1 minute to detect
Page 97 of 310
ER 381
and locate damage. For the purpose of testing, access to the sheath is provided by
link boxes connected to the sheath at each accessory.
The measures described above to protect and monitor the outer jacket and the metallic sheath
of an XLPE cable are the same as those for the service proven methods used for SCFF cables.
However, SCFF cables have the advantage that the internal fluid pressure is continuously
monitored, such that an alarm is given when the sheath is punctured. No such warning is able
to be provided for an XLPE cable.
Manufacturers of XLPE cable have been freed from the constraint of applying a thick walled
extruded metallic sheath to contain fluid pressure in SCFF cable types. They have developed
lower cost designs with thinner metallic walls. These are prospectively more vulnerable to
puncture by mechanical damage and corrosion. For direct buried and duct installations the
XLPE cable can be expected to be exposed to moisture from the ground. It is important to
specify a robust design of sheath and jacket and to ensure that routine maintenance tests on the
jacket are diligently performed. In a lower risk, protected environment, such as a dry tunnel,
advantage may be taken of a lighter design of metallic sheath.
4.5
The accessories (joints and terminations) are the critical components on which the reliability of the
XLPE cable system for the 500 kV Study Project primarily depends. Accessories are of equal, if not of
more importance, in achieving circuit reliability than the XLPE cable, and so the key international test
specification, IEC 62067[1] and the key North American constructional specification, AEIC CS-9, both
advocate the systems approach in which one manufacturer is responsible for the design of the system,
the Proving Tests, the manufacture and the assembly of the cable and accessories.
The critical location within the accessories is the electrically stressed interface between the outer
surface of the cable insulation and the inner surface of the joint or termination insulation. It is essential
that air filled gaps are eliminated from the interface.
The above technological challenges resulted in the service experience of joints in Japan lagging that of
cable by 10 years at each transmission voltage, as shown in Figure 52 and listed below:
1988: 500 kV 800 mm2 XLPE. The first circuit with 500 kV XLPE (no joints).
1993: 275 kV 2,500 mm2 long-length cable circuit with joints commissioned.
2000: 500 kV 2,500 mm2 long length cable circuit with joints commissioned.
Page 98 of 310
ER 381
Figure 52. Chart of XLPE cable design stress with system voltage.
In the first generation of 275 kV and 500 kV joint designs installed in Japan, the elimination of the
critical interface was achieved by bonding the joint insulation to the cable insulation in an on-site
extrusion moulding process (EMJ), which closely replicated the factory extrusion and cross-linking
processes. The EMJ joint is shown diagrammatically in Figure 53 and a photograph of in-service joints
is shown in Figure 54. 500 kV EMJ joints have given good service experience in the nine years since
their commissioning in a 40 km long circuit in Tokyo in 2000. The extrusion moulded joint has the
disadvantages that the assembly and inspection processes are complex and long. An assembly time of
five weeks being required to complete a group of three joints. This time makes it unsuitable for present
day cable projects and use as a maintenance spare.
Page 99 of 310
ER 381
Figure 54. 500 kV XLPE cable and extrusion moulded joints in a tunnel
Courtesy J-Power Systems Corporation
The second generation of joint designs use factory prefabricated components. The assembly time of
three joints is typically ten to fifteen days
The removal of air voids at the critical interface between the cable and joint insulation is achieved by:
Application of high skill and diligence by the jointer in preparing and polishing the
outer surface of the cable insulation on site to a high surface finish.
Fitting onto the cable, a factory pre-moulded rubber insulating component with a
smooth inner surface.
Applying pressure to the rubber insulation to hold it in compressive contact with
the cable interface.
Designing the joint and selecting the materials such that the rubber insulation will
remain in compressive contact during extremes of operating and ambient
temperatures during the 40 year design life.
Three types of prefabricated joints (PJ) joints have been proposed by prospective manufacturers for the
500 kV Heartland Project, each being of the factory prefabricated type, in which the insulation is
moulded or cast and is then subjected to an IEC 62067[1] high voltage routine acceptance test in the
factory on each component.
The proposed designs of joint for the 500 kV Study Project are:
EPR OPJ (one piece joint). This OPJ has a pre-moulded insulation of EPR (ethylene
propylene rubber). A schematic of the assembled joint is shown in Figure 55. When fitted to
the cable the rubber OPJ has a residual stretch of approximately 25-30%, which applies
ER 381
compressive force to the cable interface. It is essential that the grade of rubber has a low
compression set, so that the residual stretch and compressive force does not relax with time.
The photograph in Figure 56 shows a 275 kV OPJ moulding with an injection moulding
machine in the background. As part of manufacturing QC (quality control) it is usual to
perform an X-Ray inspection, a stretch test and then to electrically test the OPJ.
Silicone rubber OPJ (one piece joint). This OPJ has pre-moulded insulation of silicone
rubber. The photograph in Figure 57 shows a 400 kV silicone rubber moulding undergoing
routine inspection and high voltage test in manufacture. The mechanism of operation is the
same as that for the EPDM. In general silicone rubber components are soft and have good
ER 381
conformability to the cable surface, but some grades of silicone rubbers may have a lower
tear strength than EPDM. Silicone rubber OPJs typically use a slightly lower design stretch
and compressive force. In general silicone rubber would be expected to retain its elastic
properties to lower temperatures than EPDM rubber.
PJ (prefabricated composite joint). The PJ has a precast centre insulation of epoxy resin and
two pre-moulded stress cones of either EPR rubber or silicone rubber (Figure 58). The stress
cones are fitted onto the cable with a low stretch. Compressive force is applied by a solid
thrust cone held in position by an annular ring of metallic coil springs. Each stress cone is
thrust into a conical bore in each end of the epoxy resin centre casting. The length of the
coil springs has to be sufficient to accommodate the thermal expansion and contraction of
the stress cone, cable and epoxy resin casting whilst maintaining a near constant force. To
accommodate low temperature operation a) the springs are of increased length and b) the
metallic inserts cast into the epoxy resin centre casting (such as the high voltage electrode)
and the grade of epoxy resin are carefully selected to give good crack resistance. It is usual
for manufacturers to perform thermal shock tests and X-ray or ultra-sonic tests as part of the
QC program, either at a reduced, or a 100%, sampling rate, in addition to the electrical
withstand test. These are normal QC procedures in the cable industry for epoxy resin
insulation.
ER 381
ER 381
Experience of 500 kV joints on 2,500 mm2 XLPE cables in service and on test is summarised below:
The Shinkeiyo-Toyosu Project [27] [28] [29] in Tokyo is a 40 km long, double circuit, tunnel
application has been in satisfactory service operation for nine years. The service proven
designs of field moulded joints are no longer offered by the original four manufacturers
(now two manufacturers), nor are they preferred for future applications by the utility. The
joint type is considered to be unsuitable for future applications in the role of either a primary
joint or as a repair joint, because of a) the long times required for jointing and quality
inspections and b) the complexity and size of the extrusion equipment and the clean jointing
enclosure needed to house it. The field moulded joint has prospective attractions for
operation in the low winter temperature of the Edmonton region of Alberta. The interface
between the joint and cable cannot be disturbed as the extrusion process bonds the XLPE
joint insulation to the XLPE cable insulation. Overall it is agreed that for manholes and
vaults in direct buried and duct manhole systems it would be impractical to achieve high
levels of cleanliness and to bear the long jointing times.
The Shibo Sub Station circuit in Shanghai is a 17 km long double circuit tunnel application,
which is presently under construction, each with 630 metre section lengths and 78 joints.
Each circuit is from a different supplier and has a different type of joint. One joint is of the
OPJ type with EPDM insulation. The other is of the PJ type with EPDM insulation. The
terminations are into GIS.
The OPJ type of joint has gained much experience at 400 kV with large conductor cables.
Some premoulded insulation uses EPR rubber[37][47] and some silicone rubber[38]. Both
technologies can be extrapolated to 500 kV. Service experience for 500 kV OPJ types of
joint has been gained on the Ochakovo circuits at Kaliningrad, Russia. This experience
consists of one circuit of 2500 mm cable with three joints commissioned in December
2008, and a further circuit of 2500 mm cable with three joints commissioned mid 2009.
There is also one 500 kV circuit of 800 mm cable with six joints commissioned mid 2009.
For all these circuits the terminations at one end are of the outdoor type and at the other end
are of the GIS (gas immersed switchgear) type.
The 500 kV PJ type of joint was originally developed in Japan as the replacement to the
field moulded joint. The PJ types have completed a number of 500 kV Prequalification
Tests[39] which included a 6 month test in Japan at the Yamasaki test centre on a 3,500 mm2
cable in 2003 and a one year prequalification test in China at the Wuhan HV Research
Institute on 2,500 mm2 cable in 2008. Figure 60 shows two 500 kV joints on test. The PJ
joint was the first type to successfully complete 400 kV one year prequalification tests in
Milan in 1996, these being funded by Berlin Electricity as a prequalification requirement for
two tunnel circuits.
ER 381
4.6
The cumulative quantities of underground cables of all types in the voltage range of 220 kV to 500 kV
is given in Table 15, which was abstracted from CIGRE Technical Brochure TB 338[40], Dec 2007,
Statistics of Underground Cables in Power Networks. The table is ranked in descending order of the
country having the highest quantity of cable circuit length. The worldwide cumulative quantities for
each voltage range are given of a) underground cable of all types and b) for polymeric cable alone
where this can be identified. Polymeric cable may be taken to be XLPE cable in the voltage range
315 kV to 500 kV and predominantly XLPE in the voltage range 220 kV to 314 kV.
As most of the cable circuits analysed by CIGRE would be expected to consist of one Group of Cables,
the terms circuit and cct are taken to be equivalent to a Group of Cables, i.e. three single core
cables, one for each phase, throughout Section 4.6 of this report.
Country
Japan
USA
France
Singapore
United Kingdom
Spain
Italy
Korea
Mexico
Canada
China
Germany
Ireland
Brazil
Australia
Austria
Denmark
Others
TOTAL cct km
Polymeric
Non-polymeric
Polymeric to total %
ER 381
430
1,161
27
2,660
4,507
37
ER 381
The information was obtained from the experience lists submitted by prospective manufacturers for the
Heartland Project, from CIGRE Technical Brochure 338, December 2007[40] and the EPRI
Underground Transmission Systems Reference Book, 2007[41].
Notes:
Not all the manufacturers submitted complete experience lists for voltage of less than 400 kV and so
the applications in the lower voltage range of 220 kV to 345 kV will be understated.
Circuits may have been energized later than the years indicated and some may not be energized yet,
so cumulative time in-service will be overstated.
Equivalent three phase cable circuit length has been calculated in some cases as manufacturers
prefer to supply cumulative lengths of single core cable and not circuit length.
Where details of the project have not been declared, the likely presence of joints has been deduced
from the presence of a high length of equivalent three phase circuit, so the number of projects
containing joints will have been overstated, particularly for voltages in the 220 kV to 345 kV
range.
The type of installation was not always given in the manufacturers experience list, in which case
the entry is left blank.
The country of installation should not be taken to be the country of origin of the cable manufacturer.
Projects in countries which are expected to experience a low winter ambient temperature relevant to
the Edmonton region of Alberta have been included. In general manufacturers did not supply
this data and so the number of low temperature installations will be understated.
System
Voltage
kV
220
1,600
1,600
47.2
14.0
Qatar
Ireland
1998
2002
2004
2005
2005
2006
2006
2007
2007
2007
2007
2009
1200
1600
1200
1,600
2,500
1,200
1,200
1,200
1,200
1,200
1,600
1,200
20.6
12.4
20.4
12.0
3.3
8.8
7.9
4.7
28.1
11.4
13.9
29.7
Sweden
Vietnam
Germany
Italy
Oman
Russia
Russia
Russia
Russia
Russia
Russia
Russia
Installation
Type
Direct buried
Direct buried and river
crossing
Tunnel
Direct buried
Direct buried and pipes
Direct buried
Direct buried
ER 381
1997
2001
1,200
1,200
22.6
4.6
France
France
2001
1,200
17.9
France
2002
1,600
8.3
France
2002
1,600
7.4
France
1994
1998
2002
2006
1,200
2,000
1,267
1,267
7.7
33.0
8.2
38.0
India
Singapore
USA
USA
1990
2002
2009
2,500
2,500
1,600
12.1
28.8
10.3
Japan
Japan
UK
Tunnel
Tunnel
Direct buried
2010
2,000
26.2
Russia
Direct buried
345
2000
2003
2006
2007
2008
2,500
2,000
1,600
1,600
1,500
20.6
19.6
13.9
3.8
13.0
Taiwan
Korea
USA
USA
USA
Tunnel
Tunnel
Duct manhole
Duct manhole
Duct manhole
380-400
1997
1998
1999
2000
2000
2001
2002
2003
2004
1,600
1,600
1,600
1,600
2,500
1,200
1600
2500
1,200
21.3
12.6
12.0
10.4
11.2
4.0
6.0
12.5
27.0
Denmark
Germany
Denmark
Germany
Saudi Arabia
Iraq
Spain
Abu Dhabi
Denmark
225
230
275
Duct bank
Duct bank, trough and
tunnel
Duct bank, trough and
tunnel
Duct bank, trough and
tunnel
Duct bank, trough and
tunnel
Direct buried
Duct-manhole [42]
Ducts and direct buried
330
2006
2004
2005
2005
2005
2,000
2,500
2,500
2,500
1,200
16.8
25.6
20.6
5.4
10.4
Italy
Spain
UK
UK
Austria
2005
1,600
4.5
Netherlands
500
ER 381
2005
2006
2006
2007
2007
2007
2007
2008
2009
2009
2009
2009
2010
2010
2010
2010
2010
2010
2010
1,200
2,000
1,200
2,500
2,000
2,000
1,600
1,200
2,000
2,500
2,500
1,600
2,500
2,500
1,200
1,600
2,500
2,500
2,500
1.3
2.7
8.2
13.3
3.5
13.2
1.5
7.8
1.3
6.0
16.4
5.0
22.0
11.2
12.8
4.4
7.3
11.0
1.8
Italy
UAE
Italy
UK
Italy
Turkey
Netherlands
Netherlands
Qatar
Abu-Dhabi
Qatar
France
Qatar
Qatar
Netherlands
Netherlands
UK
UK
UK
2000
2,500
80
Japan
Direct buried
Direct buried
Tunnel
Direct buried
Direct buried
Direct buried and pipes
Direct buried
Direct buried [47]
Direct buried
Duct
Direct buried
Direct buried
Direct buried and pipes
Ducts [48]
Direct buried
Tunnel
Trough
Tunnel and bridge [27]
[28] [29] [35]
2007
2010
2,500
2,500
1.5
34.3
Russia
China
Tunnel
Table 16 Commercial applications of large conductor XLPE cable with joints by voltage, conductors size, and circuit length
System Voltage kV
220
225
230
275
330
345
400
500
TOTAL
Circuit km
234.4
60.8
86.9
51.2
26.5
70.9
351.0
115.8
997.2
Table 17 Summary of the cumulative lengths at each voltage of major XLPE circuits
with large conductors, long lengths and joints
The CIGRE Technical Brochure 379[49], published in April 2009, recorded the update of cumulative
service experience of HV underground cable systems up to the end of the year 1995 in the voltage
ER 381
range of 315kV to 500 kV. The data included cable circuits of all conductor sizes with and without
joints. The two dominant types of land cable system are the SCFF (self contained fluid filled) and the
extruded XLPE system.
Table 18 compares the quantities of cable and the numbers of each type of accessory for XLPE
systems.
Components
Terminations
ER 381
Components
SCFF
XLPE
Total
Cable
724 cct km
250 cct km
974 cct km
Joints
3,378
730
4,108
Terminations
1,798
312
2,110
Table 20 Total cable system components installed up to end 2005: 315 kV to 500 kV
Table 21 compares the statistics of XLPE cables from three sources. The statistics show a) a significant
increase in the cumulative circuit length with time in the voltage range of 315 kV to 500 kV and b) that
the Table 3 figures for the 220-314 kV range are understated. The latter is mainly attributable to the
exclusion of circuits with small conductors and with no joints.
System
Voltage
kV
220-314
315-500
TOTAL
4.7
It is normal practice to require manufacturers to perform tests of proof on their systems before
providing supplies to applications such as the 500 kV Study Project. The requirements for these tests
are stated in international specifications for cables. Some cable system users formulate their own
additional tests of proof to cover any special requirements for a particular application.
It is recommended that the cable systems must pass the following proving tests before they are supplied
to the 500 kV Study Project:
- Prequalification test: a one year test to demonstrate performance when the particular
cable voltage, cable conductor and joints have not been previously prequalified. A long
term prequalification test layout is shown in Figure 44.
- Type test: a six week long series of high voltage laboratory tests to prove the suitability
of the cable system design selected for the study project. A type test assembly is shown
in Figure 45.
ER 381
- Special proving tests: tests to demonstrate the reliability of the cable systems at
Edmonton cold winter temperatures. The reliability of the cable system, and particularly
that of the joints, needs to be proven for the extremes of temperature conditions it may
encounter in service life. The Edmonton region has lower winter ambient temperatures
than most other parts of the world where high voltage transmission cables of the XLPE
type have been installed. Some manufacturers have performed limited low temperature
testing, and have service experience in low ambient temperatures. None of the
manufacturers offered experience at the low winter temperatures expected to be
encountered in the region of Edmonton.
To ensure that the 500 kV XLPE cable systems will be able to operate reliably at
minimum in situ temperatures, it is recommended that a specific series of tests be
specified and performed.
4.7.1
The application to install two 380 kV tunnel installations in Berlin in 1998 and in 2000 is of particular
significance to the evolution of prequalification tests, because the utility BEWAG sponsored two series
of tests[25][26] in Italy at the CESI Milan laboratories. These were based on the tests recommended in
ELECTRA 151[50]. Six manufacturers took part in parallel tests in each series. Each manufacturer
assembled a 100 m test loop with samples of each type of accessory and samples of each type of
installation method (buried, tunnel, and duct). The first test series showed that the accessories, and in
particular the joint, were a major weakness with only one manufacturer completing the tests, which was
due to the robust design of a pre-fabricated composite straight joint. The first test series showed that
factory-prefabricated joint insulation had a superior performance to hand-taped insulation in resisting
disturbance from both heat and stress deformation and from conductor thermomechanical forces.
Designs of prefabricated accessories were installed in the second test series, and these exhibited a
greatly improved performance. Even then, only one manufacturer initially completed the second test
series without distress or failure. The other five manufacturers either reassembled or replaced
components and successfully completed the tests.
The majority of utilities have since required evidence of the CIGRE 151, CIGRE 193 or their
successor, IEC 62067[1], long-term prequalification tests to demonstrate compatibility of cable,
accessories, and installation design.
North American standards ICEA S-108-720-2004[8] and AEIC CS9-06[10] were issued in 2004 and
2006, respectively, and share the CIGRE and IEC approach of performing qualification and
prequalification tests. A significant difference is that in Europe the manufacturer is free to optimize and
to take responsibility for the design of the cable system, providing evidence of IEC tests are supplied,
ER 381
whereas in North America, the standards also specify the cable design stress limits and the dimensions
of the cable, leaving the manufacturer with the responsibility for quality control.
Manufacturers and utilities internationally have found difficulty in deciding when a change in cable
design, accessories, installation, manufacturing plant, and materials warrants performing a new oneyear prequalification test. The tests are expensive and delay projects. CIGRE, therefore, published a
revision of the qualification procedures in ELECTRA 303 (CIGRE 2006)[51]. The revision describes an
extension of qualification test procedure for changes in designs in EHV cable systems including their
cables and accessories. The revision also recommends a prequalification test procedure for HV cable
system design with high stresses when no earlier experience is available.
4.7.2
It is recommended that the IEC 62067[1] one year prequalification test be performed as an essential
precaution for the 500 kV Study Project, even if manufacturers wished to claim exemption based on
similar, but not identical, tests previously conducted. This is to reduce the risk arising from the
combination of increased design stresses, the low ambient temperatures and the large supply quantities.
The manufacturers have indicated for the operating stress within both the OPJ and the PJ joints
proposed for the Heartland Project at the critical jointer prepared interface between the outer surface of
the cable and the inner surface of the joint will be approximately 7 kV/mm, an increase of 17% over the
typical value of 6 kV/mm at 400 kV. This is sufficient to justify the application of the Prequalification
Test.
The following is a list of some of the references that refer to prequalification test experience on 500 kV
XLPE cable systems:
Japan
References[27][28][29] and Japanese cable manufacturers in house publications describe the 500
kV prequalification tests to Japanese Standards that were performed prior to the supply of the
500 kV 2500mm2 XLPE cable and extrusion moulded joints (EMJs) for the for the worlds
longest 500 kV cable installation in Tokyo. One reference[39] describes a long term test to
Japanese Standard JEC 3408 at the Yamasaki Test Centre of the Kansai Electric Power
Company. The standard requires a six month test period. The test was performed on a 500 kV
3,500 mm2 XLPE cable and a prefabricated composite joint (PJ) with part EPR insulation.
3,500 mm2 is the largest known conductor size at a transmission voltage above 66 kV. To date
this size has not been supplied commercially.
ER 381
Canada
References[3][4] describes a 345 kV type test to Hydro Quebec Standard SN-49.1 performed at
the IREQ laboratories in Quebec. The test was performed by a European manufacturer on a 345
kV 1,600 mm2 XLPE cable with a prefabricated joint of the EPR one piece type (OPJ) and
both outdoor and SF6 gas immersed terminations. The cable was installed in a duct-manhole
formation with the joints being located in an air filled chamber. This was followed by a series of
long term tests comprising 138 days at 345 kV, 33 days at 400 kV and 364 days at 500 kV and a
further 83 days at 400 kV. The 345 kV 1,600 mm2 cable and accessories therefore completed a
prequalification test for 500 kV application.
Europe
This reference[52] describes a 400 kV prequalification test at the CESI laboratories in Milan by a
European manufacturer to IEC 62067 on a 400 kV 1600 mm2 XLPE cable with two
prefabricated joints of the EPR one-piece type (OPJ), two outdoor terminations and two SF6
gas immersed sealing ends. One joint and a length if cable was direct buried, another joint was
installed in an air filled chamber, the two GIS terminations were installed in an air filled
chamber. Lengths of cable were also installed in a duct section and in a tunnel section. The test
installation completed 424 days at 400 kV including 184 heating cycles. Following the 400 kV
prequalification test, the test installation went on to complete 408 days at 500 kV including 180
loading cycles. The 400 kV 1,600 mm2 cable and accessories completed a prequalification test
for 500 kV application.
China
A long term 500 kV prequalification test to IEC 62076 was performed in 2009 by the Wuhan
test station in China. The test was performed on a Japanese manufactured 500 kV 2,500 mm2
cable with a prefabricated composite joint (PJ) an outdoor sealing end and an SF6 gas
immersed sealing end. The cable was direct buried and the joint was in a tunnel. The test report
is in Chinese.
If a manufacturer submits a prequalification test report, compliance with the following items needs to
be validated:
Is the test voltage 500 kV for the heating cycle voltage test?
Is the number of heating cycles 180 and the total test period 8,760 hours as specified in IEC
62067?
Is the conductor size 2,500 mm or larger?
Is the electrical stress at the conductor screen and at the insulation screen greater than or equal
to that proposed for the 500 kV Study Project?
ER 381
Are the accessory designs the same or equivalent to those being proposed for the 500 kV study
project?
Is the test arrangement representative of the installation design conditions as specified in
IEC 62067? For the 500 kV Study Project, are cables and joints buried direct?
Is the thermomechanical design appropriate for the 500 kV study project (particularly in terms
of the mechanical restraint to the joints and terminations, and of the cable adjacent to the
accessories)?
If the above items are not validated, can any exemptions be claimed for non-compliances using the
recommendations in CIGRE Technical Brochure 303[51]?
4.8
Low temperature operation of the joints and terminations for the Edmonton region of Alberta is
identified as posing a significant technical risk to achieving reliable service operation. The cable
systems must be capable of operation at the minimum temperature that they may encounter in service.
One of the worst case situations being when the cable is allowed to cool to the minimum ambient
temperature prior to being re-energised. It is recommended that the risk be minimised to an acceptable
level by selecting suitable joint and termination designs and by subjecting them to low temperature
Proving Tests. It is recommended that suitable test specifications be formulated, as at present
international specifications do not exist.
4.8.1
In meteorological terms Alberta experiences a continental climate with a range of temperatures wider
than the service experience that has been typically accumulated to date by EHV cable circuits. The
range of ambient temperatures given for the Edmonton region of Alberta are:
Maximum summer air temperature:
Minimum winter air temperature:
Air temperature range:
36oC
-50oC
86oC
The maximum design air temperature is 36C. Extreme temperatures of 34.5C and 35.3C have been
recorded at Edmonton City Centre and Edmonton International weather stations
(www.climate.weatheroffice.gc.ca)
The expected minimum operating temperatures (in brackets) for the XLPE cable system in the 500 kV
Study Project and the recommended minimum design temperatures, which include a performance
margin, are:
In air terminations:
Direct buried joints:
Duct-manhole joints:
Tunnel joints:
ER 381
Design
-50 oC
-15 oC
-20 oC
-10 oC
The minimum winter air temperature of -50oC is considered to be exceptionally low, with respect to
previous EHV XLPE cable and accessory experience. The corollary is that the range of conductor
operating temperature of 140oC (-50oC off load in winter to +90oC on load in summer) is exceptionally
high compared to that normally experienced.
A significant proportion of terminations for EHV cable systems are installed outside and are exposed to
the open air. They are expected to operate normally in the extremes of ambient air temperature and
solar heating.
Depending upon the type of installation, the cable and the joints have a measure of thermal isolation
from the above ground air temperature and in consequence experience a reduced range of ambient
temperature. Cables in the ground have the best protection from the ambient temperature. However
burying the cable deeper is counterproductive as the heat generated by the cable conductor in summer
must then flow through a higher thermal resistance path to reach the ground surface at its high summer
ambient temperature. If cables are buried deeper then the cost of the cable system may be increased
unnecessarily. The spacing between each individual cable must be increased or a larger size of copper
conductor must be selected. If the widest spacing and largest conductor are already selected, as is the
case for 500 kV Study Project in which a minimum of two cables per phase are required, then three
cables per phase may have to be selected to carry 3,000 MVA.
The minimum depth of burial in publically accessible land depends upon the regulations in the
particular country. A typical minimum depth for HV and EHV circuits to the top of the cable is 900
mm, this being increased to 1,050 mm in farmland to avoid damage from agricultural equipment. The
preliminary minimum depth of burial selected for the 500 kV Study Project was set at 1,300 mm to
give a reasonable measure of protection both from ploughs and the low winter surface temperature.
Ground isothermal plots indicated that the winter ground temperature at this depth would be
approximately -3oC. The 1,300 mm depth is also supported by its use in the 240 kV XLPE DESS
circuit to the north of downtown Edmonton. The DESS cable has an inbuilt optical fibre temperature
monitoring system, the records for which were analysed to establish the coldest cable temperatures in
the 2008/9 winter. It was found that the lowest temperatures were:
ER 381
ER 381
It is recommended that:
Discussions be held with other utilities and manufacturers to quantify their service
experience in supplying and operating lower voltage XLPE cable and accessories
in low temperature applications.
Discussions be held with manufacturers and independent test houses to gain
comments on an outline low temperature test specification.
At a later stage of either technical prequalification or formal bid submissions,
manufacturers provide a full technical justification for their proposed low
temperature designs, based on calculations and preliminary, private in-house tests.
The method of funding the low temperature development work and Proving Tests requires
consideration. The possibilities are:
4.8.2
To require the selected manufacturers to perform the tests at their own expense
after award of the contract and prior to commencing manufacture of cable and
accessories.
To wholly or partly fund the manufacturers to perform tests in advance of the
bidding process as part of a prequalification requirement.
Prospective low temperature risks are listed below in decreasing order of ranking:
Loss of radial contact of a rubber pre-moulded insulation component in a joint or termination with
the cable XLPE insulation.
Disturbance of the interface with the rubber component by longitudinal retraction of the cable
insulation.
Cracking of epoxy resin insulating components containing embedded metalwork.
Splitting of premoulded rubber components.
Failure of the conductor connectors in terminations and joints, due to increased thermomechanical
retraction forces, noting that the large 2,500 mm2 conductor size will develop high retraction
forces.
Failure of the watertight seals between the metallic sheath and the accessory casings due to
thermomechanical retraction, resulting in water entry and/or loss of electrical continuity of the
screen conductors.
Failure of the watertight joint protection around the metallic casing, resulting in the electrical
shorting of the sheath cross-bonding system, corrosion and water entry.
ER 381
Each of the above loading conditions should be performed both with and without axial
thermomechanical loads applied by the adjacent cables to the joint.
The joint protection that surrounds the metallic casing is at risk of disturbance, cracking or loss of
adhesion. The international test specification IEC 62067[1] gives tests on outer protection for buried
joints. The test comprises the application of 20 temperature cycling whilst immersed under one metre
head of water, followed by electrical tests on the cable jacket, joint protections, sheath interrupter
insulation and bonding lead. The maximum temperature is within 15 to 20oC of the design temperature
of 90oC (i.e. 70 to 75oC) and the minimum temperature is within 10oC above the ambient of the test
house (unspecified). It is recommended that the method of test be amended to cool the joint down to 20oC during temperature cycling.
Capacitor cone and insulator, Figure 61. A stress cone formed of either moulded
rubber or wrapped polymeric sheet is fitted to the lower part of the cable core
ER 381
ER 381
Stress cone and insulator. A premoulded rubber stress cone insulator is stretched
and slid over the cable insulation. A porcelain or composite insulator is fitted and
filled with insulating fluid. Low temperature risks are the same as those described
for capacitor cone and insulator termination and the prefabricated joints.
Prefabricated stress cone and insulator, Figure 62. This is a variant of the
prefabricated and insulator type. Firstly, a premoulded rubber stress cone
insulator, as described above is fitted. An epoxy resin casting with a conical bore is
then fitted above the stress cone. The rubber stress cone is inserted and held into
the conical bore by a bank of helical metallic springs. The purpose is a) to increase
the contact pressure at the critical moulding/cable interface and b) to replace the
fluid in the high electrically stressed zone around the stress cone with high strength
epoxy resin. Low temperature risks are the same as those described for capacitor
cone and insulator termination and the prefabricated joints.
Figure 62. Outdoor termination with prefabricated composite, premoulded stress cone
The following three designs exist for 500 kV GIS terminations. The low temperature risks are the same
as those described for the outdoor terminations, with the additional risk that cracks may occur within
the epoxy resin insulator adjacent to the cast-in metalwork.
ER 381
Capacitor cone and insulator. This is closely similar to that described for the
outdoor design. The insulator is a cylindrical tube of cast epoxy resin of
significantly shorter length.
Stress cone and insulator, wet design. This is closely similar to that described for
the outdoor design. The insulator is a cylindrical tube of cast epoxy resin of
significantly shorter length. It is named a wet design because the insulator is
filled with dielectric fluid.
Prefabricated stress cone and insulator, dry design. The design is closely similar
to one half of a prefabricated composite joint. The external insulator is an epoxy
resin casting with a conical bore. The rubber stress cone is inserted into the conical
bore and held in intimate contact with the interfaces by a bank of helical metallic
springs. The design does not require to be filled with dielectric fluid and so is
named a dry design. The advantage is that no monitoring or maintenance checks is
required to check that the dielectric fluid is at the correct pressure and has not
leaked either into the cable or into the environment.
ER 381
climates exists that excessive contraction will occur at the accessories. Specifications exist to test cable
samples in the factory to ensure that the magnitude of the contraction does not exceed a prescribed
limit.
For the 500 kV Study Project it is recommended that Proving Tests be formulated to ensure that
damage due to excessive contraction does not occur to the cable or terminations when the cable is
cooled to -50oC.
4.9
There are three types of installation that can be considered for a 500 kV cable land installation:
4.9.1
Direct burial
Duct-manhole
Tunnel
A direct buried installation in open land as shown in Figure 63 is the most efficient in terms of
installation costs as trenches of long length can be cut to match the maximum cable reel length. It also
slightly more efficient than a duct system in dissipating heat by natural cooling to the ground surface,
so it may be possible to select either a closer cable spacing or a smaller conductor size. In response to
inquiries for the Heartland Project, prospective manufacturers proposed maximum reel lengths of up to
700 metres for the 500 kV 2,500 mm2 cable.
ER 381
Figure 63. Typical direct buried 400kV cable trench containing one Group of Cables
A direct buried system gives the most intimate mechanical support to the cable and joints from the
thermomechanical loads generated by the expending and contracting cable conductor as it heats and
cools. A direct buried system is named as being thermomechanically rigidly constrained. The cables,
joints and terminations are prevented from moving either longitudinally or laterally, but in consequence
develop maximum axial loads during heating and cooling. The conductor connections, the termination
structures and the joint supports must be designed to withstand these forces.
It is good practice to a) encase the cables within the firm support and protection provided by cementcontaining materials such as cement bound sand (CBS) or fluidised thermal backfill (FTB) that set
solid and b) to sit the joints on a concrete pad, hold them by clamps (sometimes known as cable cleats)
and support them on CBS or FTB. CBS and FTB are designed to be sufficiently strong to support the
cables and withstand their loads, whilst being sufficiently weak to be removable in the event that the
cables have to be uncovered to effect a repair. In practice some materials can be difficult to remove
without damaging the cables so it is important to approve the material and to check it immediately prior
to use. In locations vulnerable to traffic ground loading (temporary or permanent traffic movements),
the cables and the joint bay may also be covered with a metallic plate.
In open land it is advantageous to dig a trench with battered sides, i.e. sides that are sloped to avoid
collapse, thus avoiding the cost of shoring (sometimes referred to as close-timbering) a rectangular
shaped trench. Close timbered trenches are required in locations of restricted width such as a)
ER 381
installation in urban streets and b) increased depth in open land, such as crossings under route
obstructions (roads, railroads and pipelines). Direct burial is not common in North America for EHV
cables.
The disadvantages of a direct buried installation are:
To install a given length, say 700 metres, of direct buried cable then the same
length of trench must be open. In built up urban areas open to traffic and the
public it may be difficult to obtain permission to open a long trench.
Setting up the trench for cable installation is complex and labour intensive. Skill
and experience are required.
Fencing and high security is required on the open trench and on the cable within it,
both to protect the public and vehicles from falling in and to protect the cable from
malicious damage and theft.
In certain environmentally important locations it may be required to fence the
trench and construct temporary bridges to permit indigenous creatures to cross the
trench.
To keep to the project schedule it is essential that the three reels holding the
particular lengths of cable for the designated open trench are delivered and are set
up on time.
Unpredictability of cable laying due to delays and trench damage by heavy rain,
flooding and snow falls.
The external protection is generally less than that provided by ducts encased in a
concrete duct bank. Direct buried cables are thus more susceptible to dig-ins and
third part damage.
Fault location and repair requires excavation of the Right of Way, work in
proximity to other cables and the addition of repair splices in the circuit.
ER 381
driven wheels or caterpillar tracks in contact with the cable). Cable engines would not be used if the
trench is expected to be wet as traction will be lost by slipping.
The first cable is carefully lifted off the rollers and placed in position on the floor of the trench. The
second and third cables are then pulled in. Having laid the three cables, their spacing is carefully
checked and adjusted. Ancillary services are then laid, usually in the corners of the trench, these being
small optical fibre P&T cables (pilot and telephone) or small empty ducts for future telecommunication
use. The array of cables is then covered (blinded) with the specified thickness of dry CBS or fluid FTB.
Robust cover tiles of concrete or plastic are laid to completely cover the blinding. Wide plastic marker
tapes are laid overall. Finally the trench is backfilled to ground level with the indigenous soil that had
been dug out. In some locations layers of road base and tarmac or concrete are laid to reinstate the
surface of the road or street.
4.9.2
Duct-manhole system
Duct-manhole installations are used in urban areas where it is not permissible to open a long length
trench. Although the materials are more expensive than a direct buried system, major advantages are:
The project program is more flexible as the installation date of the ducts is isolated
from that of the cable delivery. There is freedom to install cable spans in any
sequence at any position along the route.
The security measures and risks are reduced.
The joint vaults may be sealed until cable pulling occurs.
A high degree of protection is obtained if the ducts are encased in a duct block
formed of concrete or more usually of fluidised thermal backfill.
Cable installation does not require the same amount of skill as is needed for direct
burial since the ducts are designed to be within the mechanical design constraints
of the cable that is to be installed.
Cable fault repair would involve replacement of duct lengths so that additional
splices would not be added to circuit runs.
Splices are accessible for inspection and testing.
Pulling tensions can be more predictable.
A duct system is classed thermomechanically as being semi-constrained. Sufficient clearance is
provided in the duct to permit the cable to be pulled-in and to expand laterally when heated. The
advantage of lateral expansion is that the sinusoidal and helical patterns that form absorb some of the
thermal expansion strain and so reduce a) the axial thrust on the joints in the vaults and b) the sidewall
forces on the cable insulation at duct bends.
The disadvantages of a duct-manhole system are:
Differences in duct route geometry on either side of the vault apply differential
axial thrust on the joint, which can be of high magnitude. The cable clamping
ER 381
ER 381
advantages of FRE are that it is a) unlikely to distort at bends and b) less likely to suffer thermal
damage in the event of a high energy cable fault, thus permitting the cable to be pulled-out.
The three ducts are positioned in the trench at the correct spacing by being fixed to plastic formers at
regular spacings. A fourth empty duct may be installed to house a replacement cable should a failure
occur and it is not possible to extract the faulted cable. Smaller auxiliary cables ducts are installed to
house the pilot and telecommunication cables.
Fluidised backfill is poured around the ducts to form a duct block.
A mole (or mandrel) is pulled through the duct to ensure that the duct is of correct circular diameter
and that there are no obstructions at the duct joints. The duct is also pigged to ensure it is clean. It is
good practise to inspect the inside of the duct using a CCTV pipe inspection system.
The ducts are sealed to the joint vault (historically named a manhole), which is usually a pre-cast
concrete construction. The joints are clamped to a constraint system which in turn is bolted to the walls
and floor of the vault. The vault also houses the link box. Alternatively in some installations a
temporary joint bay is formed, which after cable jointing has occurred, is backfilled, thereby reducing
cost. The disadvantage is that access to the joints is lost for maintenance and more that complexity is
required to seal the open duct ends to the cable to prevent entry of the backfill.
4.9.3
Tunnel Installation
It is not reasonably possible either to find a route in roads congested with other
services, or to obtain permission to open trenches and stop traffic.
Part of the route is required to cross under a major obstacle, such as a wide river.
Tunnels are generally the most expensive form of construction; however they have the advantages of:
Providing independence from weather delays during tunnel construction, cable
installation and jointing.
Providing uniform route cross-section geometry to facilitate the installation of the
cable, without the need to incur engineering complexity and cost increases
associated with route obstructions encountered at ground level.
Providing a protected environment for the cable, free from risk of third party digins and, if the tunnel is designed to be water tight, reduced risk of water damage to
the cable, joints and link boxes.
Providing access for the 500 kV Study Project to all parts of the cable at any time
of the year for monitoring, maintenance and repair.
ER 381
Providing an asset for future use, either in installing more circuits or in replacing
or repairing existing cable without need to disturb the ground at surface level.
Permitting use of a cable with a lower cost, less robust design of metallic sheath.
However, the proposals by the cable manufacturers for the Heartland Project were
did not show this.
Deep tunnels are typically built at 20 to 60 metres depth, are circular and are equal to or greater than 3
metres in internal diameter. The thermal resistance is too great to permit heat to dissipate naturally to
the ground surface and so forced cooling is employed by drawing cool air down a shaft. The air flows
along the tunnel where it extracts the heat from the cable to be vented to atmosphere at another shaft at
a typical spacing of 3 to 5 km. A maximum air flow rate of 5 metres per second and a maximum
exhaust air temperature of 50oC are typically specified. Acoustic baffles are fitted to reduce cooling fan
noise to an acceptable level. A tunnel design study was performed for the 500 kV Study Project showed
that for a 5 km long section between shafts it is possible to cool the cables in summer and, by
restricting air flow in winter, to limit the minimum joint temperature in the tunnel to 0 oC. This would
give a wider choice of joint design and reduce low temperature risk.
Shallow tunnels are normally of the cut and cover type and are rectangular in cross section. The
advantage is that they are lower in cost and prospectively faster to construct as tunnelling machines and
deep shafts are not required. It is possible to dissipate some of the cable heat by conductive heat flow to
the ground surface, but forced air flow will still be required.
4.9.4
The first major 400 kV cable circuit in Europe was installed direct buried in Copenhagen in 1997[24].
In 2005 a 400 kV 2,500mm2 XLPE cable circuit with a 1,600 MVA power rating was commissioned in
a 21 km long deep tunnel under London[32] [33]. The first major 500 kV 2,500 mm2 XLPE circuit was
commissioned in 2000 and was in a 40 km shallow tunnel under Tokyo.
Table 22 shows that at 400 kV two thirds of the three phase cable lengths are direct buried and these
comprise two thirds of the number of installations. One third of the circuit lengths are installed in
tunnels. The average three phase circuit length at 400 kV is approximately 10 km for both buried and
tunnel installations.
System Voltage kV
400
500
TOTAL
Direct buried
km
#
225.4
20
1.5
1
226.9
21
Duct
km
1.5
0
1.5
#
1
0
1
Tunnel
km
#
109.9
9
114.3
2
224.2
11
All Types
km
#
336.8
30
115.8
3
452.6
33
Table 22 EHV installation types, three phase cable lengths and number of projects
ER 381
There are two significant installations to date at 500 kV one in-service, the 40 km long ShinkeiyoToyosu Project in Tokyo, and one in construction, the 17 km long Shibo Sub Station circuit in
Shanghai[2], both of which are installed in tunnels. The average three phase cable lengths for the two
tunnel installations is 40 km, this being the same length as would be required for the 10 km scenario in
the 500 kV Study Project which has a maximum of four groups of cable.
Combining the 400 kV and 500 kV installation statistics, results in 50 % of the project three phase
lengths being direct buried and 50 % being in tunnels, with the average length per project being 10 km
and 20 km in tunnels.
One of the major disadvantages of tunnels, especially if more than one circuit is installed, is fire. An
incident on one cable can cause fire or arc damage to adjacent cables or circuits. Whilst XLPE cables
are superior to SCFF in this respect, they will still burn under some circumstances.
4.9.5
The majority of long tunnel installations are cooled by forced air ventilation, for example, the 6.3 km
and 5.2 km long, 400kV, 1,600 mm, installations in Germany[25][26] and the 20.6 km long, 400 kV,
2,500mm installation in UK[31][32][33]. Some tunnels have assisted cooling by the presence of water
circulation in one or more pipes separate from the cables with the function of cooling the tunnel
air[27][28][29].
The majority of direct buried and duct-manhole systems are naturally cooled. Two notable forced
cooled XLPE cable systems are:
direct buried, 400 kV 1,200 mm installation in Austria[46] which uses lateral water
pipe cooling.
400 kV 1,600 mm system in the Netherlands[48] which uses integral sheath water
cooling.
Forced cooling is described in Section 3.11.
ER 381
installation in a tunnel be revisited for the 500 kV Study Project, then GIL is recommended to be reassessed as a prospective alternative solution.
ER 381
Conductor
The conductor is a hollow busbar normally fabricated from aluminium tube. Example dimensions are
280 mm diameter with an area of 13,000 to 15,000 mm2. A conventional cable has a maximum size of
copper conductor of typically 2,500 mm2; the equivalent size in aluminium being approximately
4,100 mm2. Thus GIL possesses 3 to 4 times more conductor area and has the prospective capability of
achieving a similar increase in power capacity. The load current of 3,460 A for the 500 kV Study
Project rating of 3,000 MW could be carried by one Group of three GIL compared to two groups of
conventional cable.
Sections of busbar are typically 13 m long. They are connected by electrical plug-in connectors that
permit it to axially expand and contract when heated. Thus the generation of thermomechanical forces
in the busbar is avoided. Sliding elastomeric seals are provided to contain any particulate contaminants
that may be produced and prevent them from entering the gas insulation. The specified permissible
temperature rise of the connector usually dictates the maximum current rating of the GIL.
Support Insulator
The busbar is supported on insulators, as shown in Figure 64. The insulators are cast from a
thermosetting material that is formulated to reduce the accumulation of space charge and the attraction
of particles. Special diaphragm insulators are used to support the busbar at the ends of a gas section
and segregate the gas compartments. These insulators are usually conical in shape and have sufficient
thickness to withstand the pressure forces when one GIL gas section is depressurised. In the event of
an internal electrical fault the diaphragm insulators stop the power arc, (which travels longitudinally
under Lorentz forces), from passing into the adjacent GIL section, thereby limiting the length of
surface damaged busbar and enclosure.
Insulating Gas
The insulating gas is either a) 100% SF6 (sulphur hexafluoride) at a pressure of approximately 4 to 5
bar at 20oC, or b) an SF6/N2 nitrogen mixture, for example 20% to 80% with a pressure of
approximately 7 bar. The electro negative properties of SF6 gas give high breakdown strength. The gas
mixture was introduced to reduce the concentration of SF6 available to leak into the atmosphere.
Special gas handling plant is available to store and refurbish the gas mixture for reuse.
Enclosure
The enclosure is a spirally welded, aluminium alloy tube with typical dimensions of 600-700 mm
diameter and 10 mm wall thickness. The thickness is calculated to:
Provide sufficient low electrical resistance to limit the heat generation and temperature rise to
specified limits. A voltage is induced along the enclosure by the magnetic field from the
ER 381
primary load current in the busbar. The GIL enclosure is solidly bonded to adjacent phases and
to ground at certain positions along the route. The induced voltage drives a circulating current
along the enclosure. The enclosure has low electrical resistance and so the magnitude of the
circulating axial current is high and is of almost equal magnitude to the load current in the
busbar. In comparison, the metallic sheaths and shields of conventional transmission class
cables are specially bonded to prevent current circulation and to avoid the derating effects of
unwanted heat.
Withstand the internal gas pressure and remain within its elastic limit.
Prevent power arc burn-through in the event of a short circuit.
Particle traps are positioned on the floor of the enclosure. The traps locally distort the electrostatic field
and so generate dielectrophoretic force, which attracts and traps any conducting particles that may be
present.
In early designs, the 13 m long sections of GIL enclosure were provided with flanges that permitted
them to be bolted together on site. Present designs of GIL enclosure are flangeless, Figure 65 and
Figure 66, and are joined together on site by automatic orbital pipe welding machines. This technique
achieves economies in material and fabrication and prospectively reduces the risk of gas leakage.
The diameters of the busbar and the enclosure are optimised to provide an economical design by:
Achieving the minimum radial electrical clearance necessary at the limiting electrical design
stress at the busbar. The optimum geometry occurs when the diameters are in the ratio of 2.7:1.
Increasing the gas pressure to raise the electrical withstand strength of the insulating gas, whilst
remaining within the pressure retraining design limits of the enclosure.
Ensuring that the resultant dimensions maximise convective and radiant heat transfer.
The inner and outer surfaces of the busbar and enclosure may be treated and coated to improve the
electrical withstand strength and heat transfer.
For applications in air the outer surface of the GIL enclosure is typically left unjacketed to maximise
heat transfer. For direct burial the enclosure would require to be protected by a corrosion resistant layer
of the type used on pipe lines, together with a design of cathodic/electrolytic cell protection. Such
protection would be required to withstand the enclosure currents (circulating current and short circuit
through current).
ER 381
Figure 65. Two groups of 275 kV gas insulated line installed in a tunnel
Courtesy of Siemens
Figure 66. One group of 400 kV gas insulated line installed on stilts in a substation
Courtesy of Siemens
ER 381
similar tests on conventional direct buried 400 kV XLPE cable. Applications followed in France for
conventional 400 kV XLPE cable, but to date have not occurred for buried GIL.
Table 23 shows that GIL has generally been selected for special applications that require high power
transmission in air in the controlled environment of a substation or tunnel (note: as such these fall
outside the original definition of GIL). The number of applications compared to conventional cables
and overhead lines is small. The longest circuit length of GIL is 3.25 km, which occurred in a utility
owned tunnel in Japan in 1998.
Table 23 records the in-progress installation for RWE Transportnetz Strom GmbH at Frankfurt airport
in Germany of two 0.9 km long 400 kV GIL circuits. This application is of significance as it is the first
true commercial application of direct buried GIL with a length of greater than 0.5 km for 33 years. The
commissioning date is planned for the first quarter of 2010. In their internet web press release, a
spokesman for RWE said that What we want to do with this pilot project is to try this transmission
technology as an alternative to cable solutions. We have already carried out joint tests with the
manufacturer on a prototype, which have provided convincing proof of its technical feasibility. Each
GIL conductor matches the rating of one overhead line conductor of 2,598 A. A group of three GIL has
a rating of 1,800 MW. 500 lengths of 10.8 m long GIL tube have been delivered to site for the
conductor bus-bars to be plugged together and the outer enclosure to be welded in-situ to make gastight joints.
Table 23. Details of significant GIL applications
Year
Length
Circuit
Total
km
km
Voltage
Current
kV
SF6
%
GIL Type
Installation
Method
Application
Type
1972
0.414
0.414
230
100
buried
commercial
1975
1.45
1.45
138
1250
100
buried
commercial
1975
0.58
500
3000
100
buried
commercial
1977
0.13
0.13
138
100
buried
commercial
1975
-
0.7
-
1.4
0.14
400
275
820
6300
100
100
tunnel
tunnel
commercial
test
1998
0.07
400
3200
20
tunnel
test
1999
0.1
400
4000
20
buried
test
1998
0.3
400
4000
10
buried
test
1998
2 x 3.25
19.5
275
2730
5980
100
tunnel
commercial
Project
Na
me
US, Hudson SS
NJ
US, Lynchburg
Indianapolis
US, Ellensburg
Washington
US, Spy Run SS
Indianapolis
Germany, Wehr
Japan, CRIEPI
Test Site
Germany, IPH
Test Site
Germany, IPH
Test Site
France, EDF
Test Site
Japan,
Shinmeika-
ER 381
1997-2000
8 x ~2.1
17.0
400
1200
100
stilts
commercial
2001
6 x 0.4
2.4
220
2000
20
tunnel
commercial
2002
5 x 0.24
1.2
500
4000
60
stilts
commercial
2004
1.64
1.64
400
4000
10
commercial
2010
0.9
1.8
400
2600
stilts and
covered
trench
buried
>2010
0.155
0.155
400
20
tunnel
Pilot/
commercial
commercial
Tokai[56]
Saudi Arabia,
PP9[57]
Switzerland,
Palexpo[58]
Thailand, Sai
Noi[59]
UK, Hams
Hall[60]
Frankfurt
Airport
Austria,
Limberg II[61]
A low characteristic impedance, because the inductive and capacitive reactances are of similar
magnitude and so nearly balance. The impedance of GIL is more resistive than that for
overhead line (inductive) and underground cable (capacitive) and thus has prospective system
design merits for long distance transmission as there is less need for reactive compensation than
there is with conventional cable.
Suitability for installation in a tunnel, Figure 65, having low risk of fire spread to other circuits.
Suitability for installation on stilts in non-public land, Figure 66.
High power, voltage and ampacity ratings on a single group of three GIL, for example 4,300
GW, 500 kV and 5,000 A in a force ventilated tunnel application.
Near zero external emf.
Ease of connection to GIS, thereby avoiding the complexity and cost of either overhead line
bushings or cable terminations.
ER 381
Tunnels and shafts need to be designed differently from those required for conventional
flexible cables, to a) withstand different and prospectively greater mechanical point loading at
some fixing points and b) have shaft access to lower the rigid sections of GIL and to transport
them to the point of assembly.
Risk of leakage of increased volumes of the greenhouse gas SF6 due to the high volume of long
length GIL. SF6 is a green house gas with a Global Warming Potential (GWP) of 22,200. To
reduce the leakage risk, GIL is segregated into smaller gas sections, enclosures are welded and
diluted gas mixtures with reduced concentrations of SF6 are available.
Increased complexity of the maintenance necessary to monitor the GIL pneumatic equipment
compared with overhead lines and buried cables.
The risk of impairment of the dielectric performance due to particulate contaminants. The
number of connections between GIL sections in a long route increases the risk and prospective
failure rate.
Risk of liquefaction of the gas at extreme low ambient temperatures. It was stated by a GIL
supplier that SF6 is suitable for operation down to -40oC.
4.11.1 Superconductivity
The metallic conductors used in conventional room temperature cables posses the property of electrical
resistance to current flow, which is manifested in the generation of unwanted heat and power loss.
Conventional cables and their installation environments are designed to a) reduce the magnitude of the
ER 381
heat and power loss by selecting a large conductor size and b) dissipate the heat efficiently to ambient
temperature. The present generation of superconducting cable is quite the opposite as it operates at a
very low temperature. It is necessary to:
Design the HTSC cable and its installation environment to minimise the inrush of heat into
the cable from ambient temperature.
Provide a forced cooled refrigeration system to extract a) the residual heat that enters the
cable from the environment, b) the heat that is generated within the HTSC cable by the
passage of AC current and c) the heat that is generated by the flow of the coolant.
Should an ideal superconductor be found it would exhibit zero resistance, zero heat generation and an
unlimited current rating at room temperature. An ideal superconductor would conceptually permit a
group of three, small diameter cables, to transmit an unlimited level of power, at low AC voltage, over
very long distances, with complete independence of the thermal environment. Should such a
superconducting material be found it would revolutionise all electrical equipment and the present way
of life. For the latter reasons intensive research into superconductivity has been directed since the
discovery in 1911 of the first superconductor, this being the metal mercury in solid form at a
temperature of 4.2 K (-268.8oC) i.e. a temperature close to absolute zero at 0 K (-273oC). The physics
of superconductivity is described in Tinkham[62].
Restrict the choice of coolant (also named the cryogen) to liquid helium this being a high cost
liquid. Helium is suitable for the extraction of heat by circulation in liquid form in the
temperature range between 3 - 5 K (melting point) and 4.2 K (boiling point).
Restrict the choice of thermal insulation to a vacuum vessel containing wrappings of super
insulation (also named the cryostat).
Require powered refrigerating equipment to extract heat from the helium cryogen.
One of the most suitable Type 1 LTS superconductors for industrial application was found to be
Niobium and some alloys, such as niobium-tin, that being ductile could be formed into tapes and wires.
These are suitable for the fabrication of the coils of electromagnets to generate magnetic fields of high
strength in high technology applications such as clinical magnetic resonance imaging (MRI), electrical
ER 381
power storage devices and atomic particle accelerators. These applications are rendered practical
because the coil is contained in a box shaped cryostat of comparatively small dimensions.
Power cable applications of superconductivity are perhaps the most difficult to realise[63][64]. The long
circuit lengths of typically 0.3 km to 50 km, and their inaccessibility for maintenance, requires
containment in an equally long vacuum containing cryostat envelope. Pumps and heat exchangers are
required to be distributed along the route, each having high reliability, availability and long life.
The first experimental, model superconducting AC cable was constructed in 1968 in London. It was
designed to operate at 138 kV and to carry 1,000 MVA. The model was only a few metres in length and
was far from a practical component of a transmission system, comprising only one cable, having a
limited design of termination and no joints. In 1984 a technical paper reported field trials performed at
the Brookhaven National Laboratory on a more advanced single phase cable rig designed to carry 1,000
MVA. In 1983 a technical paper reported a demonstration application in which a 50m length of
superconducting cable was connected for a period of time to the Austrian National Grid. The
development of these LTS cables was not taken further as they could not compete on cost with
conventional cables having copper wire conductors and natural heat dissipation.
ER 381
The cable is installed around the various bends present in the route.
The HTSC superconducting wires are actually ribbon shaped. Two types have been developed for
power cable prototypes:
OPIT (oxide powder in tube) wire technology. This produces 1G (first generation) wires). A
powder of BSCCO (bismuth strontium calcium copper oxide) is used to fill a round silver
tube. BSCCO has a critical temperature of ~110 K (-163 oC). The tube is swaged to a small
diameter and is then flattened into the shape of a ribbon. The ribbon is heated to high
temperature to turn the powder into a ceramic. The swaging process also stretches the wire
ribbon to a length in excess of 1,000 m. The dimensions of the ribbon are typically 4 mm wide
by 0.2 mm thick (with an area of 0.8 mm2). The majority of HTSC cable prototypes have used
OPIT wires, these being reasonably robust and hermetically sealed. The silver encapsulation
permits the ribbons to be jointed together by soldering without losing the superconducting
properties. The down side is the silver tube is a significant cost item.
CC (coated conductor) technology. This produces 2G (second generation) wires. A buffer layer
is deposited onto a thin, wide metallic ribbon. Thin layers of superconducting material are then
deposited onto the buffer layer. The superconducting material is YBCO (yttrium, barium
copper oxide), or similar. YBCO has a critical temperature of ~92-110 K (-181 oC to -163 oC).
The tape is slit to a similar 4 mm width to the OPIT wire, but is usually thinner. The advantage
of the 2G wire is that its manufacturing cost is lower. The initial disadvantage is that the
effective critical current density has been lower than that of the 1G wire, although it is hoped
that this will be increased with development.
ER 381
A conceptual 3,000 MW cable design is shown in Figure 67. The cable would have similar dimensions
to the 500 kV 2,500mm2 cable described in this report and thus prospectively the despatch reel would
accommodate the same typical 700 m length. The HTSC conductor would be required to carry
approximately 12,550 A, compared to 1,732 A for the 500 kV Study Project XLPE cable. To take
advantage of the high current rating, the system voltage may be reduced from 500 kV to 138 kV. The
reduction in voltage permits the thickness of insulation to be reduced. The reduction in thickness
provides room for the additional outer HTSC conducting layers and the vacuum filled cryostat. The
reduction in system voltage also permits the insulation design stresses to be reduced for both the cable
and the joints.
The components of one of the three single core HTSC cables are described below Figure 67. A
photograph of a 13 kV concentric three phase cable is shown in Figure 68.
Former
Cable manufacture starts with a flexible tube or cylinder.
Inner Quench Conductor
A conventional copper wire conductor is stranded (wound) onto the former. The purpose of the quench
conductor is to carry the rated short circuit current for the specified circuit breaker clearance time. This
ER 381
is because sufficient HTSC wires are applied to take the rated current of 12,550 A only and thus they
would lose their superconducting property and would quench. The quench conductor is placed inside
the HTSC conductor to protect it from magnetic induction.
Inner HTSC Conductor
Sufficient HTSC wire ribbons are applied to carry the rated current; for example 170 tapes each
carrying an average of say 75 A. The diameter of the former is increased until the magnetic field on the
outer layer of HTSC tapes falls to a sufficient value that the 100 A superconducting rating can be
achieved (in conjunction with a suitably low LN2 temperature of say 65 K.) Layers of tapes are
applied in alternate lay directions (left and right hand). The detailed construction of an AC HTSC
conductor are important. The AC magnetic field induces eddy currents in the metallic components
which must be kept small a) to reduce generation of conventional I2R heating in them and b) to reduce
the magnitude of any residual magnetic fields that do not cut the superconductor parallel to its surface
as these adversely affect its superconducting properties.
Insulation and Shields
For the conceptual Study Project HTSC cable a CD (cold dielectric construction is preferred). In a CD
cable the whole cable is housed within an LN2 cooled cryostat. A wet dielectric has the most
experience of use in prototype CD cables. The wet type comprises lapped tapes, which are 100%
impregnated with pressurised LN2, which performs the role of the dielectric fluid. The tapes are
usually PPLP (polypropylene laminated paper). The wet CD cable is therefore closely similar to the
SCFF cable except the hydrocarbon impregnant DDB (dodecyl benzene) is replaced with LN2.
The inner and outer shields are formed of conducting tapes.
Inner HTSC Conductor
Layers of HTSC wire ribbons are applied to form the outer conductor. After the cable system is
installed, the three outer HTSC conductors are bonded together and to ground at their ends. The
magnetic field from the inner conductor induces a voltage in the outer HTSC conductor, that circulates
a current of equal and opposite magnitude. This has the essential benefit of eliminating the magnetic
field external to the cable, such the three cables are magnetically isolated and shielded from each other,
thereby ensuring that the HTSC tapes only experience a cylindrical field. The secondary benefit is that
the surroundings of an HTSC cable experience zero external magnetic field. The downside is that
almost twice the number of HTSC wires are required.
Outer Quench Conductor
A conventional copper wire conductor is applied onto the insulation outer HTSC conductor. This
performs the same protective role as the inner quench conductor in carrying short circuit current.
ER 381
Sheath
Depending upon the particular design of the HTSC cable a sheath is applied over the cable core. In
the case of a wet design of CD cable the sheath may be a permeable tape. In the case of a dry design
of CD cable, the sheath would be formed of, say, longitudinally welded stainless steel is applied to
permit the surrounding LN2 to permeate the insulation and conductors.
Annular LN2 Duct
The duct is formed by the annular gap bounded on the inner side by the sheath and on the outer side by
the cryostat. LN2 is pumped longitudinally along the cable for a distance named a hydraulic cooling
section. The pressure of the LN2 falls along the hydraulic section due to its hydraulic impedance. The
maximum inlet pressure is typically 20 bar and the minimum outlet pressure is typically 5 bar. The
minimum pressure limit ensures that the insulation is fully impregnated and that the LN2 boiling point
is depressed such that N2 gas filled voids cannot form in the insulation.
Cryostat
The cryostat comprises two stainless steel sheaths with an annular gap in between. The inner sheath is
wrapped with super thermal insulation comprising multiple layers of thin metalized mylar tape. The
purpose of the super insulation is to reflect radiant heat and prevent it entering the cable. The annular
gap is evacuated and held at a high vacuum to minimise conductive heat transfer into the cable. A
chemical getter may be included within the gap to absorb residual gas.
Outer Jacket
The cryostat is covered with an extruded polymeric layer (for example polyethylene) similar to that
applied to conventional cables. The jacket provides protection from abrasion during installation and
from corrosion when installed below ground level.
ER 381
ER 381
records the progress of the development of HTSC cables. The HTSC cable systems have moved from
being laboratory test prototypes to field demonstration test prototypes. Operational experience is now
being gained when connected to either industrial or utility grid systems. This progress and the
majority, if not all of the projects, have been assisted by funding.
The applications fall into two types:
Low system voltage, three core cable applications, in which a conventional cable application is
replaced by an HTSC cable of similar size, but of three to five times power supply capability.
The HTSC cable can increase the power rating of a substation in an existing downtown
location, when there is no room a) to bring in either multiple conventional cables, or a single
higher voltage cable and b) to locate a voltage step-down transformer. Plans were being
prepared[65] [66] in 2007 and 2008 for a possible 6 km long demonstration project in down town
Amsterdam. An existing 150 kV gas pressure cable in a pipeline with a power rating of 100
MVA was proposed to be replaced by a 50 kV concentric three phase HTSC cable having a 2.5
times higher power rating of 250 MVA. An example of a 13 kV cable with a concentric three
phase construction is shown in Figure 68.
Higher system voltage, single core applications, in which the need to install a short length of
higher voltage transmission cable can be avoided. The commissioning of the 138 kV, 574
MWA, single core demonstration cables at Holbrook, Long Island Sound, in 2008, is the closest
application to the 500 kV 3,000, MW Study Project. Work to develop a 225 kV HTSC was
reported in 2000[67], was subsequently discontinued. It is understood that R&D is presently
being performed in Japan to produce a 275 kV cable. For an HTSC cable to be considered for a
future commercial 3,000 MW application the following would require to be demonstrated:
o An increase in cable current rating from 2,400 A to ~12,500 A,
o Practical designs of joints that can be quickly assembled and which are suitable for
maintenance spares. At present there are none in the demonstration cable.
o Ability to scale up manufacturing capacity from supplying a 0.6 km route length to
supplying a 10 km route.
o Ability of the vacuum filled cryostats to maintain their long term thermal efficiency and
to be maintained.
o The operational reliability and availability of the LN2 hydraulic circuits together with
their distributed pumping and refrigeration equipment.
ER 381
Year
Design
Current
Length
Power
Voltage
Cable Type
Cold or
Cores
Warm
#
Joint
Type
MVA
kV
1999
50
400
115
2,000
WD
yes
test
2001-2007
30
27
12.4
1,250
CD
3 con
no
grid
demo
2001-2003
30
104
30
2,000
WD
1x3
no
grid
demo
2002
100
115
66
1,000
CD
no
test
2003-2005
500
133
77
3,000
CD
no
test
2005-2006
100
50
23
1,260
CD
yes
test
2006
300
69
13.2
3,000
CD
yes
grid
demo
3 con
Application
Location
Italy, Milan HV
lab[68]
US, Carrolton,
Georgia
Denmark, AMK
SS,
Copenhagen[69]
Japan, Yokosuka
test site[70]
Japan, Yokosuka
test site[71]
Korea, KEPCO
test centre[72][73]
US, Bixby,
Columbus,
Ohio[74] [75]
ER 381
2006-2009
350
48
34.5
800
CD
yes
grid
demo
2008
610
574
138
2,400
CD
1x3
no
grid
demo
2010-2011
300
62
13.8
3,000
CD
3 con
no
grid
demo
2011
1,760
48
13.8
2,000
CD
3 con
yes
grid
demo
US, Albany, NY
US, Holbrook,
Long Island
Sound[76] [77]
US, Manhattan,
NY City
US, LabarreMetairie SS,
Louisiana, New
Orleans
4.11.6 Installation of a conceptual HTSC cable system for the Study project
To provide n+1 redundancy for maximum reliability and availability it is proposed that the cables
would be installed as shown in Figure 69, Figure 70 and Figure 71:
Each cable to be cooled by containment in an annular LN2 duct. A central conductor duct is not
to be used. This simplifies the design of the cable and avoids the need for joint designs to have
complex LN2 stop and feed capabilities.
Each single core cable to have its own separate LN2 cryostat return pipe, instead of a shared
return through a parallel cable. If one cable is damaged, the other two will be retained in sound
condition.
Each cable and return pipe to be housed in a separate trough to permit access without disturbing
the adjacent cables. HTSC cables are thermally and magnetically independent and so an
increase in spacing is permissible.
Two groups of three cable to be provided per circuit, each normally carrying half load and only
taking the full 3,000 MW load in a contingency situation. This is the arrangement recommended
for the 500 kV Study project. The HTSC cable has the additional advantage that the symmetry
ER 381
of their spacing is not critical. If a single cable should be taken out of service, then its place can
be taken by one cable from the adjacent Group of Cables. This can be repeated three times,
thereby maximising n+1 redundancy.
The resulting 39 m width of the swathe, Figure 71, required for two circuits of 138 kV HTSC cable,
each comprising two Groups of cable is closely similar to the 40 m width required for the conventional
500 kV cable shown in Figure 78. No advantage in the swathe width of an HTSC installation for the
500 kV Study Project is envisaged.
Conceptual HTSC cables do have a prospective advantage for the 500 kV Study Project in that they are
thermally independent of their environment. The crossing of route obstructions at depth would not have
the thermal limitations experienced by conventional cables.
ER 381
a
l
mm
200
150
200
200
50
50
1000
h
i
j
k
l
75
75
75
75
500
ER 381
mm
1000
3050
500
1000
1500
Figure 70. Conceptual cross section dimensions of a HTSC buried, three phase group / trench
arrangement
ER 381
To allow physical separation between Groups of Cables and sufficient clearances for
installation, the following dimensions are proposed:
Dimension
mm
a
b
c
d
e
3000
2000
10000
3000
10000
39000
Figure 71. Conceptual installation swathe dimensions for a HTS cable trenches
ER 381
ESTIMATES OF RELIABILITY.
Expectations of reliability
Utilities throughout the world are now purchasing XLPE cable systems at voltages up to the
highest EHV levels, which demonstrates their confidence in the reliability of this
technology.
ER 381
The reliability assessment for the complete transmission system must be performed to
include the other components, which include overhead lines, transition station components
and substation termination components.
5.1
The failure rates reported by CIGRE[49] only include failures which either result in an instantaneous
failure leading to automatic disconnection or an occurrence requiring subsequent unplanned outage, it
can therefore be assumed that if any failure occurs then an unplanned outage will occur that will
require to be repaired. The average outage repair time given in CIGRE TB 379[49] for the 220 kV to
500 kV category is 25 days with a difference in repair times of up to 14 days (Page 41 therein).
However, for the climate during the winter period in the Edmonton region of Alberta, the repair times
would be extended by the need for additional measures to mitigate the effects of the cold temperatures.
This would typically be expected to extend the repair times by approximately one week during the
period from October to April. For the Edmonton region of Alberta the average outage repair time
should therefore be increased to 29 days. It is likely that faults which involve the primary insulation
will take significantly longer to repair than affect only the cable jacket or external protection of
accessories.
Further details of cable system repairs are given in Section 7.22.
5.2
In this section and in Section 5.3 fault statistics are given separately for XLPE cable and overhead line.
A comparison has not been performed as the data upon which the cable failure statistics has been based
is too small in number, and for too short a duration, to be trustworthy. It is expected to be several more
years before sufficient failure data becomes available for reliable analysis.
5.2.1
The cable fault statistics are derived from those published by CIGRE in Technical Brochure number
379[49]. These are based a cumulative 220 kV to 500 kV cable circuit length of 1,388 km collected in a
limited worldwide survey. This is significantly smaller than the 54,381 km length of overhead line in
the same voltage category installed in Canada alone. The authors of CIGRE 379[49] state on page 10
That caution should be used when interpreting failure rates, particularly in the case when the size of
the data population is small.Failure rates are mean failure rates and it is not appropriate to use
them to calculate mean time between failures and availability of circuits. Further commentary on the
activities of Cigre Study Committee B1 is given in the Jicable 07 paper[78], this includes the statement
that, There is still limited service experience with EHV XLPE cable systems. The design,
ER 381
manufacturing methods and materials employed in joints and terminations differ significantly amongst
manufacturers. Consequently the service experience from any particular system cannot necessarily be
taken as a guide to the likely service experience of other systems. Thus whilst the number of failures
in the following Table 28, Table 29, Table 30, and Table 31 have been extrapolated from the CIGRE
379 data, they cannot be regarded as being anywhere near as accurate as the data relating to overhead
lines.
Study Committee B1 of the international organisation CIGRE collects and analyses the service
experience of cable systems and their component parts. The most recent work was prepared by working
group WG B1.10, which was published by CIGRE in April 2009 as Technical Brochure 379[49],
Update of service Experience of HV Underground and Submarine Cable Systems. A questionnaire
was prepared by the members of the working group and issued to 25 regions world wide. Seventy three
positives responses were received from 24 regions, which comprised returns from 73 utilities. The
questionnaire collected data up to the end of the year 2005. The categories of interest to the 500 kV
Study Project are a) failures in AC land cables in the voltage range of 220 kV to 500 kV of the
extruded type, these being XLPE and PE cables, b) failures in all types of land cables in the voltage
range of 220 kV to 500 kV in categories of installation type and d) repair outage times in the voltage
range of 220 kV to 500 kV for extruded cables. The trend in AC failure for XLPE systems cable
systems with age of failed components is illustrated in a bar chart in Figure 12 on page 32 therein, in
four voltage categories.
The Executive summary of the above Technical Brochure states on page 3:
That between the years 2000 and 2005, almost all installed AC cables have been of the XLPE or
SCOF cables with XLPE being the preferred type. At voltages below 220 kV, more than 90% of the
cable circuit length installed from 2001 to 2005 was of the XLPE type. For voltage levels above
220 kV SCOF (SCFF) cables still account for more than 40% of the cables installed.
The failure rates for XLPE cable system components in the voltage range of 220 kV to 500 kV are
given in Table 11 on page 30 of the CIGRE publication[49] and are summarised in Table 25 below.
Component
Cable (all failures)
Joints (all failures)
Terminations (all failures)
Failure Rates
Per year per 100cct.km1
Per year per 100 joints
Per year per 100 terminations
0.133
0.048
0.050
Table 25 CIGRE failure rates of components in 220 kV to 500 kV XLPE cable systems
The cable failure rates are given by CIGRE in units of failures per year per 100cct.km. As most of the
cable circuits analysed by CIGRE could be expected to consist of one Group of Cables, the CIGRE
findings are taken to be equivalent to failures per year per Group of Cables, i.e. three single core cables.
ER 381
Table 26 (Table 11 in TB 379[49]) shows the distribution of faults by cause for each component of the
extruded 220 kV-500 kV AC land cable system. Approximately half the faults are ascribed to internal
causes, and half to external causes. An internal failure is attributable to the cable or component, and an
external failure is attributable to external parameters (e.g. third party interference, subsidence, etc).
Component
Cable (internal)
Cable (external)
Cable (all failures)
Failure Rates
Per year per 100cct.km
Per year per 100cct.km
Per year per 100cct.km
0.067
0.067
0.133
50%
50%
100%
Joint (internal)
Joint (external)
Joints (all failures)
0.026
0.022
0.048
54%
46%
100%
Terminations (internal)
Terminations (external)
Terminations (all failures)
0.032
0.018
0.050
64%
36%
100%
Table 26 Failure rates of components in 220 kV to 500 kV XLPE cable systems by cause
5.2.2
Because of the particular features of the 500 kV Study Project, the following conditioning factors could
be applied to the internal failure rates for accessories (joints and terminations) given in Table 26.
1.3 (30%) to allow for the possibility that the failure rate in the higher electrically
stressed, large conductor, 500 kV Study Project is likely to be higher than the
average in the 220 kV-500 kV category.
1.3 (30%) to allow for the possibility that the failure rate may be increased as a
result of the high operating temperature range and low winter ambient temperature
in the Edmonton region of Alberta.
When the above factors have been applied, the conditioned failure rates are as shown in Table 27.
ER 381
Component
Cable (all failures)
Joints (all failures)
Terminations (all failures)
Failure Rates
Per year per 100cct.km
Per year per 100 joints
Per year per 100 terminations
0.133
0.066
0.072
Table 27 Conditioned failure rates of components in 220 kV to 500 kV XLPE cable systems
Both the above unconditioned and conditioned failure rates have been applied to the eight scenarios
considered for the 500 kV Study Project. The results are given in the following tables of failure rates
(Table 28, Table 29, Table 30 and Table 31).
In each of the tables of failure rates for the study scenarios, the failure rates are also given for one
Group of Cables. Each group is equal to the route length of underground cable.
Stage
Total number of
Groups of Cables
Table 28 and Table 30 are based on the unconditioned failure rates in Table 25.
Table 29 and Table 31 are based on the conditioned failure rates in Table 27.
Table 28 (unconditioned) and Table 29 (conditioned) show the number of failures
for one year in-service.
Table 30 (unconditioned) and Table 31 (unconditioned) give the total number of
failures over a 40 year service life.
One Group of
Cables
1A-10
1B-20
2A-10
2B-20
3A-10
3B-20
4A-10
4B-20
n/a
n/a
n/a
n/a
Route length
km
10
20
10
20
10
20
10
20
10
20
Cable failures
0.01
0.03
0.05
0.11
0.03
0.05
0.04
0.08
0.03
0.05
Joint failures
0.03
0.05
0.10
0.21
0.05
0.11
0.08
0.16
0.05
0.11
Termination failures
0.00
0.00
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.04
0.08
0.17
0.33
0.08
0.17
0.13
0.25
0.08
0.17
Table 28 Unconditioned cable system failure rates for the study scenarios for one year in-service
Stage
Total number of
Groups of Cables
ER 381
1A-10
1B-20
2A-10
2B-20
3A-10
3B-20
4A-10
4B-20
n/a
n/a
n/a
n/a
Route length
km
10
20
10
20
10
20
10
20
10
20
Cable failures
0.01
0.03
0.05
0.11
0.03
0.05
0.04
0.08
0.03
0.05
Joint failures
0.04
0.07
0.14
0.29
0.07
0.15
0.11
0.22
0.07
0.15
Termination failures
0.00
0.00
0.02
0.02
0.01
0.01
0.01
0.01
0.01
0.01
0.05
0.10
0.21
0.42
0.11
0.21
0.16
0.31
0.11
0.21
Table 29 Conditioned cable system failure rates for the study scenarios for one year in-service
Table 28 (unconditioned) and Table 29 (conditioned) give the total number of failures for one year inservice and show that:
In one year the likelihood of failure of a single Group of Cables is low, the
unconditioned value being 0.04 per year (equivalent to one failure in a 25 year
period) for a single Group of Cables, 10 km in length. This is shown in Table 28.
In one year the likelihood of one failure in all of the parallel Groups of Cables
together is increased in proportion to the number of Groups of Cables, thus
extrapolating from the previous example, the lowest likelihood of failure for the
500 kV Study Project is 0.08 per year (equivalent to one failure in a 12.5 year
period) for the 10 km length with two Groups of Cables in parallel, again without
the conditioning factor applied. This is shown in Table 28, Scenarios 2A-10
(Stage 1) and 4A.10 (Stage 1). .
The numbers of failures also increase with the route length and if the conditioning
factor is applied. The highest is 0.42 per year (equivalent to one failure in 2.4 year
period) for four Groups of Cables, 20 km route length, with the conditioning factor
applied. This is shown in Table 29, Scenario 1B.20. .
Stage
Total number of
Groups of Cables
ER 381
1A-10
1B-20
2A-10
2B-20
3A-10
3B-20
4A-10
4B-20
n/a
n/a
n/a
n/a
Route length
km
10
20
10
20
10
20
10
20
10
20
Cable failures
0.53
1.06
2.13
4.26
1.06
2.13
1.60
3.19
1.06
2.13
Joint failures
1.04
2.13
4.15
8.52
2.07
4.26
3.11
6.39
2.07
4.26
Termination failures
0.12
0.12
0.48
0.48
0.24
0.24
0.36
0.36
0.24
0.24
1.69
3.32
6.76
13.26
3.38
6.63
5.07
9.95
3.38
6.63
Table 30 Unconditioned cable system failure rates for the study scenarios for 40 years in-service
Stage
Total number of
Groups of Cables
One Group
of Cables
1
1A-10
1B-20
2A-10
2B-20
3A-10
3B-20
4A-10
4B-20
n/a
n/a
n/a
n/a
Route length
#
k
m
10
20
10
20
10
20
10
20
10
20
Cable failures
0.90
1.80
2.13
4.26
1.06
2.13
1.60
3.19
1.06
2.13
Joint failures
1.75
3.60
5.70
11.71
2.85
5.86
4.27
8.78
2.85
5.86
Termination failures
0.20
0.20
0.69
0.69
0.35
0.35
0.52
0.52
0.35
0.35
2.85
5.60
8.52
16.66
4.26
8.33
6.39
12.49
4.26
8.33
Table 31 Conditioned cable system failure rates the study scenarios for 40 years in-service
Table 30 (unconditioned) and Table 31 (unconditioned) give the total number of failures over a 40 year
service life and show that:
The lowest likelihood of failure for the 500 kV Study Project is 3.38 for the 10 km
length with two Groups of Cables in parallel, again without the conditioning factor
applied. This is shown in Table 30, Scenarios 2A-10 (Stage 1) and 4A.10 (Stage
1). (As it is envisaged that the Stage 1 cable systems would be augmented by the
Stage 2 cables at some point during the 40 years, this figure would have to be
increased to represent the whole project)
The numbers of failures increase with the route length and if the conditioning
factor is applied. The highest likelihood of failure for the 500 kV Study Project is
ER 381
16.66 for four Groups of Cables, 20 km route length, with the conditioning factor
applied. This is shown in and Table 31, Scenario 1B.20.
5.2.3
Based on the information in Section 5.2.2 and the published data[49] therein, the estimated numbers of
faults per year which that occur in the 500 kV Study Project are given below for different numbers of
Groups of Cables.
5.2.4
10 km
0.04 to 0.05
0.08 to 0.11
0.13 to 0.16
0.17 to 0.21
20 km
0.08 to 0.10
0.17 to 0.21
0.25 to 0.31
0.33 to 0.42
Table 32 records the number of faults reported in all types of AC land cable (XLPE, SCFF and HPFF)
in the voltage range 220 kV to 500 kV. Care is required in the interpretation as the reported quantities
of cable and accessories are not given. CIGRE TB 379[49] reports in a fault analysis on page 47 therein:
That at all voltages and for all cable types, buried cable systems are about ten times more likely to be
damaged by external conditions than cable systems installed in ducts or tunnels. In practice the ratio
would be expected to be smaller at the EHV voltages as the buried cables are likely to be buried deeper
and to be protected by more robust materials. CIGRE TB 379[49], Table 10c, shows that at 220 kV to
500 kV for all types of cable and for all types of installation 57% of the faults were internal and 25%
were due to third party damage, 17% were attributable to other unspecified external causes.
Installation Type
Internal
Direct buried
Ducts
Tunnels
Troughs
Bridges
In-air
All installation types
59
5
7
2
0
1
74
Numbers of Faults
Third Party
Other
External Causes
28
17
3
2
0
2
2
2
1
0
0
0
34
23
Total
104
10
9
6
1
1
131
Table 32 Numbers of faults in all types of 220 kV-500 kV AC land circuits by installation type
5.3
ER 381
The Line-Related Sustained Forced Outage rate for 500 to 599 kV overhead lines is given in Appendix
Section 1 which has been abstracted by HPT from Canadian Electricity Association publication, Forced
Outage Performance of Transmission Equipment 2007 [79]. This data is based on the performance of a
cumulative length of 9,853 km of 500 to 599 kV transmission lines in Canada alone.
The overhead line rate is for sustained forced outages of duration one minute or more and excludes
automatic re-closure events. The rate is 0.2366 events per 100 km per year. For the purpose of this
report these events are referred to as failures.
The mean duration of each Line-Related Sustained Forced Outage is 4.9 hours.
The total number failures for each scenario for both one year in-service and for forty years in-service is
shown in Table 33 and Table 34 respectively.
Stage
1A-10
1B-20
2A-10
2B-20
3A-10
3B-20
4A-10
4B-20
n/a
n/a
n/a
n/a
km
55
45
55
45
55
45
55
45
0.2366
0.2366
0.2366
0.2366
0.2366
0.2366
0.2366
0.2366
OHL failures
0.26
0.21
0.26
0.21
0.26
0.21
0.26
0.21
Table 33 OHL failure rates for the study scenarios for one year in-service
Stage
1A-10
1B-20
2A-10
2B-20
3A-10
3B-20
4A-10
4B-20
n/a
n/a
n/a
n/a
km
55
45
55
45
55
45
55
45
0.2366
0.2366
0.2366
0.2366
0.2366
0.2366
0.2366
0.2366
OHL failures
10.41
8.52
10.41
8.52
10.41
8.52
10.41
8.52
Table 34 OHL failure rates for the study scenarios for forty years in-service
The Canadian Electricity Association publication also gives statistics for line related transient forced
outages of duration less than one minute which only covers automatic reclosure events, the rate being
0.8718 events per 100 km per year. These events have been excluded from the study because the
overhead line is still available for service.
ER 381
An environmental overview has been prepared by the HPT and is given in full in the Appendix, Section
11.
The overview outlines some of the potential effects on biophysical components related to underground
transmission lines. As is the case with any project, detailed design and the environmental context are
important for understanding and describing specific potential effects related to an underground
transmission development. Discussions must occur with appropriate regulators relative to any
underground transmission development better to identify appropriate mitigations and regulatory
expectations.
The overview also considers the environmental impact of the installation activities and of the installed
plant of a non-specific 500kV high capacity underground transmission project. The document describes
the following components of the project:
1.
2.
3.
4.
5.
6.
The document then continues to address the potential environmental effects and mitigation measures
under the following headings:
Terrain and Soils
Soil disturbance and contamination from leaks and spills during construction.
Vegetation and Wetlands
Destruction of native and sensitive vegetation during construction, introduction of non native species,
disturbance of wetland and riparian vegetation which might be difficult to reclaim. Potential soil
erosion when vegetation is removed. Alterations to drainage patterns and contamination from leaks and
spills during construction.
Wildlife and Wildlife Habitat
Habitat destruction during construction and maintenance, changes in direct and indirect mortality risk
due for example to the clearing of forested areas increasing the line of sight. Effect on nesting and
rearing sites due to vegetation clearance and trenching.
ER 381
ER 381
A preliminary underground cable scoping study was conducted for the 500 kV Study Project in order
to:
Provide the outline installation cross-section dimensions necessary for the HPT to
study and cost. This could then be performed concurrent with the cable
manufacturers design work.
Provide a point of reference for the manufacturers design proposals to ensure that
they had understood the requirements.
This preliminary scoping study has been based upon the same design parameters as have been provided
to prospective cable suppliers for the Heartland Project.
Installation cross sections have been prepared for the following:
Duct manhole system
Direct burial of cables
Deep tunnel
Cut and cover tunnel
7.1
Description of the cable type used for the preliminary scoping study
500 kV cables with high power transmission capability have been supplied using either extruded XLPE
insulation or fluid filled PPL insulation. For this scoping study XLPE cable has been used. The reasons
for this choice are:
It is available from many suppliers
It is perceived as the technology of choice for the future, with manufacturers phasing out their
manufacturing capability for SCFF cable thus spares and resources to repair XLPE cable are more
likely to be available for the lifetime of the circuit
The selected XLPE cable constructional details and dimensions are shown diagrammatically in Figure
72.
ER 381
Diagrammatic only
Item
1
2
3
4
5
6
7
8
Details
Oxidised copper conductor
Conductor binder
Extruded screen
XLPE Insulation
32mm nom
Extruded screen
Water-blocking cushioning tapes
Aluminium shield (welded)
Polyethylene Jacket with semi-conductive coating
Nominal
diameter
(mm)
64.0
68.0
132.0
135.0
137.5
141.0
152.0
ER 381
The following conductor type has been used for the scoping study:
2,500 mm copper.
AC resistance typical of conductors with oxidised wires.
constructed using several stranded segments (Milliken construction).
The reasons for the use of this material, size and construction of conductor for the scoping study are:
2,500 mm represents the maximum conductor size that is available from most
manufacturers. (Some manufacturers have designs and/or manufacturing capability
for 3,000 mm or possibly 3,500 mm but little or no service experience exists.) If
aluminium conductors are selected then at least three cables per phase would be
required for each circuit of the 500 kV Study Project. This would not be
economically advantageous.
For the 500 kV Study Project the ampacity requirements are such that the use of
plain copper wire conductors is likely to result in a requirement for three cables per
phase, particularly for some of the obstruction crossings. Ampacity can be
increased by the use of coated wire. Most manufacturers are able to offer some
kind of coated wire conductor design. The designs available are oxidation and
enamelling. Conductors with enamelled wires generally have lower resistance
than those with oxidised wires but may not be offered by all manufacturers or
otherwise inappropriate for the 500 kV Study Project.
A segmental construction is offered by virtually all manufacturers for large
conductor sizes as it is significantly more efficient than non-segmental designs.
An insulation thickness calculated to give an electrical stress at the insulation shield (i.e. the outer
shield) of 7 MV/m at 525 kV between phases has been selected. This design stress has been selected
as:
It is the stress experienced by the accessories and is considered to be reasonably
safe with current technology.
It is around the average stress that most manufacturers were believed likely to
offer.
It is not so low as to make the cables unfeasibly large for transportation to site.
XLPE cables are frequently constructed using one of the following methods to prevent radial water
penetration and to enable short circuit currents to be carried:
A longitudinally welded aluminium sheath.
A corrugated seamless aluminium sheath.
A copper wire screen included under a lead sheath.
A copper wire screen included under an aluminium or copper foil laminate.
A copper wire screen included under a longitudinally welded stainless steel sheath.
ER 381
A longitudinally welded aluminium sheath without a separate copper wire screen has been used for the
scoping. This construction has been selected for the scoping study as:
This type of construction is available from several suppliers.
It gives a reasonably high degree of water penetration resistance required for
important cable circuits.
It results in a cable with a relatively small overall diameter when compared to
cables with corrugated sheaths or a combination of copper wire screen and metallic
sheath and thus is considered to be representative of a possible eventual solution.
This type of cable is offered as being suitable for all installation methods, rigidly
cleated in air, flexibly cleated in air, in unfilled ducts, and direct buried in the
ground. Separate designs are thus not needed for this scoping study.
The sheath losses from this design are relatively high compared with other types
thus not giving overly optimistic results.
The cable design used for this scoping study has a sheath thickness of 1.75mm.
This has been selected as being sufficient for the short circuit current level of 40kA
for 1 second.
The base case cable for this scoping study has an outer jacket made of extruded medium or high density
polyethylene (MDPE or HDPE). This has been selected as:
It available from all manufacturers and it has been proven in-service to give a
sufficiently high resistance to abrasion, cracking and water penetration.
(For use within tunnels, polyethylene is commonly perceived to have too great a flammability, and
hence other materials are often used).
7.2
A duct-manhole, system:
Installed directly in the ground:
ER 381
7.3
Figure 73 Scenario 1
In Figure 73 two circuits are depicted between Station A and Station B. Each of the black
dotted lines represents one Group of Cables underground cable
There could be one or more obstacles on the route which require the use of three cables per phase. If it
is not possible to achieve the required ampacity along the whole of the route with two cables per phase,
then three cables per phase will be required.
ER 381
A flat, horizontally spaced configuration has been selected for the scoping study. This has been
selected because
it offers better ampacity than trefoil or vertically spaced arrangements
it offers better access to the cables should a repair be necessary
Different types of cable formations are shown in Figure 38 and Figure 39.
7.4
ER 381
7.4.1
Based on installation primarily in agricultural land a trench cross section typically as shown
below is proposed:
Reinstatement as required
to match original
Ground surface
Compacted excavated
material
(if thermally suitable)
including replacement of
topsoil to landowners
requirements
Warning tape
(as required)
Warning tapes placed
on top of full area of
ductbank
Thermal Backfill
6mm poly placed on
top of full area of
ductbank
Power Cable ducts
Auxiliary ducts
Concrete
ER 381
To achieve the required ampacity, the following dimensions have been calculated:
Dimension
a
b
c
e
d
p
q
mm
250
250
200
500
250
900
1100
7.4.2
7.4.3
ER 381
Trench filling
It is vital that the thermally resistivity of the soils and other material surrounding the cables is
controlled. The details of the trench filling materials for this scoping study are as follows:
The backfill placed above the concrete ductbank shall be of the fluidised thermal backfill type
or selected sand/gravel or crushed rock and shall have a dried out thermal resistivity no greater
than 0.9 K.m/W. [For information, in the absence of specific local measurements, a value of
0.9 K.m/W has been taken for the backfill in all of the cable ampacity calculations, having been
abstracted from a) IEC 60267[80] for the typical values in Canada, there being no recognised
national values and b) the value given in the technical specification[81] for the recent 240 kV
cable installation in Edmonton for native soil resistivity for depths of less than 3.5 m.]
Where the route crosses agricultural land the top of the thermal backfill must be no
less than 900 mm below the surface to avoid disturbance by agricultural equipment
(this would require to be verified for Edmonton farming conditions).
The thermal backfill placed above the concrete ductbank forms part of the thermal
design of the circuit; the warning tapes or tiles placed above thermal backfill must
extend the whole length and width of the route.
This layer can be replaced with concrete if more economical.
Trench filling above the thermal backfill and to either side of the trench must have a thermal
resistivity of not greater than 0.9 K.m/W[80,81] and not greater than 3.0 K.m/W[82] when fully
dried out. (The latter values would need to be verified by taking measurements and samples in
situ in trial holes dug along the route when selected).
The indigenous soils must be tested for thermal resistivity and can only be used to
fill the trench if it is found to have a thermal resistivity which meets the above
requirement. If unsuitable imported material must be allowed for.
Parts of the route may have very high thermal resistivity, specifically where there is
sphagnum moss. In such cases it should be assumed that the ground approximately
three metres both side of the trench will have to be removed and replaced with
suitable imported material. Sphagnum moss is also unlikely to be mechanically
suitable for the supporting of cable trenches.
Local regulations or landowners may have specific requirements for topsoil to be stripped and
stored during the course of construction and replaced as part of the final reinstatement. There
may be requirements as to the time of year when topsoil can be stripped and the methods of
storage.
Where minor roads are to be crossed, the thermal backfill should be extended upwards to the
road reinstatement.
7.5
ER 381
Reinstatement as required
to match original
Ground surface
Compacted
excavated material
(if thermally
suitable) including
replacement of
topsoil to
landowners
requirements
Warning tape
(as required)
Thermal Backfill
Position of DTS fibres
(if not included within
cable construction)
Power Cables
Auxiliary ducts
ER 381
To achieve the required ampacity, the following dimensions have been calculated:
Dimension
mm
a
450
b
175
c
100
d
1300
e
100
f
450 *
g
1000
* Dimension f is based on a nominal cable diameter of 150mm
Dimensions for Figure 75
For the purpose of initial cost estimates:
Auxiliary ducts shall be 100 mm PVC conduit
(Any optical fibre cable must be suitable for operation at 50 70C when installed in close
proximity to power cables)
The trench may be of rectangular cross section as shown in which case shoring (usually timber)
is generally required or may be battered (sloped) to avoid the need for support. An example of
a trench with sloped sides is shown in Figure 76. With this type of arrangement it can be more
difficult to keep the bottom of the trench clear of falling debris.
ER 381
ER 381
three metres both side of the trench will have to be removed and replaced with
suitable imported material. The trench fill must be carefully compacted.
Local regulations or landowners may have specific requirements for topsoil to be stripped and
stored during the course of construction and replaced as part of the final reinstatement. There
may be requirements as to the time of year when topsoil can be stripped and the methods of
storage.
Where minor roads are to be crossed, a ducted arrangement will be required. For the purposes
of this installation study this may be considered identical to the duct block proposed for the
duct-manhole system except that the ducts must generally be filled with bentonite for
thermomechanical compatibility.
7.6
ER 381
7.7
Greater circuit security by having better survivability against third party damage
Reduce the induced voltage effects of one circuit on another, to facilitate the
continued operation of one circuit whilst repairs are being conducted on the other.
Greater circuit security as adjacent Groups of Cables are less likely to be damaged
by excavation in the event of a repair.
Minimise risk of damage to existing cables in a staged installation, when installing
the Stage two Groups of Cables.
The spacing between Groups of Cables was initially selected as 7 metres, thus the spacing
between circuits would be at least 7 metres to give the same amount of physical protection.
This spacing between circuits was increased by a further 3 metres to 10 metres to allow for the
construction of a temporary haulage road with room for passing places. This arrangement has
been used previously for the construction of cable routes with two circuits comprising four
ER 381
separate trenches. A consequence of this is that 10 metres gives thermal independence between
the circuits. In normal operation the circuits are required to carry 1,500 MVA simultaneously.
For contingency operation each circuit alone is required to carry 3,000 MVA. The thermal
independence between the circuits would prospectively increase the maximum simultaneous
loading of both circuits to 3,000 MVA, although this has no benefit for this feasibility study.
Typical installation Swathes (right of way) are shown in Figure 78 and Figure 79.
For the purposes of this scoping study, the following dimensions have been assumed:
Dimension
a
b
c
e
d
mm
1,500
5,500
10,000
10,000
3,000
f (total)
40,000
ER 381
40 m wide swathe
Positions of
trenches
Haul road
ER 381
ER 381
The above ampacity calculation relates to XLPE cables installed in ducts, with two cables per
phase, i.e. a total of six cables. The result is shown for the cable with the lowest ampacity.
The above calculation gives a maximum ampacity of 1,732 amps; for a three phase group this is
equivalent to 1,500 MVA at 500 kV. For six cables, i.e. two cables per phase, this is equivalent
to a total carrying capacity of 3,000 MVA.
The above calculation includes an allowance for the effect of mutual heating between two
Groups of Cables. However, a centre to centre spacing of 7,000 mm between Groups of Cables
has been selected for the scoping study. This gives nearly complete thermal independence and
thus mutual heating is of very little significance and the ampacity with only one cable group
carrying load will only be marginally greater than with both groups loaded. When installed as
described for Stage 1, i.e. with one cable per phase, the transmission capacity can be taken as
1,500 MVA.
No allowance is included for the effects of any mutual heating from the adjacent 500 kV circuit
as 3,000 MVA is only required in a contingency situation for each circuit, i.e. the adjacent
500 kV circuit would not be carrying any load.
7.9
Stabilised backfill
At the maximum cable operating temperature the ground surrounding buried cables exceeds 50C
at all practical depths. At this temperature moisture migration occurs with a consequent rise in
the soil thermal resistivity, the thermal resistivity of most soils and backfill materials being
highly dependant on the moisture content. To avoid a reduction in ampacity the following
methods can be used:
The effect of the higher thermal resistivity of dried out soils is included in the
ampacity calculation and the installation designed accordingly. Whilst this method
is commonly applied to lower power cable systems, the high power transmission
requirement of this project is such that little use can be made of this method of
calculation.
The cables are surrounded with suitable material which has a stable value of
thermal resistance over a long period of time even when subjected to constant
heating. This is known as stabilised backfill. The stabilised backfill must fill an
area equivalent to the 50C isotherm surrounding the cables.
The preliminary dimensions of the trenches shown in Figure 74 and Figure 75 include sufficient
concrete or stabilised backfill to encompass the 50C isotherm so that the value of thermal
resistivity of 0.9 K.m/W can be taken for all the surrounding materials. Careful selection of
concrete or backfill materials may allow a lower thermal resistivity to be used.
ER 381
7.10.1 Methods of maintaining the ampacity where the cable depth must be increased.
The most common type of obstruction which is likely to be encountered is where the cables must
be installed at an increased depth to pass under an obstruction. For the purposes of this scoping
study, the ampacity at increased depth the cables can be maintained either by installing the
cables:
At increased phase spacing
In tunnels
ER 381
500
1000
1500
2000
2500
500
1000
1500
2000
2500
3000
3500
4000
ER 381
ER 381
Local increases in phase spacing increase the induced sheath voltage in the particular cable section. To
eliminate sheath circulating currents, the difference between the induced sheath voltages in each of the
minor sections of the cross bonding arrangement must not exceed the design tolerance. This can be
accomplished by reducing the length of the section containing the wider phase spacing, or, less
commonly, increasing of the phase spacing in other sections. The requirement to balance the cross
bonding arrangement also restricts the maximum length of a trenchless installation.
Headhouse
Ground surface
Cables in
trench
Obstruction
Shaft
Cables in Tunnel
ER 381
Figure 85: Compound containing two headhouses for naturally ventilated tunnels
ER 381
Dimension
Overall reel width
Overall reel diameter
Gross weight
mm
4,300
4,300
35,000kg
ER 381
Street furniture is objects and pieces of equipment installed on roads, including traffic barriers,
streetlights, traffic lights, traffic signs, bus stops and waste bins. Larger structures such as pedestrial
bridges may also be removed.
ER 381
ER 381
ER 381
7.13 Tunnels
As an alternative to the surface route 500 kV XLPE cables may be installed within a tunnel. The two
tunnel designs envisaged are as follows and as depicted in Table 35 below:
Internal dimensions
ER 381
The cable drums will be mounted above ground on powered stands with a braking
system. The cables will be lowered vertically down the shaft through a temporary
guide system and then around a preformed bend at the base of the shaft. In the
tunnel design shown we have allowed for an I-beam transportation system in
which the cable is supported on hangers and nose pulled by a specially designed
vehicle.
ER 381
The cable will be supported on steel supports within the shaft such that it is vertically waved and held
rigid at nodes by high strength clamps, this being a semi-flexible system. The cable in the tunnel will
be set into a vertically sagged system with saddle cleats affixed to supporting steelwork at 7 metre
intervals. The sag is designed to accommodate the expansion and contraction of the cable, such that
longitudinal forces do not occur.
Figure 93: Typical tunnel cable clamp (cleat) for a sagged system
A typical saddle cable clamp is shown in Figure 93; it is curved lengthwise to allow the cable to
expand and contract.
The three phase cables will be restrained at mid span by a short circuit strap arrangement comprising of
three simple single phase clamps joined by two vertical straps.
ER 381
ER 381
Figure 96 Scenario 2, one group per circuit installed initially (black), the second later
In Figure 96 the block dotted lines represent underground cable which would be installed in Stage 1,
and the red dotted lines represent underground cable which would be installed in Stage 1
The objective of this section of the document is to give
a) The installation layout for the costing of the staging option and
b) The reasons for the proposed layouts.
Stage 1 is circuit A and circuit B each having a maximum capability of 1,500 MVA
Stage 2 is circuit A and circuit B each having a maximum capability of 3,000 MVA
The installation cross sections are shown and described for stage 1 (1,500 MVA) and Stage 2
(3,000 MVA) for direct buried, duct-manhole, deep tunnel and cut and cover tunnel installation
options. The reasons for the proposals are given.
For un-staged installation in tunnels, permanent lighting equipment is not necessarily recommended,
with the consideration of reducing the maintenance requirement. For the staged work, however,
permanent lighting should be installed to assist the timely installation of the Stage 2 cable and joints.
The advantages of staging are:
That investment can be staged, allowing expenditure to be deferred (The financial effects of
staging are analysed in Appendix, Section 3).
ER 381
The cable installation time is halved and will help achieve the objective of installing all of the
cable in one summer season in which the air temperature is above the minimum of 0C required
for a PE jacket
A wider range of service proven, designs of straight splice will be available for selection for the
final circuit upgrading in say, 20 years time. Full advantages of improvements in the cable
design cannot necessarily be taken, for the reasons given below.
For arrangements with two Groups of Cables per circuit, i.e. Scenarios 1A.10 and 1B.20, it may be
possible to arrange the electrical connections at the Transition Stations in such a way that one of the
two Groups of Cables that comprise the cable Circuit could remain in-service whilst the other Group of
Cables is taken out of service for maintenance or repair. This advantage is lost in the case of Stage one
of Scenarios, 2A.10 and 2B.20, where each circuit would consist of one Group of Cables only. In this
case each circuit would not be capable of transmitting any power whilst its only Group of Cables was
out of service. This would give the transmission system operator less flexibility in how he would be
able to operate the system. In the event that both Groups of Cables had to be taken out of service for
repair concurrently then no power could be transmitted.
The key parameters of staged installation are summarised below:
Installation type
Phase
spacing
Duct-manhole system
500 mm
One
Two
Direct buried
450 mm
One
Two
Cables in tunnels
500 mm
One
Two
ER 381
All four duct banks (Circuit A, Groups 1, and 2 and Circuit B, Groups 1, and 2) and manholes
are installed together.
The cables are installed in the Circuit A, Group 1 and Circuit B, Group 1, ducts and the splices
are assembled
The ducts in Circuit A, Group 2, and Circuit B, Group 2, are proven by pulling through a
mandrel, are sealed and a low positive gas pressure applied (equivalent to 5 psi at -10C).
Maintenance checks will be required to ensure that the ducts and manholes remain in sound
condition.
The haul road in the centre (if used) has to be removed to allow the land to be returned to its
former use.
ER 381
The haul road is rebuilt to allow delivery of reels and accessories etc. to each manhole. If
possible the haul road may be reduced in width to single track to take advantage of reduced
construction traffic.
The Circuit A, Group 2, and Circuit B, Group 2, ducts are unsealed, are visually inspected by
CCTV camera, are proven by mandrel and are cleaned.
The Circuit A, Group 2, and Circuit B, Group 2, cables are installed.
The new cables are required to have a) closely similar dimensions to the original cables to
achieve the same impedances and to ensure that the load is shared 50/50, b) closely similar
diameters to ensure the same thermomechanical performance. Full advantage cannot
necessarily be taken of possible improvements to cable technology at the date at which the
circuit is required to be upgraded.
The two circuits, A and B, are widely spaced by the width of the haul road (approximately
10 meters) to minimise the risk of third party damage to both circuits and common mode
failure.
The layout permits Circuit A and Circuit B to diverge and take different routes at certain
positions
Installation of all the ductbanks at Stage 1
Reduces the risk of damage during installation of the existing Circuit A Group1
and Circuit B Group 1 cables
Reduces the investment cost of Stage 2
Achieves economies of scale in reducing the unit costs of installing all the duct
banks together.
Reduces the installation time of Stage 2
ER 381
ER 381
The new cables are required to have closely similar dimensions to the original cables and
spacing to achieve the same impedances and to ensure that the load is shared 50/50. Full
advantage cannot necessarily be taken of possible improvements to cable technology at the date
at which the circuit is required to be upgraded.
The two circuits, A and B, are widely spaced by the width of the haul road (approximately
10 meters) to minimise the risk of third party damage to both circuits and common mode
failure.
The layout permits Circuit A and Circuit B to diverge and take different routes at certain
positions
This arrangement has been satisfactorily used in the UK to increase the capacity of a buried
cable circuit.
ER 381
The two tunnels are constructed together with the supporting metalwork for all four groups of
cables.
The full air cooling equipment is designed and installed for each tunnel. Note, if required
approximately half of the cooling equipment may be omitted and installed at the time of the
installation of the Stage 2 cables.
One circuit is installed in each tunnel (Circuit A Group 1 and Circuit B Group 1)
Stage 2: 3,000 MVA total per circuit
Circuit A, Group 2, and Circuit B, Group 2, cables are installed; noting that an outage will be
required on Circuit A and Circuit B in turn to permit cable installation and jointing to be
performed.
The new cables are required to have closely similar dimensions to the original cables and
spacing to achieve the same impedances and to ensure that the load is shared 50/50. Full
advantage cannot necessarily be taken of possible improvements to cable technology at the date
at which the circuit is required to be upgraded.
The installation method and associated tunnel furniture (for example the I beam transport
system) will require to be maintained and reused.
The performance and condition of the ventilation system shall be reviewed and up-rated as
necessary.
The two circuits, A and B, are installed in separate tunnels to minimise the risk of common
mode failure.
The layout permits Circuit A tunnel and Circuit B tunnel to diverge and take different routes.
ER 381
Circuit A
Group 1
Circuit B
Group 1
Circuit B
Group 2
(Steelwork installed)
Circuit A
Group 1
Circuit B
Group 1
Circuit B
Group 2
Figure 101: Scenario 2, staging for cables installed in cut and cover tunnels
The two tunnels are constructed together with the supporting metalwork for all four groups of
cables.
The full air cooling equipment is designed and installed for each tunnel. Note, if required
approximately half of the cooling equipment may be omitted and installed at the time of the
installation of the Stage 2 cables.
One circuit is installed in each tunnel (Circuit A Group 1 and Circuit B Group 1)
ER 381
Circuit A, Group 2, and Circuit B, Group 2, cables are installed, note an outage will be required
on Circuit A and Circuit B in turn to permit cable installation and jointing to be performed.
The new cables are required to have closely similar dimensions to the original cables and
spacing to achieve the same impedances and to ensure that the load is shared 50/50. Full
advantage cannot necessarily be taken of possible improvements to cable technology at the date
at which the circuit is required to be upgraded.
The installation method and associated tunnel furniture (for example the I beam transport
system) will require to be maintained and reused.
The performance and condition of the ventilation system shall be reviewed and up-rated as
necessary.
7.18.2 Reasons
The two circuits, A and B, are installed in separate tunnels to minimise the risk of common
mode failure.
The layout permits Circuit A tunnel and Circuit B tunnel to diverge and take different routes.
ER 381
ER 381
Diagrammatic only
Item
1
2
3
4
5
6
7
8
Details
Central fluid duct
Copper conductor
Conductor binder and screen
LPP or paper insulation
25.5mm min
Insulation screen and binder
Radial clearance
Corrugated Aluminium Sheath
Polyethylene Jacket with semi-conductive coating
Nominal
diameter
(mm)
16.4/18
72.5
73.8
124.4
125.6
142.2
150.2
ER 381
ER 381
3,000 mm cables per phase at a phase spacing of approximately 1 metre, this phase spacing is too wide
to be used practically for long routes as:
To cross obstructions the cable depth must be increased. With two cables per phase the
maximum depth at which the required ampacity can be maintained would not be sufficient
to cross some obstructions. (Ampacity can normally be maintained at increased depths by
local increase of the phase spacing; if the phase spacing is already very wide then further
increases offer little increase in ampacity)
The induced sheath voltage is greater at wider phase spacing. The voltage induced on the
sheath at a phase spacing of 1 metre will be significantly greater than at the 450 mm to 550
mm considered for other arrangements. In consequence the maximum length of section that
can be used without exceeding the maximum permissible sheath voltage will be lower at
wider phase spacing and an increased number of splices will be required.
It is often difficult to find a route sufficiently wide to accommodate this spacing for the
entire length of the route.
A system using two SCFF LPP cables in ducts has therefore not been considered further at this stage,
but if XLPE cables prove unsuitable then the feasibility of using SCFF cables with a conductor size
larger than 3,000 mm could be considered.
A system with three Groups of Cables installed in ducts has not been considered in detail as this is
likely to be a very expensive system. If it is to be considered further then the following could be
considered:
Reduced conductor size and/or reduced phase spacing
Installation of the cables in three stages rather than two, with the first stage consisting of
one Group of Cables only per circuit, but having an ampacity of less than 1,500 MVA per
circuit.
A cable system design using paper insulation instead of LPP may be possible but is unlikely to offer
any advantages because of its higher dielectric loss.
ER 381
ER 381
During the course of the test links in link boxes are removed or rearranged so as to sectionalise the
sheath and temporarily ground sections adjacent to the one under test.
Most modern designs of SVL should not have to be disconnected for these tests but this must be
checked before commencing testing.
The 5 kV DC source should be designed to limit the current in the event of a breakdown. A small
portable generator may be needed to power the test set.
Any excessive leakage current will required to be investigated and repairs conducted as necessary.
At the same time the SVLs should be checked and the electrical resistance characteristic measured; the
SVLs and leads should be visually inspected for signs of degradation, e.g. corrosion, moisture ingress,
etc.
Frequency of routine tests on sheath bonding equipment:
If an internal or through fault occurs on a cable circuit then the oversheath (jacket)
and SVL tests shall be conducted. In addition the cable sheath to ground metallic
path should be checked.
It is also prudent to check the integrity of the oversheath (jacket) prior to the
commencement of any major works which are to be conducted in the vicinity of
the cable circuit.
Whenever links are removed and replaced then the contact resistances must be
checked.
ER 381
Where manholes include cable splices, any cable clamps installed to support or restrain the cables
should be inspected for mechanical integrity and to ensure that expansion forces from the cables have
not compromised their installation. The condition of any cable splices in the manholes shall be
inspected to ensure that cable expansion is not changing the geometry of the splice or moving the
splice.
Inspection frequency: annual.
ER 381
After several years operation at high temperature DTS fibres may deteriorate. Depending upon how
these are installed it may be possible to blow in replacement fibres.
If fitted, the correct operation of any in-service PD detection systems should be checked in
accordance with the suppliers recommendations.
If fitted, the correct operation of any SVL monitoring systems should be checked in accordance with
the suppliers recommendations.
If conducted as part of the commissioning tests, the cable systems have been fingerprinted by TDR
measurements, then repeat TDR measurements should be made if and when possible.
ER 381
ER 381
For 500 kV cables systems installed in tunnels, the tunnel should be designed initially to ensure that
repair joint positions can be constructed at any appropriate positions within the tunnel. Again the
normal arrangement would be a short length of cable and two joints, or one joint and one termination.
Cables in tunnels are virtually immune from third party damage so a failure in a tunnel is therefore
more likely to involve a joint.
In the event of a joint being replaced, it will be necessary to ensure that the sheath bonding cable
lengths are not excessive. These are normally limited to a maximum of 10 metres, but detailed
calculations would be necessary to establish the maximum permissible length in each case. In an
extreme case so much cable could have been damaged that it is not possible to locate either of the
repair joints close enough to the original joint position that the bonding cable limit is not exceeded. In
such cases three repair joints may be required, one joint with sheath sectionalising insulation at the
same position as the original joint, and two joints without sheath sectionalising insulation, positioned
either side of the original joint position. This situation could occur in the event of a fire in either a
tunnel or a jointing vault. In such cases it is also possible that the adjacent phases could have suffered
damage, and up to nine repair joints would be required.
In the event of a cable system fault, tests should be done prior to re-commissioning of the circuit.
Ideally these tests would include an HV AC test similar to the commissioning test, but at a reduced
voltage depending upon the age of the circuit, accompanied by PD monitoring of accessories. This
would be particularly important in the case of a repair following an electrical failure of a joint, when it
would be advisable to check the condition of all other joints as well as the newly installed repair joints.
It may not be possible to obtain suitable AC test equipment before the time that the user wishes to reenergize the cables. In such cases it may be appropriate to conduct a soak test, whereby the cables
are connected to the system for test purposes only.
Prior to re-commissioning the sheath voltage limiters in the link boxes should also be checked. It
would therefore be prudent to keep a supply of SVLs in storage; so that they are available should
replacements be necessary.
The cost of spares which have been prepared for the 500kV Study Project are based on the maintenance
information given in Appendix, Section 25.
ER 381
The electromagnetic field (EMF) is comprised of two components, a magnetic field which is produced
by the flow of current in the conductor, and an electrostatic field produced by the voltage at the
conductor. Both components exist in the proximity of an overhead line. In an underground cable,
(a) the electrostatic field is completely contained within the cable by the insulation screen and does not
exist outside the cable and (b) the magnetic field exists in the proximity of the cable.
The magnetic field profile, transverse to the route, has been calculated by HPT and is given in
Appendix, Section 13. Magnetic field magnitude is expressed in North America, in units of magnetic
flux density, milligauss (mG). This has been calculated for both underground cable and overhead lines
at 1 metre above ground carrying the same power. For convenience some of the values from Section 2,
Summary of Findings, of the HPT report are copied below in Table 36.
The majority of potential suppliers proposed cables laid in flat, horizontally spaced, formation at a
depth of 1.3 metres. Horizontal spacing is the most efficient and economical solution for a direct
buried system. Whilst cables can be installed in other formations such as open trefoil, these formations
have disadvantages of thermal inefficiency in dissipating heat, complexity of installation to lay cables
at different levels and difficulty of access for repair.
Magnetic field flux densities calculated for the laid flat spaced arrangement, with four trenches
(Scenarios 1A.10 and 1B.20), are shown in Table 36 to be 81 mG when both circuits carry 500 MW.
The equivalent magnetic field at 1,500 MW per circuit would be 243 mG. The equivalent magnetic
field for contingency operation in which one circuit carries 3,000 MW would be approximately
486 mG. Each of these levels is below the exposure guidelines established by the International
Commission on Non-Ionizing Radiation Protection (ICNIRP) [84] for public exposure (833 mG).
Location
Directly over/below the cable/line
25m from the center of the ROW
50m from the center of the ROW
75m from the center of the ROW
100m from the center of the ROW
150m from the center of the ROW
250m from the center of the ROW
500m from the center of the ROW
800m from the center of the ROW
Cable
Overhead line
Magnetic Field (mG) Magnetic Field (mG)
81.0
55.0
3.7
39.1
0.3
11.0
0.1
5.0
0.0
3.0
0.0
1.0
0.0
0.4
0.0
0.1
0.0
0.0
Table 36. Magnetic field from EMF report (Appendix, Section 13)
ER 381
Table 36 shows that (a) the maximum magnetic field directly over the buried cable is 47% higher than
immediately under the overhead line and (b) 50 metres away from the centre of the right of way the
magnetic field of the buried cable has fallen 97% of that of the overhead line.
The maximum magnetic field above the cable can prospectively be reduced to equal that of the
overhead line by burying it at a greater depth, whilst keeping the spacing between cables constant. The
disadvantage is that the dissipation of heat is less effective at greater depth and either the cables would
have to be de-rated, or more cables installed. It has been recommended in Section 1.8.3.1 that in the
Next Steps an ampacity study be performed to asses whether it would be possible to install the cables at
a greater depth than 1.3 metres, by taking into account such parameters as the cyclic nature of the
loading and the reduction in ground temperature at greater depth.
ER 381
CCI requested 15 prospective suppliers of cable systems (conventional cable and GIL) to submit
technical designs and budgetary prices for the underground transmission system.
They were sent the following documents:
Manufacturers were initially requested to supply information by Sept 4th 2009. An extension was
subsequently given until Sept 4th 2009. Because of the scope of the information requested, some
suppliers did not provide information until Oct 13th. Further clarification questions were raised by
CCI.
The majority of manufacturers expressed interest and responded positively providing useful
information. This included the provision of some of the photographs included within this document.
9.1
9.1.1
Inquiry document
ER 381
[1] Notes:
Suppliers were requested to base their proposals on both circuits being required to carry a continuous
load of 3,000 MVA at 500 kV with both circuits loaded.
It was later advised that the requirement was for 3,000 MVA with one circuit loaded only.
The request to manufacturers was reviewed and it was determined that a reissue of the enquiry
document would not be necessary as:
9.2
The size of the cable and the number of cables per phase could not have been reduced as these
are determined by the need for each circuit alone to carry 3,000 MVA.
In principle the spacing between circuits used for the scoping study could have been reduced
without reducing the ampacity at 1,500 MVA to less than 7 metres, this being the spacing
between the Groups of Cable within each circuit. The spacing between groups of cables is
determined by both thermal and circuit security considerations, as described in section 7.6 and
section 7.7. Thus the minimum spacing between circuits could not be reduced to less than
7 metres.
Requests for technical information from prospective suppliers of 500 kV cable systems
CCI requested several prospective suppliers of 500 kV cable systems to provide technical
recommendations for two parallel 500 kV cable circuits, each of a generic route length of 10 km. At
the date of issue of the enquiry document the scenarios of 20 km, 65 km and those utilising GIS
switching substations at the cable transitions had not been developed.
ER 381
They were told that a service life of 40 years would be required, and also that the cable should be
suitable for continuous operation at approximately 525 kV as previous system studies had indicated
that the voltage in areas where cable might be used were likely to be around this value.
Whilst it was envisaged that each circuit would require multiple cables per phase, they were not given
any instructions as to how many underground cables they should propose.
In order for them to be able to prepare designs, they were given the following parameters:
The above depth, temperatures and ground thermal resistivities were based on those used in the
design of the cable system for the recently installed Downtown Edmonton Supply and Substation
240 kV cable system.
To give prospective suppliers an indication of the climatic conditions for which the cable systems
must be designed, they were asked to base their recommendations on the following minimum
temperatures:
Ground at 1.3m depth for direct buried cable and joint design
-10C
-15C
Air for duct- manhole system design: cable and joint
-20C
-20C
Air within deep tunnels for cable and joint design
-10C
-10C
Air within cut and cover tunnels for cable and joint design
-20C
-20C
Outdoor air for cable and termination design
-50C
-50C
Indoor air for cable and termination design
-10C
-10C
(Note: the temperatures in italics are those that were recommended at the end of the feasibility study)
Installation design
Designs based on three types of installation were requested:
Prospective suppliers were not asked to propose designs of SCFF cable types for use in tunnels as
these perceived to present too great a fire hazard. Prospective suppliers were not required to
ER 381
perform detailed ampacity calculations for their tunnel proposals, as, at this feasibility study
stage, it was not considered necessary or appropriate to request multiple suppliers to perform the
complex calculations necessary to prepare proposals for tunnel ventilation arrangements.
Reel lengths
Prospective suppliers were advised that the maximum sizes of cable reels which can be delivered
to site should be taken as:
ER 381
At the time that the enquiries were sent to prospective suppliers the transportation survey had not
been completed. The above limits are typical for road transportation in many countries.
Tests
Prospective suppliers were advised that the test requirements for XLPE cable systems would be
generally in accordance with the requirements of IEC 62067[1] but that tests additional to those
in IEC 62067[1], in particular to demonstrate the performance of the cable system at the minimum
temperatures which could be encountered in cables and accessories for the Edmonton region of
Alberta.
DTS fibres
Prospective suppliers were advised that DTS (Distributed Temperature Sensing) fibres would be
laid with the cables and that to give a useful indication of cable temperatures when installed in
ducts, it is preferred that:
for XLPE cable the fibres would be included within the cable construction
proposals for DTS fibres external to the 500 kV cables and ducts would also be
considered for XLPE and SCFF cables
9.3
Most suppliers offered systems utilising two cables per phase with two Groups of Cables per circuit, in
separated trenches fairly widely spaced apart as depicted in Figure 103. All suppliers offered naturally
cooled systems. No supplier offered a system requiring only one group of cables per circuit, either
with or without forced cooling.
ER 381
ER 381
Cables in Ducts
Ground surface
Duct
Cable
Duct block
Phase
spacing
Phase
spacing
Group spacing
Phase
spacing
Phase
spacing
Cable
Backfill
Phase
spacing
Phase
spacing
Group spacing
Phase
spacing
Phase
spacing
9.3.1
ER 381
Duct-Manhole systems
The phase spacing ranged from 450 mm to 1,300 mm, and the group spacing ranged from 2,500 mm to
7,000 mm. In general proposals with wider group spacing had narrower phase spacing.
Proposals were also received for very closely grouped cables with all the cables required for one circuit
being installed in a single duct block. This arrangement required three cables per phase using
3000 mm conductors.
Bentonite filling of the ducts was also proposed by some suppliers to achieve the required ampacity.
9.3.2
The phase spacing ranged from 350 mm to 1,000 mm, and the group spacing ranged from 2,500 mm to
6,000 mm. In general proposals with wider group spacing had narrower phase spacing.
Proposals were also received for very closely grouped cables with all the cables required for one circuit
being installed in a single trench. This arrangement required three cables per phase using 3,000 mm
conductors. Each circuit would consist of nine cables installed in a trench 3,500 mm wide.
9.3.3
Tunnel systems
For installation in tunnels, some suppliers proposed a reduced number of joints for cables installed in
tunnels. Up to 30% fewer joints were proposed for cables installed in tunnels. Depending on the phase
spacing, longer section lengths could result in higher sheath voltages. Higher sheath voltages could be
considered for tunnel installations than for buried systems.
9.3.4
All XLPE and SCFF cable suppliers based their proposals on cross bonded cable sheath systems. A
typical cross bonding arrangement is shown in Figure 105 and Figure 106.
ER 381
9.4
ER 381
insulated line) was also offered. The supplier of HPFF (High pressure fluid filled) cable
responded that they had no suitable product to offer for the 500 kV Heartland Project.
9.4.1
9.4.2
9.4.3
9.4.4
ER 381
The metallic shield or sheath over the insulated core has to provide:
a low impedance path for fault currents
a watertight radial barrier to prevent moisture reaching the insulation.
The metallic shield can either be a single metallic layer which fulfils both these functions, or it
can comprise two separate components, a layer of wires to carry the fault current, and a separate
metallic layer to provide the water barrier.
Both weight and diameter can limit the maximum length of cable that can be delivered to site as
they will govern the overall weight and dimensions of the reels upon which the cables travel from
the factory to the installation site.
The weight of the cable can limit the maximum length that can be pulled in to a duct block.
Heavier cables cannot be pulled in such long lengths as lighter cables.
Manufactures also advised the sheath losses for their designs, i.e. the sheath losses are
dependent upon the design of the sheath (and also upon the phase spacing at which the cables are
installed)
According to the method for calculating ampacity described in IEC 60287[83], any losses in wire
screens can be considered negligible. The losses in annular metallic sheaths tend to be higher in
cables with lower sheath resistance. Thus cables with annular sheaths of low resistance
aluminium have higher losses than those with higher resistance annular sheaths, although this is
not so significant at wider phase spacing. The lowest loss type is that utilising a stainless steel
sheath. Cables with lower losses can be laid in more compact formation, with lower external
magnetic fields and lower induced sheath voltage.
For cables to be installed in tunnels, where the cables will not be immersed in water, some
manufacturers have offered cable designs with an overlapped or welded aluminium foil that is
substantially thinner than the annular sheaths proposed for installation in duct-manhole or direct
burial arrangements. These offer lower losses, lower weight and possibly reduced cost.
9.4.5
ER 381
9.4.6
9.4.7
No
All manufacturers have offered Polyethylene jackets for duct-manhole or direct burial
arrangements. SCFF cables are not generally considered suitable for installation in tunnels.
9.4.8
GIL design
In addition to conventional, flexible, cable systems GIL has also been proposed. The state of the
art together with significant applications of GIL is described in Section 4.10.
GIL was offered for installation in a tunnel and budgetary prices were provided. GIL was not
offered for direct burial in the ground.
The GIL system design proposed by prospective suppliers for the 500 kV Study Project is
substantially different to that of conventional, flexible, cable in the following ways:
GIL design, Figure 115, is significantly larger in diameter than XLPE or SCFF
cable types and thus it has been proposed that it would be delivered in straight
ER 381
sections and assembled together on site. The maximum length of each section
would be approximately 10 metres.
Each GIL tube is rated at 4,000 amps assuming that means exist to dissipate the
heat into the ambient air. This is equivalent at 500 kV to 3,464 MVA, or
3,000 MW at a 0.865 power factor). Thus only one set of three phase tubes would
be required per circuit. For two circuits six phases was offered.
Previous GIL installations have not generally been buried in the ground; they have
either been supported on structures above ground, or in underground tunnels.
9.4.9
ER 381
Diagrammatic only
Item
Details
1
Copper conductor
2
Conductor binder
3
Extruded screen
4
XLPE Insulation
27-32 mm
5
Extruded screen
6
Water-blocking cushioning tapes
7
Extruded lead sheath
4-5 mm
8
Polyethylene Jacket with semi-conductive coating
Approximate weight 55-60 kg/m
Approximate diameter 150-160 mm
Figure 107: Proposed 500 kV design: extruded lead sheath
ER 381
Diagrammatic only
Item
Details
1
Copper conductor
2
Conductor binder
3
Extruded screen
4
XLPE Insulation
27-32 mm
5
Extruded screen
6
Water-blocking cushioning tapes
7
Smooth (welded) aluminium sheath
0.75-1.5 mm
8
Polyethylene Jacket with semi-conductive coating
Approximate weight 38-40 kg/m
Approximate diameter 145-155 mm
Figure 108: Proposed 500 kV design: welded aluminium sheath
ER 381
Diagrammatic only
Details
Copper conductor
Conductor binder
Extruded screen
XLPE Insulation
27-32 mm
Extruded screen
Water-blocking cushioning tapes
Corrugated aluminium sheath
7
1.5-3.5 mm
(extruded or welded)
8
Polyethylene Jacket with semi-conductive coating
Approximate weight 40-42 kg/m
Approximate diameter 155-170 mm
Item
1
2
3
4
5
6
ER 381
10
Diagrammatic only
Item
Details
1
Copper conductor
2
Conductor binder
3
Extruded screen
4
XLPE Insulation
27-32 mm
5
Extruded screen
6
Water-blocking cushioning tapes
7
Distributed temperature sensing fibre
8
Copper wire screen
9
Corrugated stainless steel sheath
0.75-1.0 mm
10
Polyethylene Jacket with semi-conductive coating
Approximate weight 45-47 kg/m
Approximate diameter 160-170 mm
Figure 110: Proposed 500 kV design: copper wire screen and corrugated stainless steel
sheath
ER 381
10
Diagrammatic only
Item
Details
1
Copper conductor
2
Conductor binder
3
Extruded screen
4
XLPE Insulation
27-32 mm
5
Extruded screen
6
Water-blocking cushioning tapes
7
Distributed temperature sensing fibre
8
Copper wire screen
9
Extruded lead sheath
2-3 mm
10
Polyethylene Jacket with semi-conductive coating
Approximate weight 53-58 kg/m
Approximate diameter 145-165 mm
Figure 111: Proposed 500 kV design: copper wire screen and lead sheath
ER 381
10
Diagrammatic only
Item
Details
1
Copper conductor
2
Conductor binder
3
Extruded screen
4
XLPE Insulation
27-32 mm
5
Extruded screen
6
Water-blocking cushioning tapes
7
Distributed temperature sensing fibre
8
Copper or aluminium wire screen
9
Smooth (welded) aluminium sheath
0.5-1.0 mm
10
Polyethylene Jacket with semi-conductive coating
Approximate weight 38-40 kg/m
Approximate diameter 155-160 mm
Figure 112: Proposed 500 kV design: wire screen and smooth aluminium sheath
ER 381
10
Diagrammatic only
Item
Details
1
Copper conductor
2
Conductor binder
3
Extruded screen
4
XLPE Insulation
27-32 mm
5
Extruded screen
6
Water-blocking cushioning tapes
7
Distributed temperature sensing fibre
8
Copper wire screen
9
Overlapped aluminium laminate
0.2-0.4 mm
10
Polymeric Jacket
Approximate weight 35-43 kg/m
Approximate diameter 145-150 mm
Figure 113: Proposed 500 kV design: copper wire screen and aluminium laminate
ER 381
Diagrammatic only
Item
Details
1
Central fluid duct
2
Copper conductor
3
Conductor binder and screen
4
Impregnated LPP insulation
25-26 mm
5
Insulation screen and binder
6
Radial clearance
7
Corrugated Aluminium Sheath
3-4 mm
8
Polyethylene Jacket with semi-conductive coating
Approximate weight 41 kg/m (2,500 mm) to 48 kg/m (3,000 mm)
Approximate diameter 145 mm (2,500 mm) -155 mm (3,000 mm)
Figure 114: Proposed 500 kV design: self contained fluid filled
ER 381
Cross section
Longitudinal section
Diagrammatic only
Item
Details
1
Aluminium alloy conductor
2
Pressurised SF6 gas
3
Aluminium alloy enclosure
4
Support insulator
Approximate weight 45 kg/m (average, includes insulators)
Approximate diameter 550 mm
Figure 115: Proposed 500 kV design: GIL
9.5
ER 381
Prospective suppliers of cable systems were asked to provide values of resistance, conductor and sheath
losses, capacitance and dielectric losses. The averages of the appropriate values provided by the
prospective suppliers were calculated and tabulated below. These were passed to AESO for use in the
power flow studies and calculations of power loss performed by Teshmont. The results of their
calculations are given in Appendix, Section 5.
Table 37 shows the average cable capacitance and charging current provided for XLPE cable
Capacitance per cable
Charging current per cable at 500 kV
Dielectric loss per cable at 500 kV (estimated)
Dielectric loss per group of three single phase cables at 500 kV (estimated)
pF/m
mA/m
W/m
W/m
213
23.1
5.2
15.6
Table 37 Supplier responses: Average capacitance and dielectric losses for XLPE cable
Table 38 shows the average cable capacitance and charging current provided for SCFF cable
Capacitance per cable
Charging current per cable at 500 kV
Dielectric loss per cable at 500 kV (estimated)
Dielectric loss per group of three single phase cables at 500 kV (estimated)
pF/m
mA/m
W/m
W/m
290
24.5
12.7
38.1
Table 38 Supplier responses: Average capacitance and dielectric losses for SCFF cable
Table 39 shows the average capacitance and charging current provided for GIL
Capacitance per cable
Charging current per cable at 500 kV
pF/m
mA/m
53
5.8
ER 381
Conductor and Sheath losses at 1,500 MVA per group of cables at 500 kV
Equivalent resistance per cable
W/m
/m
103.6
11.5
Table 40 Combined conductor and sheath losses: XLPE cable mean and maximum
No complete system design utilising two SCFF cables per phase, and suitable for the transmission of
3,000 MVA per circuit, has been proposed. The power losses for a SCFF cable system have therefore
not been analysed. Because an SCFF cable has higher dielectric losses than the equivalent XLPE
insulated cable, the power losses at low transmitted loads would be higher for an SCFF cable than for
an XLPE cable.
Table 41 shows the combined conductor and enclosure losses provided for GIL.
Conductor and enclosure losses at 3,000 MVA per 3-phase group of GIL
Equivalent resistance per single phase GIL
W/m
/m
105.8
11.8
9.6
Three different types of splice designs were offered for XLPE cables:
One piece silicone rubber prefabricated.
One piece EPR rubber prefabricated.
Prefabricated composite with EPR rubber stress cones
The major electrical components of the proposed one piece joint (Silicone rubber or EPR rubber) and
prefabricated composite joint offered are shown schematically in Figure 116 and in Figure 117
ER 381
ER 381
10 TRANSITION STATION
The technical details of the transition stations were complied by the HPT and are given in Appendix,
Section 17 and 26.
Transition station types:
Scenarios 1 and 2 are air insulated switchgear (AIS) in the open air (-50oC design
temperature).
Scenarios 3 and 4 will be gas insulated switchgear (GIS) in a building. An example of gas
insulated switchgear is shown in Figure 118.
An indoor heated station is not included at this stage in the engineering work, but will be
added to the Project Risks, Section 15 to cover the risk that the cable terminations will not
operate at -50oC.
ER 381
A study has been performed to show the need for the reactor is needed in the circuit in
normal loading and in circuit energisation, (reference Teshmonts report in Appendix
Section 5).
ER 381
11 POWER LOSSES
The losses in an underground cable and overhead line are comprised of two parts:
A variable part that is dependent upon load current, this being the heating of the conductor
by the flow of load current.
A fixed part of constant magnitude that is independent of load current. The fixed losses are
all a function of the applied system voltage which is constant irrespective of the loading.
The ratio of variable to fixed losses are different in underground cables and overhead lines:
The ratio is high in an overhead line, as the overhead line possesses higher conductor
resistance than a cable, but lower voltage related losses.
Conversely the ratio is low in an underground cable because the fixed losses of a cable are
high. The fixed losses associated with a cable are:
Insulation losses in the XLPE insulation
Losses in the conductor due to the flow of charging current into the XLPE
insulation
Insulation and conductor losses in the reactors
A cross over load exists at which the losses in the cable are equal to the losses in the same length of
overhead line.
11.1.1 Relationship of power loss to power transfer for the 500 kV Study Project
Teshmont performed a system study for AESO, Appendix Section 5, and compared the losses for each
of the scenarios. Each scenario has different lengths of overhead line and cable connected in series and
has reactors connected in parallel. In consequence the scenarios have a modified ratio of variable to
fixed losses.
A comparison of one circuit of a 65 km all-cable scenario with an all overhead-line scenario in Figure
119 shows:
The cross-over load occurs at 1,700 MW at which the overhead line and underground
cable scenarios have equal losses.
For transmitted loads up to 1,700 MW, the all-overhead line Scenario 6 has lower losses.
ER 381
For transmitted loads greater than 1,700 MW, the underground cable scenario has lower
losses. However, a single circuit will only experience loads in excess of 1,500 MW in
contingency situations in which the other circuit is un-available.
Thus the prospective power loss benefits of XLPE underground cables are unlikely to be
realised in the 500 kV Study Project.
Figure 119. Power losses for selected scenarios at different levels of transmitted power
At loads less than the 1,700 MW cross over load, the scenarios containing a portion of cable have a
higher loss than Scenario 6, which is all-overhead line. The difference in losses compared to the
overhead line Scenario 6 is lowest in those scenarios that contain a) the shortest length of cable and b)
the fewest number of Groups of Cables. Figure 119 shows that:
ER 381
Scenario 2A.10 has slightly higher losses than the overhead line Scenario 6. This is because
Scenario 2A.10 contains the smallest quantity of cable. It is the first stage of a staged
option and comprises one group of cables (per circuit) instead of two. Note that the losses
for Scenario 2A.10 are only plotted up to 1,500 MW as this is the limiting load for a single
Group of Cables.
Scenario 1A.10 comprises two Groups of Cables and so has a load capability under
contingency operation of 3,000 MW. The losses in Scenario 1A.10 above 1,700 MW are
less than those of the overhead line Scenario 6 because variable losses in the overhead line
conductor are greater than those in the underground cable conductor.
Scenario 5.B.65 comprises two Groups of Cables of 65 km length. The two Groups of
Cable, under contingency operation, have a load capability of 3,000 MW:
At 3,000 MW the losses in the cable Scenario 5B.65 are 16 MW compared to
28 MW in the overhead line Scenario 6.
At a nominal low load of, say, 400 MW the losses in the cable Scenario 5B.65 are
6 MW, compared to 0.5 MW in the overhead line Scenario 6.
457.3 MW
1,000.0 MW
For the average load of 457.3 MW in the period up to and including 2026 , the average power losses for
the relevant scenario Stages are presented in Table 42 and Figure 120.
Scenario
ER 381
Total loss
1A.10
2A.10
3A.10
4A.10
Length
km
10
10
10
10
1B.20
2B.20
3B.20
4B.20
20
20
20
20
2.4
1.7
1.7
1.7
5A.65
5B.65
65
65
3.4
6.5
65
1.0
MW
1.7
1.4
1.4
1.4
Table 42. Power losses for each scenario at an average load of 457.3 MW
Key to the Figure 120 bar chart :
Yellow: All-overhead line i.e. Scenario 6.
Green: One Group of Cables in operation, i.e. 2A.10, 2B.20, 3A.10, 3B.20, 4A.10, 4B.20 and 5A.65.
Blue: Two Groups of Cable in operation, i.e. the un-staged Scenarios 1A.10, 1B.10 and 5B.65.
Scenario
ER 381
1A.10
2A.10
3A.10
4A.10
Length
km
10
10
10
10
MW per circuit
3.9
3.7
-
1B.20
2B.20
3B.20
4B.20
20
20
20
20
4.4
4.0
-
5A.65
5B.65
65
65
Not applicable
2 Group of Cables per circuit
7.1
65
3.5
Total loss
Table 43. Power losses per circuit for each scenario at an average load of 1,000 MW
The estimated NPV of the losses is 7.3% of the estimated NPV Revenue Requirement* for
Scenario 6, all-overhead line, and between 4.2 and 4.7% of the NPV Revenue Requirement
for the scenarios that include cable. *Present Value of capital and maintenance costs, etc, as
detailed in Appendix, Section 3
The estimated Net Present Value (NPV) of differences in losses between those of the scenarios
containing cable and the all-overhead line Scenario 6 are also given in Table AB. These show:
The difference in estimated NPV of the losses for all scenarios ranges from 5 $M
(Scenario 3A.10) to 19 $M (Scenario 1.B.20).
The difference in estimated NPV of the losses as a percentage of the estimated NPV
Revenue Requirement ranges from 0.6% (Scenario 3A.10) of to 1.6% (Scenario 1.B.20).
Scenario
Staged
1A.10
No
2A.10
Yes
3A.10
No
4A.10
Yes
1B.20
No
2B.20
Yes
3B.20
No
4B.20
Yes
5A.65
5B.65
6
No
Description
ER 381
OHL
Route
km
km
km
Estimated NPV
Revenue
Requirement
$M
Estimated
NPV of
losses
Estimated NPV
Loss difference
from OHL
$M
$M
10
55
65
756
42
4.7
1.0
10
55
65
727
40
4.5
0.8
10
55
65
696
38
4.6
0.6
10
55
65
691
39
4.7
0.7
20
45
65
1,020
52
4.3
19
1.6
20
45
65
951
47
4.0
14
1.2
20
45
65
886
43
4.1
10
1.0
20
45
65
865
44
4.2
11
1.0
65
65
0
0
0
65
65
65
65
Ref
Ref
380
Table 44. Estimated NPV of power losses over a forty year period.
NPV is the net of PV of losses and PV of Revenue requirement.
Not calculated
Not calculated
33
7.3
ER 381
Average cost of cable system per km of each Group of Cables, including supply of 3 km of
cable (i.e. sufficient single core cable for one kilometre of a Group of Cables in a single
trench), splices, jointing, bonding equipment, ancillary equipment, and supervision of cable
laying, delivery to Edmonton.
Average cost per termination of each Group of Cables, including 3 terminations, jointing,
bonding equipment, ancillary equipment, delivery to Edmonton
Average cost per commissioning test for each Group of Cables
Average cost per set of development tests per supplier, including prequalification tests, type
tests, and an allowance for low temperature tests
Average cost per set of type tests per supplier. In the event of a staged installation, repeat
type tests would be performed prior to the implementation of stage 2. In the intervening
period between Stage 1 and Stage 2, there may have been minor changes to materials,
manufacturing processes, etc, necessitating repeat type testing.
Average cost per set of spares per supplier, including cable, splices and terminations.
From these the capital cost estimate of the cable system for each scenario was calculated and
incorporated by HPT into the total capital cost estimate for each scenario.
ER 381
Cable system components (cable, terminations, joints and ancillaries) and jointing (CCI)
Spares (CCI/HPT)
Underground cable civil works (HPT)
Cable installation into the ground, (HPT)
Overhead line components and assembly (HPT)
Transition station construction and equipment, such as reactors (HPT)
Works and equipment in two substations (HPT)
Owners costs (HPT)
ER 381
Scenario
Staged
Description
UGC
OHL
Route
Stage 1
Stage 2
Total
1A.10
2A.10
3A.10
4A.10
No
Yes
No
Yes
km
10
10
10
10
km
55
55
55
55
km
65
65
65
65
$M
574
606
$M
201
105
$M
748
775
687
711
1B.20
2B.20
3B.20
No
Yes
No
20
20
20
45
45
45
65
65
65
689
-
350
-
1014
1039
877
4B.20
Yes
20
45
65
720
185
905
No
65
65
382
All-overhead line
Table 45. Capital cost estimates for each scenario (2009 dollars)
Figure 121
Figure 122
Figure 123
Figure 124
Figure 125
NOTE: The diagrams only show half of the route for clarity; the values represent the total estimated
capital costs for the entire 65 km route.
ER 381
Stage 1 estimated costs are given in white on blue. Stage 2 estimated costs are given in black above
red.
Total estimated costs for each component are the sum of the Stage 1 and Stage 2 costs
Figure 121. Estimated capital cost components in $M for 4 groups of Cables, 10 km long
ER 381
Stage 1 estimated costs are given in white on blue. Stage 2 estimated costs are given in black above
red.
Total estimated costs for each component are the sum of the Stage 1 and Stage 2 costs.
Figure 122. Estimated capital cost components in $M for 3 groups of Cables, 10 km long
ER 381
Stage 1 estimated costs are given in white on blue. Stage 2 estimated costs are given in black above
red.
Total estimated costs for each component are the sum of the Stage 1 and Stage 2 costs.
Figure 123. Estimated capital cost components in $M for 4 groups of Cables, 20 km long
ER 381
Stage 1 estimated costs are given in white on blue. Stage 2 estimated costs are given in black above
red.
Total estimated costs for each component are the sum of the Stage 1 and Stage 2 costs.
Figure 124. Estimated capital cost components in $M for 3 groups of Cables, 20 km long
ER 381
Figure 125. Estimated capital cost components in $M for all overhead line (Scenario 6)
12.4 Estimated Net Present Value of the life cycle costs for the 65 km route length
The estimated Net Present Value of the lifecycle costs were compiled by the AESO for the end to end
estimated capital costs, maintenance and spares are given in Appendix, Section 3, for the 500 kV Study
Project route length of 65 km. A summary of the estimated NPVs for each scenario is given in Table
46.
Scenario
Staged
ER 381
1A.10
2A.10
No
Yes
3A.10
4A.10
No
Yes
1B.20
2B.20
No
Yes
3B.20
4B.20
No
Yes
No
All-overhead
UGC
OHL
Route
PV
Revenue
Requirement
PV
Losses
NPV
Net
Cost
km
10
10
km
55
55
km
65
65
$M
756
727
$M
42
40
$M
798
767
10
10
55
55
65
65
696
691
38
39
733
730
20
20
45
45
65
65
1,020
951
52
47
1,072
997
20
20
45
45
65
65
886
865
43
44
928
909
65
65
380
33
412
Table 46. Estimated NPV of the life cycle cost for each scenario
Cable length km
ER 381
Number of
Groups of Cables
Estimated NPV of
Life Cycle costs
Un-staged
Staged
$M
$M
Un-staged
$M
Staged
$M
748
(1A.10)
775
(2A.10)
798
(1A.10)
767
(2A.10)
687
(3A.10)
711
(4A.10)
733
(3A.10)
730
(4A.10)
Difference
-61
-64
-65
-37
1,014
(1B.20)
1,039
(2B.20)
1,072
(1B.20)
997
(2B.20)
877
(3B.20)
905
(4B.20)
928
(3B.20)
909
(4B.20)
Difference
-137
-134
-144
-88
10
20
Cable length km
Number of
Groups of Cables
Estimated NPV of
Life Cycle costs
Un-staged Staged Difference
$M
$M
$M
Un-staged
$M
Staged
$M
Difference
$M
748
(1A.10)
775
(2A.10)
+27
798
(1A.10)
767
(2A.10)
-31
687
(3A.10)
711
(4A.10)
+24
733
(3A.10)
730
(4A.10)
-3
1,014
(1B.20)
1,039
(2B.20)
+25
1,072
(1B.20)
997
(2B.20)
-75
877
(3B.20)
905
(4B.20)
+28
928
(3B.20)
909
(4B.20)
-19
10
20
12.6 Differences between the estimated cost of underground cable and overhead line
Table 49 compares the estimated capital cost and the estimated NPV of the life cycle cost:
ER 381
Estimated cost differences for each scenario compared to all-overhead line (Scenario 6)
Estimated cost ratios for each scenario compared with the all overhead line (Scenario 6)
Average estimated costs of the 10 km and 20 km scenarios
Average of the 10 km and 20 km scenarios estimated cost differences compared with alloverhead line (Scenario 6)
Average estimated cost ratios compared to all overhead line, for the 10 km and 20 km
scenarios
Scenario
1A.10
748
366
2.0
798
386
1.9
2A.10
775
393
2.0
767
355
1.9
3A.10
687
305
1.8
733
321
1.8
4A.10
711
329
1.9
730
318
1.8
Average
of all
10 km
scenarios
730
348
1.9
757
345
1.8
1B.20
1,014
632
2.7
1,072
660
2.6
2B.20
1,039
657
2.7
997
585
2.4
3B.20
877
495
2.3
928
516
2.3
4B.20
905
523
2.4
909
497
2.2
Average
of all
20 km
scenarios
959
577
2.5
977
565
2.4
382
412
Table 49. 500 kV Study Project Estimated costs, cost differences and cost
ratios compared to all-overhead line
Table 50 compares, for information only, the ratio of the estimated installed cost of 10 km and 20 km
of underground cable to that of equal lengths of overhead line, excluding all other equipment. The
values in Table 50 are derived from Table 3 of Appendix, Section 3.
Scenario number
1A.10 / 1B.20
2A.10 / 2B.20
3A.10 / 3B.20
4A.10 / 4B.20
ER 381
4
2 + 2 (staged)
3
2 + 1 (staged)
Average
Table 50. Ratio of estimated installed cost of underground cable to an equal length of overhead line
An example of how these ratios have been obtained is given below for Scenario 1B.20 (20 km):
From column 2 of Table 3 given in Appendix, Section 3 the Transmission line estimated costs, i.e.
excluding all other associated costs, are 205 $M for Scenario 6 (overhead) and 582 $M for Scenario
1B.20.
The average overhead line estimated cost per km can thus be taken as 205 $M / 65 km = 3.15 $M/km
Scenario 1B.20 includes 45 km of overhead line, the estimated cost of which can therefore be assumed
to be some 3.15 $M/km x 45 km = 141.9 $M.
Subtracting this from the total of 582 $M leaves 440.1 $M which relates to the estimated cost of 20km
of cable.
The cable estimated cost per route km is thus 440.1$M / 20km = 22 $M/km. The estimated cost ratio of
underground cable to overhead line is therefore = 22 / 3.15 = 7.0.
Table 51 shows the estimated cost ratio of installed cable, transition stations and additional
telecommunication equipment to overhead line. This is also derived from Table 3 of Appendix,
Section 3.
Scenario number
1A.10 / 1B.20
2A.10 / 2B.20
3A.10 / 3B.20
4A.10 / 4B.20
Number of
Groups of Cable
4
2 + 2 (staged)
3
2 + 1 (staged)
Average
Table 51. Ratio of estimated cost of underground cable and transition stations to an equal length of
overhead line
ER 381
The cost studies, summarised in Table 49, Table 50 and Table 51 show that for the 65 km 500 kV
Study Project:
The estimated NPV of life cycle costs are greater than the estimated capital costs; however
the cost ratio for each scenario compared to the all-overhead line scenario is not
significantly changed.
The average ratio of installed cable cost estimates, to those of an equal length of overhead
line is:
6.5 : 1 excluding all other equipment.
8.7 : 1 including transition stations and associated other equipment.
The average ratio of NPV of life cycle cost estimates for the 65 km route length with and
without underground cable is:
1.8 : 1 for a 10 km cable length.
2.4 : 1 for a 20 km cable length.
Increasing the length of underground cable from 10 km to 20 km, increases the average
estimated capital cost by 229 $M.
The lowest cost cable scenario for estimated capital cost is Scenario 3A.10 for the 10 km
underground route length. Scenario 3A.10 comprises three Groups of Cables. The ratio of
estimated cost to an all-overhead scenario (Scenario 6) is 1.8:1 and the estimated capital
cost difference is 305 $M.
The estimated cost of Scenario 4A.10 is closely similar, but higher with estimated capital
cost and lower estimated NPV of life cycle costs .
* Note: Scenarios 3A.10* has a less substantial n-1 redundancy margins than other 10 km
scenarios to meet the contingency condition of 3,000 MW, as two Groups out of the three
available in the fully staged options are required.
If four Groups of Cables* are used (scenario is 1A.10) the ratio of estimated cost to an alloverhead scenario (Scenario 6) is 2:1 and the estimated capital cost difference is 366 $M.
* Note: Scenario 1A.10 has a more substantial n-1 redundancy margin to meet the
contingency condition of 3,000 MW, as it comprises four Groups of Cables (two Groups out
of the four being required).
ER 381
There is a reduction in the estimated NPV of life cycle costs for staged installation. The
reductions are:
- Staged Scenario 2A.10 to un-staged Scenario 1A.10:
3.9% (31 $M)
- Staged Scenario 4A.10 to un-staged Scenario 3A.10:
0.4% ( 3 $M)
- Staged Scenario 2B.20 to un-staged Scenario 1B.20:
7.0% (75 $M)
- Staged Scenario 4B.20 to un-staged Scenario 3B.20:
2.0% (19 $M)
12.7 Sensitivity studies on the estimated capital cost of the cable system
12.7.1 Sensitivity: Effect on cost of SCFF cable
The estimated increase in the capital cost if SCFF cable is used in place of XLPE is given in Table 52.
This is based on there being two SCFF cables per phase. Table 52 includes only cost differences for
the supply and jointing of the cable system and does not include any differences which there may be in
the installation costs.
Scenario
Staged
1A.10
2A.10
No
Yes
3A.10
4A.10
No
Yes
1B.20
2B.20
No
Yes
3B.20
4B.20
No
Yes
Description
UGC
OHL
Route
km
Stage
1
$M
Stage
2
$M
km
km
10
10
Total
Change
55
55
65
65
+7
+7
$M
+12
+13
10
10
55
55
65
65
+6
+3
+9
+10
20
20
45
45
65
65
+12
+12
+24
+24
20
20
45
45
65
65
+12
+6
+18
+18
12.7.2 Sensitivity: Canadian Dollar value falls against other currencies by 20%
Cable systems would be imported into Canada and the price would thus be dependent upon the
exchange rate between the Canadian dollar and the native currency of the supplier. A fall in the value
of the Canadian Dollar would result in an increase in the price of the cable system; a rise in the value of
the Canadian Dollar would result in a fall in the price of the cable system. The historic variation in the
value of the Canadian Dollar against other currencies over the past four years is shown in Figure 126.
This shows that the value of the Canadian Dollar has fallen significantly against the value of the
Japanese Yen, particularly in the period between 22 Feb 2008 and 6 July 2008. Exchange rates could
ER 381
vary again between the time that the prospective suppliers prepared their indicative budgetary prices
and the time that they submit commercial quotations.
1.2
140
1.0
120
USDollar
Euro
80
0.6
60
0.4
Japan Yen
100
0.8
40
0.2
20
0.0
Euro
JPY
Scenario
Staged
1A.10
2A.10
No
Yes
3A.10
4A.10
No
Yes
1B.20
2B.20
No
Yes
3B.20
4B.20
No
Yes
ER 381
UGC
OHL
Route
km
Stage
1
$M
Stage
2
$M
km
km
10
10
Total
Change
55
55
65
65
12
11
$M
23
24
10
10
55
55
65
65
12
17
18
20
20
45
45
65
65
22
21
44
43
20
20
45
45
65
65
22
11
33
33
Table 53. Estimated capital cost change if Canadian dollar value should vary by 20%
ER 381
Staged
1A.10
2A.10
No
Yes
3A.10
4A.10
No
Yes
1B.20
2B.20
No
Yes
3B.20
4B.20
No
Yes
Description
UGC
OHL
Route
km
Stage
1
$M
Stage
2
$M
km
km
10
10
55
55
65
65
$M
12
13
10
10
55
55
65
65
9
10
20
20
45
45
65
65
12
12
24
24
20
20
45
45
65
65
12
18
18
Table 54. Estimated capital cost change if cable metal prices should vary by 50%
Total
Change
ER 381
Number of
Groups of Cables
km
4/2
10
Un-staged
Time
Scenario
November 1, 2014 1A.10
57 months
November 1, 2014
57 months
November 1, 2014
4/2
57 months
November 1, 2014
3/2
57 months
All Overhead Line
March 29, 2013
3/2
20
3A.10
1B.20
3B.20
-
Staged
Time
December 1, 2013
46 months
December 1, 2013
46 months
November 1, 2014
57 months
November 1, 2014
57 months
-
Scenario
2A.10
4A.10
2B.20
4B.20
-
Table 55. Duration of cable supply and installation for each scenario
The draft project schedules, summarised in Table 55, show that:
The two 10 km long scenarios with two Groups of Cables to be installed in stage 1 have a
cable supply and installation time of 46 months.
All other scenarios have a cable supply and installation time of 57 months.
The project schedule includes estimates for the duration of the following work items:
ER 381
13.1 Cable
ER 381
Commissioning time
14.2.2 Reduction in useful power transmission capacity because of cable charging current
Whenever cable insulation is subjected to a voltage, an electric current flows into the cable insulation.
This current is referred to as the Charging current. This Charging current flows through the cable
terminations, along the cable conductor and into the insulation. The following example is given to
demonstrate the effect. The linear apportionment of charging current with length is correct.
Every kilometre of 500 kV XLPE cable of the type that would be selected for the 500 kV Study
Project would have a charging current of about 23.1 amps. (This is based on the technical information
provided by prospective cable suppliers and is shown in Table 37.) 23.1 amps is 1/75th of the
maximum current carrying capacity (ampacity) of the cable conductor of 1,732 amps. Similarly for 2
km of cable, the charging current would be 46.2 amps, or 2/75ths of the ampacity. The effect of this
ER 381
charging current flowing in the conductor is negligible for short lengths of cable, but becomes more
important if the length increases, and the limiting case is when the total charging current reaches
75/75ths. In this case all the current carrying capacity of the conductor would be used to carry the
charging current with no spare capacity available to carry any useful current to the load. To avoid
overheating the cable the total current in the conductor cannot exceed its ampacity. The useful power
that can be carried by the cable is thus reduced by the need to carry the charging current as well as the
useful current to the load. It is the charging current that makes a very long AC cable unviable. This is
one of the main reasons why very long cables, for example undersea interconnectors, utilise DC rather
than AC transmission systems.
For a 65 km cable length for the 500 kV Study Project, the total charging current would be 65/75ths
(i.e. 87%) of the ampacity. The reader is cautioned that the calculation of the useful load current that
can be carried is not a simple linear subtraction. The calculation and its explanation are beyond the
scope of this report, but the results, based on a maximum cable ampacity of 1,732 amps, and a charging
current of 23.1 amps per km, are as follows:
65 km with no reactor: The useful load current would be 863 amps, a reduction of 50%.
65 km with a reactor at the circuit end: The useful load current would be 1,562 amps, a
reduction of 10%.
Further reductions in the charging current flowing in the cable conductor could be made if reactive
compensation is also added along the length of the cable route. This would require that Substations
containing the reactive compensation be constructed at one or more positions along the route.
Teshmont have studied the effects of cable capacitance on power demand and voltage control for a
65 km cable length (Scenarios 5A.65 and 5B.65) and their report is in Appendix, Section 5.
ER 381
km. This means that the quantity of cable and accessories would exceed that of the Tokyo project by a
factor of 3.25.
Table 56 and Table 58 are based on the unconditioned failure rates in Table 25.
Table 57 and Table 59 are based on the conditioned failure rates in Table 27.
Table 56 (unconditioned) and Table 57 (conditioned) show the number of failures
for one year in service.
Table 58 (unconditioned) and Table 59 (conditioned) give the total number of
failures over a 40 year service life.
Route length
km
65
65
65
65
Cable failures
0.09
0.17
0.26
0.35
Joint failures
0.18
0.35
0.53
0.70
Termination failures
0.00
0.01
0.01
0.01
0.27
0.53
0.80
1.06
Table 56 Unconditioned failure rates for a 65 km cable route length for one year in-service
ER 381
Route length
km
65
65
65
65
Cable failures
0.09
0.17
0.26
0.35
Joint failures
0.24
0.48
0.72
0.97
Termination failures
0.00
0.01
0.01
0.02
0.33
0.66
1.00
1.33
Table 57 Conditioned failure rates for a 65 km cable route length for one year in-service
#
Route length
km
65
65
65
65
Cable failures
3.46
6.92
10.37
13.83
Joint failures
7.03
14.05
21.08
28.11
Termination failures
0.12
0.24
0.36
0.48
10.61
21.21
31.82
42.42
Table 58 Unconditioned failure rates for a 65 km cable route length for forty years in-service
#
Route length
km
65
65
65
65
Cable failures
3.46
6.92
10.37
13.83
Joint failures
9.65
19.31
28.96
38.61
Termination failures
0.17
0.35
0.52
0.69
13.28
26.57
39.85
53.14
Table 59 Conditioned failure rates for a 65 km cable route length for forty years in-service
ER 381
At the earliest opportunity and prior to drafting low temperature proving test
requirements, gather information from other utilities and manufacturers on lower
voltage XLPE cable systems with accessories operating under low ambient
conditions.
Remedial Action:
At the pre-bid stage revise the system design parameters:
o Install the cables at a greater depth in the direct buried and duct-manhole systems at a
depth where the ground temperature is higher. This reduces the ampacity of each cable.
For a significant increase in depth it will be necessary to add an additional cable per
phase, increasing the number of groups of three single core cables from four to six for
Scenarios 1 and 2.
o Install the cables in a tunnel in which the minimum air temperature is limited to an
acceptable level by the ventilation control system.
Select an SCFF cable system instead of an XLPE cable system. (The additional
maintenance liabilities of, and the implications of possible fluid leakage from, an
SCFF system would have to be accepted)
ER 381
At the pre-bid stage examine in detail the status and relevance of any 500 kV
2,500 mm2 prequalification tests already performed and only accept bids from
manufacturers with proven EHV, large conductor, test and service experience.
Only accept bids from manufacturers with sufficient in-house development
resources.
Remedial Actions:
ER 381
Train the HPT project engineers for 500 kV cable systems in:
Cable and accessory factory inspection and monitoring procedures.
Installation inspection and monitoring procedures.
Commissioning inspection and monitoring procedures.
In-service routine monitoring, inspection and maintenance procedures.
Repair inspection and maintenance procedures.
Install four Groups of Cables to give full contingency.
Purchase each group of three single phase cables from a separate manufacturer, to
eliminate common mode failure.
Add a performance penalty clause to the contract for an extended warranty period
to require that the supplier has an engineer and jointers on site within, say, 48
hours of notification of failure.
Remedial Actions:
Switch to the load to the parallel circuit.
Replace all the suspect components supplied by the particular manufacturer.
ER 381
Remedial Actions:
Switch the load to the parallel circuit.
Repair the circuit when the ambient temperature rises.
Investigate the cause of the problem, determine and take remedial action. Attribute
or apportion blame accordingly in an attempt to recover costs.
ER 381
Allow sufficient time within the project schedule for manufacture. (A period of
approximately eighteen months has been anticipated for the manufacture of 120
km of single core cable as the range of manufacturing periods advised by
prospective manufacturers was generally between one to two years. Whilst this is
believed to be reasonable at this stage, the programme requires agreement with the
manufacturers.)
Engage multiple suppliers so as to reduce the impact of a delay by any one
supplier.
Engage sufficient suppliers to enable required quantity of cable to be manufactured
within the required time frame.
Check that the manufacturers have allowed for reasonable durations and
contingencies in their programmes.
Engage suitable expediter services.
Impose conditions within the contract that penalise the supplier for late delivery.
Ensure that agreed quality control and inspection and test plans are in place and are
being observed.
Perform frequent visits to suppliers factories to ensure manufacture and testing is
being performed correctly.
Remedial Actions:
At the contract stage, the manufacturer must remedy the situation.
ER 381
Ensure that there are detailed specifications for a) the cable pulling eyes and
despatch cap fitted in the factory are fully water and pressure tight, b) the reel and
its battening, c) the reel transport cradle and d) the reel lifting eyes are sufficiently
robust and stable to withstand without damage the shipping, lifting and road
delivery activities.
Specify that the temporary lay down areas for the reel are stable load bearing and
level surfaces.
Specify that the route to site be proven by performing a trial drive-through.
Establish a buffer stock of reels.
Position the joint bays to use equal section lengths of cable to allow maximum
flexibility and contingency.
Specify that a cable installation trial be performed, especially if specialised or nonstandard equipment is to be used and if the cable is to be installed in a special
configuration.
Specify that the cable installers have evidence of relevant experience with large
diameter, heavy, long length EHV cables and that their references are validated.
Specify that the pulling tensions be a) calculated for the particular span and that
these are below the manufacturers limit for the cable and b) measured during the
pull.
Specify that jointers be present on site to immediately make the cable water tight
should a pulling eye be pulled off or the metallic sheath damaged.
Ensure that a type approved jacket repair technique together with materials is
available.
Perform an HV DC test on the jacket as soon as the cable is laid, locate the
position of any damage, repair the jacket and re-test.
Mark the cable phase colours and note the cable numbers on each of the cable ends
in the joint bays and vaults before and after rolling them at the cross bonded
transposition.
Apply protection to the exposed cable ends in the joint bay or vault.
Ensure that the full security measures are put in place until the trench is backfilled.
Ensure that the trench base and/or duct bores are clean.
Ensure that the blinding and backfill is free of sharp stones that could damage the
cable.
Ensure concrete cover tiles are not placed on the side of the trench when pulling-in
cable.
Remedial Action
ER 381
Select plastic cover tiles in preference to concrete cover tiles to reduce the risk of
them being dropped and penetrating the cable through the blinding layer.
Perform a repeat HV DC test on the cable jacket immediately after backfilling.
Prevent site vehicles from driving over the filled trench or joint bay.
Ensure that all damage is reported to the supplier and is investigated immediately.
If damage is proven to be confined to the jacket, apply a jacket repair and re-test.
If damage to the cable insulation is suspected then remove and replace the span
length.
Remedial Action
ER 381
At the contract stage, the critical suppliers and contractors must remedy the
situation.
The presence of any partial discharge detected during the commissioning tests
shall be investigated and shall be shown not to have emanated from within the
cable system irrespective of the magnitude or type of partial discharge.
Any failure of the cable or accessories is to be immediately reported and
investigated by the supplier, who is to advise remedial actions supported by a full
technical justification.
As for 15.1.4.
Require the suppliers to provide extended warranties to cover Latent Defects in
manufacture.
Engage a different manufacturer to supply each parallel Group of Cables
Remedial Actions
During the warranty period the supplier must remedy the situation.
Identify cause of failures.
From the quality records identify all suspect joints or cable and monitor, repair or
replace.
After warranty period engage the supplier or another manufacturer:
o For latent defect in cable: to replace all suspect cable spans and associated accessories.
ER 381
o For latent defect in joints: to replace all suspect joints with two joints and a short length
of cable
As for 15.3.5
Engage a different manufacturer, using different jointers, to supply each parallel
Group of Cables.
Remedial Actions
During the warranty period the supplier must remedy the situation.
From the quality records identify all suspect joints and monitor, repair or replace.
After warranty period engage the supplier or another manufacturer to replace all
suspect joints with two joints and a short length of cable
Install each buried group of three single phase cables in individual trenches, widely
spaced apart.
Enforce no dig zone over cable route
Publicise phone before you dig policy
Install mechanical protection around buried cables
Install cables at sufficient depth to avoid damage whilst other services are being
worked upon
Install cables at sufficient depth to avoid damage from agricultural machinery
Install warning tapes and tiles above cables
Install distinguishing coloured backfill or trench fill above cables
Install marker posts above cable route
Install robust barriers around ground level sheath bonding equipment
Prepare detailed route records
Regularly walk over and inspect the route.
Install cables in a tunnel
Hold spare joints and cable to minimise unavailability
Install cable terminations where they will not be a target for malicious damage.
ER 381
Remedial Actions
Repair all damaged cables with two joints, or one joint and a termination, and a
length of cable
Remedial Actions
Repair tunnel structure. Replace all damaged cables, accessories, ancillaries and
support structures
intumescent paint: a substance which swells as a result of heat exposure and provides a useful degree
of fire protection to the polymeric cable jacket.
ER 381
Remedial Actions
Install joints direct in the ground and completely surround with backfill.
Install blast proof screens between joints and adjacent cables in manholes or
tunnels
Remedial Actions
Ensure manhole dimensions are suitable to accommodate two sets of repair joints
Remedial Actions
Following failure of a DC jacket test, prohibit the burning out of faults by the
application of continued current as this risks igniting the jacket and spreading fire
to adjacent cables in ducts and tunnels
Use visual inspection instead of DC voltage to check the integrity of cables jacket
in tunnels.
ER 381
Limit the available energy that can be released in the event of a failure during HV
AC testing by using a resonant test set and not connecting the circuit to the grid for
testing
Remedial Actions
Ensure cables are in horizontally flat spaced configuration in buried and duct
systems
Ensure cables in tunnels are in a configuration where all cables can be safely
removed and replaced, generally this implies vertically flat spaced configuration.
Prohibit the use of mechanical excavation immediately above cables or ducts.
Excavate to the side and use hand tools thereafter.
Use only approved and tested sand blasting or water jetting methods to exhume
cables and accessories buried in cement bound sand
Remedial Actions
ER 381
Authors:
Unsigned: Electronic copy
Alan Williams
Brian Gregory
ER 381
500 kV Study
Project
AC
Alternating Current. A current that flows alternately in one direction and then
in the reverse direction. In North America, the standard for alternating current is
60 complete cycles each second. Such electricity is said to have a frequency of
60 hertz. Alternating current is used in power systems because it can be
transmitted and distributed more economically than direct current.
Accessories
Parts of the cable system. Terminations that provide connections to other items
of transmission plant or joints that connect lengths of cable. Cable Accessories
are described in more detail in Section 3.4 of this report.
AEIC
AESO
AltaLink
AltaLink is a TFO that owns and operates transmission lines and substations. It
is part of the HPT.
Amp
Ampacity
The current in amperes a conductor can carry continuously under the conditions
of use without exceeding its temperature rating. It is also known as current
rating. Ampacity is measured in amps.
Ancillaries
Parts of the cable system. Equipment, other than cables and accessories, such
as bonding equipment, used to complete a cable system. It includes equipment
that is used to provide monitoring and maintenance facilities.
ER 381
Backfill
The materials of suitable thermal properties that are placed around and tamped
over the underground cable and joints to restore the excavation to its final
finish. The materials used immediately around the cables or ducts. It is also the
act of placing and tamping these materials.
BEWAG
BIL
Basic Insulation Impulse Level. The very short duration lightning impulse
voltage to which equipment must be tested.
Bonding
Bonding Cables
The insulated conductor forming the connection between the sheath or shield of
the cable, joint or termination base-plate, and a link in the link box.
Cable Clamp
Cable Joint
Cable Jointer
The trained person who assembles cable joints on site. In North America
commonly referred to as a Cable splicer (or journeyman).
Cable Loss
The total energy loss in the form of heat generated in the cable. The Cable Loss
comprises Conductor loss, Dielectric loss and Sheath loss. It is measured in
Watts per metre.
Cable Splice
Another expression for Cable Joint. Cable Accessories are described in more
detail in Section 3.4 of this report.
Cable Splicer
Cable System
Cable complete with installed Accessories and Ancillaries which permits flow
of power from one end of the circuit to the other.
Capacitance
CBS
ER 381
CCI
Cct
Circuit.
CCTV
CESI
CESI is a company located in Milan, Italy, that can test power system
equipment including EHV cable.
Charge
Charging Current
The flow of electricity into and out of the cable dielectric. This current flows
whenever the cable is energized with AC voltage in-service, whether or not it is
carrying any useful power.
CIGRE
Circuit
Cleat
Close Cleated
A way of installing cables in air, whereby the cables are restrained against
lateral and longitudinal movement by locking the cable into position with cleats
located at a comparatively short spacing.
Conductor
Conductor Loss
The energy loss in the form of heat generated in the conductor as a result of the
flow of current. It is measured in Watts per metre.
ER 381
Conduit
Duct
Current
Current Rating
Similar to ampacity.
CV
Continuous Vulcanising. The process used for cross linking an extruded XLPE
insulated cable cores.
DC
Direct Current
DESS
Dielectric
The insulating material in a cable that separates the conductor from the outer
protective covering. Dielectrics are non-metallic. Also known as insulation.
Dielectric Loss
The energy loss within the dielectric of a cable. This loss occurs whenever the
cable is energized on voltage, whether or not it is carrying any useful power.
Direct Buried
A method of installing cables in the ground whereby the cables are intimately
surrounded by, and are in contact with, the backfill. It is often called laid
direct.
Direct Current
Dissipation Factor
The tangent of the Dielectric Loss Angle, . It is often called tan . A measure
of the energy loss characteristics of a dielectric material. A low Dissipation
factor Dielectric exhibits low energy loss.
DTS
Duct
Duct Bank
A number of ducts combined in a group. In this report duct banks are typically
buried in the ground encased in concrete or Fluidized Thermal Backfill (FTB).
ER 381
Duct-manhole
system
EHV
ELECTRA
EMJ
Extrusion Moulded Joint. This is described more fully in Section 4.5 of this
report.
EPCOR
EPCOR is a TFO that owns and operates electricity distribution & transmission
and water and wastewater facilities in Alberta. It is part of the HPT.
EPDM
EPR
EPRI
EQ
Extra High
Voltage
In this report Extra High Voltage cables are those with a nominal system
voltage equal to or greater than 215 kV.
FRE
Fibre Reinforced Epoxy. FRE duct is a type of duct that can be used for cable
duct bank construction.
Frequency
FTB
ER 381
GIL
GIS
Group of Cables
In this report a Group of Cables is used to describe three single core cables, one
for each phase. In this report one group of three single phase cables would
typically be installed in one trench or ductbank.
GWP
HDD
HDPE
High Density Polyethylene. A type of plastic commonly used for cable jackets.
Heartland
Transmission
Project
High Voltage
In this report High Voltage cables are those with a nominal voltage above
36 kV but less than 215 kV.
HPT
Heartland Project Team. The Project team comprise AltaLink and EPCOR.
HTS cable
HV
High Voltage.
Hz
Hertz. The unit of frequency for alternating current. Formerly called cycles per
second. The standard frequency for power supply in North America is 60 Hz.
ER 381
ICEA
ID
Internal Diameter.
IEC
IEEE
Induced Voltage
Induced voltages are the voltages which can be induced in power cables and
associated auxiliary cables and other parallel metalwork, due to their proximity
to cables, overhead lines or to natural phenomena.
Insulation
Insulation is a material that resists the flow of electric current. The insulation of
an AC cable is also called the dielectric.
IPCC
IREQ
Jacket
The outer extruded polymeric layer of a cable. Cable components are described
in more detail in Section 3 of this report.
Joint
Joint Bay
K.m/W
kcmils
Thousands of circular mils. A circular mil is a unit of area, equal to the area of
a circle with a diameter of one mil. A mil is one thousandth of an inch.
ER 381
kg/m
Kilograms per metre. A unit of mass per unit length. Often used to describe
the weight of a cable.
kV
kW
Kilowatt. 1 kilowatt equals 1000 Watts. The unit of real, or useful, electrical
power. Power is the rate of delivery of electrical energy.
LDPE
Low Density Polyethylene. A type of plastic used as the base material for
XLPE cable insulation.
Latent Defect
Link box
A box through which cable sheath bonding and/or grounding connections are
made. The box contains removable links and may also contain sheath voltage
limiters.
Link Pillar
LPP
LSZH
mA/m
Milliamps per metre. A unit of current per unit length. It is commonly used for
charging current in cable dielectric.
Manhole
MDPE
Min
Minimum.
ER 381
mm
Mutual Heating
The temperature rise on one cable due to the head generation by the adjacent
cables (or any other sources of heat).
MV/m
Megavolts per metre. A unit of electrical field strength or stress used in the
design of cable insulation. One Megavolt equals 1,000,000 volts.
MVA
MW
nom
Nominal Value
NPV
OD
Outside Diameter.
OHL
Overhead Line
OPJ
One piece joint. This is described in more detail in Section 4.5 of this report.
Oversheath
P&T
Pilot and Telephone. A generic term to describe the additional cables that are
commonly installed alongside power cables.
PD
Partial Discharge.
Partial Discharge
PE
Polyethylene.
Polyethylene
ER 381
Poly Vinyl
Chloride
PVC
pF/m
Phase
In this report, a phase is one of the three conductors or cables used for the
transmission of high voltage AC electricity. Each phase of a circuit may
comprise several conductors or cables.
PIB
Poly Iso Butene. One of the types of insulating liquid used to fill some types of
cable Terminations.
PJ
Pothead
PQ
Prequalification Tests.
Prequalification
Tests
Prequalification Tests are long term (typically 1 year in duration) tests on cable
systems. The test arrangement shall be representative of the installation design
conditions. Requirements for Prequalification Tests are specified in
IEC 62076[1]. AEIC CS9-06[10] also makes reference to Pre-Qualification tests
which are similar in scope and purpose to those required by IEC 62076.
Testing requirements for 500 kV cable systems are described in more detail in
Section 3.13 of this report.
Private Tests
In this report, Private Tests are those instigated by and conducted on behalf of
manufacturers in the course of their product development. Manufacturers may,
or may not, wish to share the results of such tests with their clients.
Production Tests
ER 381
Proving Tests
In this report, the term Proving Tests is taken to include any Prequalification
Tests which are prescribed in published standards and specifications and
specified by the client, plus any additional tests which the client requires to be
satisfactorily passed before acceptance for service.
QC
Quality Control. The process by which the required level of product integrity
and performance is monitored and achieved.
Qualification Test
Rated Voltage
Reactor
Reel
Cables are stored and transported from the manufacturers works to the
installation site on cable reels. These are also sometimes referred to as cable
drums.
Relative
Permittivity
Resistance
Right of Way
A strip of land reserved for public roads, railway tracks, pipelines, supply lines,
communication lines, or other services.
Route Length
In this report the Route Length of the cable is used to describe the distance
along the route between the cable terminations. It is also used to describe the
total route length of a circuit which can comprise both cable and overhead lines,
in which case it is the distance between the substations at each end.
ER 381
Routine Tests
Sample Tests
SCFF
Screen
A conducting layer that bounds the inner and outer surface of the cable or
Accessory Insulation. Also known as a Shield.
Screen Interruption An insulated gap within a joint or termination that insulates the screen on one
side of the joint from that on the other side for the purpose of Special Bonding.
Sealing Ends
SF6
Sheath
The metallic layer surrounding the cable insulation. Cable sheaths are
described in more detail in Section 3 of this report.
Sheath Loss
The energy loss in the form of heat generated in the sheath as a result of the
flow of current. It is measured in Watts per metre.
The ratio of the losses in a cable sheath to those in the central conductor. It is
used in the calculation of ampacity and effective resistance.
ER 381
Sheath Voltage
Limiter
Shield
A conducting layer that bounds the inner and outer surface of the cable
Insulation. Also known as a Screen. The word Shield is also used for the
integral ground return conductor within some cable constructions.
Silicone Oil
One of the types of insulating liquid used to fill some types of cable
Terminations.
Span
Special Bonding
The type of sheath or shield bonding in which the flow of circulating current
and generation of unwanted heat is prevented.
Splice
Stage
In this report a stage refers to a part completion of the complete cable system.
Typically the final system might be commissioned in several stages, with the
total transmission capability only being available after completion of the final
stage.
Stress
Substation
In this report a Substation is a fenced compound at which the circuit starts and
ends. Other items of electrical equipment may also be located in the compound.
SVL
Swathe
In this report a Swathe is the temporary land width used for construction of an
underground cable system. It would typically be bounded by fences during the
construction period.
Tan
The tangent of the dielectric loss angle. It is often called the Dissipation Factor.
ER 381
TAT
TB
TDR
Termination
TFO
Thermal
Resistivity
Transition Station
Transmission
The process of transporting electric energy in bulk on high voltage lines from
the generating facility to the local distribution facility for delivery to retail
customers.
TSB
Type Tests
Uo
ER 381
Um
Vault
Vg
Vm
Void
Volt
Vt
Water Tree
W/m
Watts per metre. A unit of power per unit length. It is commonly used for
power losses from a cable.
XLPE
Relative permittivity.
/m
ER 381
IEC 62067 Edition 1.1 2006, Power Cables with Extruded Insulation and their Accessories for Rated
Voltages above 150 kV (Um = 170 kV) up to 500 kV (Um = 550 kV) Test Methods and
Requirements.
2
Cao X, Liu Y, Fang H and Gong Z, 500 kV Power Supply Cable Project for City Central Zone of
Shanghai, Paper B1-106, CIGRE Conference, 2008, Paris.
3
Parpal JL et al, 'Prequalification Testing of 345kV Extruded Insulation Cable System', Paper 21-101,
CIGRE Conference 1998, Paris.
4
Parpal JL et al, 'Prequalification Testing of 290/525 (525) kV Extruded Cable System at IREQ', Paper
A2.3, Jicable Conference 1999, Versailles.
5
Williams DE, Natural and Forced Cooling of HV Underground Cables: UK practice, pp137 161,
IEE PROC, Vol 129 Pt. A. No 3 May 1982.
6
IEEE 404-2006, Standard for Extruded and Laminated Dielectric Shielded Cable Joints Rated 2,500
V to 500,000 V, Institute of Electrical and Electronics Engineers, March 2007, ISBN: 0738152943.
7
IEEE 48-2009, Standard for Test Procedures and Requirements for Alternating Current Cable
Terminations Used on Shielded Cables Having Laminated Insulation Rated 2.5 kV through 765 kV or
Extruded Insulation Rated 2.5 kV through 500 kV, Institute of Electrical and Electronics Engineers,
August 2009.
8
ICEA S-108-720-2004, Standard for Extruded Insulation Power Cables Rated above 46 through 345
kV.
9
AEIC CS2-97 (6th Edition), Specification for Impregnated Paper and Laminated Paper
Polypropylene Insulated Cable, High Pressure Pipe Type, March 1997.
10
AEIC CS9-06 (1st Edition), Specification for Extruded Insulation Power Cables and Their
Accessories Rated Above 46kV through 345 kV ac, 2006.
11
IEC 60840 ed 3.0, Power Cables with Extruded Insulation and their Accessories for Rated Voltages
above 30 kV (Um = 36 kV) up to 150 kV (Um = 170 kV) - Test methods and requirements, April
2004.
12
Arkell C.A, Blake W.E, Brealey A.D.R, Hacke K.J.H and Hance, G.E.A, Design and Construction
of the 400 kV Cable System for the Severn Tunnel, Vol 124, No 3, Proceedings IEE, London.
13
Ray J.J, Arkell C.A, and Flack H.W, 525 kV Self-Contained Oil-Filled Cable Systems for Grand
Coulee Third Power Plant Design and Development, Paper T73, IEE, 1973, London.
14
Ray J.J, Arkell C.A and Flack H.W, 525 kV Self-Contained Oil-Filled Cable Systems for Grand
Coulee Third Power Plant Design and Development, IEEE Trans. PAS-93, 1974.
15
Arkell C.A, Johnson D.F and Ray J.J, 525 kV Self-Contained Oil-Filled Cable Systems for Grand
Coulee Third Power Plant Design Proving Tests, IEEE Trans. PAS-93, 1974.
16
Rosevear R. D and Vecelli B, Cables for 750/1100 kV Transmission, 2nd IEE International
Conference on Power Cables for 220 kV and Above, 1979, London.
ER 381
17
Foxall R.G, Bjorlow-Larsen K and Bazzi G, Design, Manufacturing and Installation of a 525 kV
Alternating Current Submarine Cable Link from Mainland Canada to Vancouver Island, Paper 21-04,
CIGRE Conference, 1984, Paris.
18
Cherukupalli S, MacPhail G.A, Nelson R.E, Jue J.S and Gurney J.H, Application of Distributed
Fibre Optic Temperature Sensing on BC Hydros 525 kV Submarine Cable System, Paper B1-203,
CIGRE Conference, 2006, Paris.
19
Minemura S, et al, Completion of Installation of 500 kV PPLP-insulated Self-contained Oil Filled
Cable Along Seto Ohashi Bridge for Honshu-Shikoku Interconnecting Transmission Line, Sumitomo
Electric Technical Review, 29, 1990.
20
EPRI Underground Transmission Systems Reference Book, Chapter 4, Cable Construction:
Extruded Dielectrics, 2006 Edition, EPRI, Palo Alto, CA:2007.1014840.
21
Toya A, Kobashi K, Okuyama Y, Sakuma S, Katakai S and Kato K, Higher-stress Designed XLPE
Insulated Cable in Japan, Paper B1-111, CIGRE Conference, 2004, Paris.
22
EPRI Underground Transmission Systems Reference Book, Chapter 8, Cable Systems
Accessories, 2006 Edition, EPRI, Palo Alto, CA:2007.1014840.
23
Attwood J.R, Gregory B, Dickinson M, Hampton R.N and Svoma R, Development of High Stress
HV and EHV XLPE Cable Systems, Paper 21-08, CIGRE Conference 1998, Paris.
24
Andersen P, et al, Development of a 420 kV XLPE Cable System for the Metropolitan Power
Project in Copenhagen, Paper 21-201, CIGRE Conference 1996, Paris.
25
Helling K, Henningsen C.H, Polster K and Schroth R.G, Power Supply for the City of Berlin: Are
380 kV XLPE Cables a Safe Alternative to Long-Time Proved LPOF-Cables?, Paper 21-106, CIGRE
Conference, 1994, Paris.
26
Henningsen C.H, Muller, K.B, Polster K and Schroth R.G, New 400 kV XLPE Long Distance Cable
Systems, Their First Applications for the Power Supply of Berlin, Paper 21-109, CIGRE Conference,
1998, Paris.
27
Kaminaga K, et al, Long Term Test of 500 kV XLPE Cables and Accessories, Paper 21-202,
CIGRE Conference 1996, Paris.
28
Ohata K, et al, Construction of Long Distance 500 kV XLPE Cable Line, Paper 31-36, Jicable
1999, Versailles.
29
Ohne H, et al, Construction of the Worlds First Long-Distance 500 kV XLPE Cable Line, Paper
21-106, CIGRE Conference, 2000, Paris.
30
Granadinor R, Portillo M, Planas J and Schell F, Undergrounding the First 400kV Transmission
Line in Spain Using 2500mm2 XLPE Cables in a Ventilated Tunnel: The Madrid Barajas Airport
Project, Paper A.1.2, Jicable Conference, 2003, Versailles.
31
Miller D, London Infrastructure Project, CIGRE Electra 206, PP 24-35, February 2002.
32
S Sadler, S Sutton, H Memmer and J Kaumanns, 1600 MVA Electrical Power Transmission with an
EHV XLPE Cable System in the Underground of London, Paper B1-108, CIGRE Conference, 2004,
Paris.
33
S. Sutton. R Plath and G Schroder, The St. Johns Wood-Elstree Experience- Testing a 20 km long
400 kV XLPE-Insulated Cable System After Installation, Paper A2.2, Jicable Conference, 2007
Versailles.
ER 381
34
Bjorlow-Larsen K, Del Brenna M, Kaumanns J, Meier R, Kirchner M and Argaut P, Large Projects
of EHV Underground Cable Systems, Paper A.25, Jicable Conference, 2003.
35
Argaut P, Bjorlow-Larsen K, Zaccone E, Gustafsson A, Schell F, Waschk W, Large Projects of
EHV Underground Cable Systems, Paper A.2.1, Jicable Conference, 2007.
36
Smith C, Galloway S, Gregory B, Lloyd S and Notman D, The Development of an Ultrasound
Quality Monitoring Process for the Manufacture of Enhanced Reliability HV and EHV XLPE Cables,
Paper A.2.6, Jicable Conference, 2003, Versailles.
37
Fudamoto K, Watanabe Y, Kish K, Uozumi T and Terayama A, Development of One-Piece Type
Joint (Self pressurized Joint) for 400 kV XLPE Cable, Paper A.1.3, Jicable Conference, 2007,
Versailles.
38
Kuwaki, A, Hayashi K, Kato, K and Imai N, Development of 400 kV XLPE Cable and
Accessories, Paper A.1.1, Jicable Conference, 2007, Versailles.
39
Kobashi K, Ban S, Kanaoka M, Yonemura T and Ninobe H, Completion of Prefabricated Joint for
500 kV XLPE Cable, Paper A.5.4, Jicable Conference, 2003, Versailles.
40
CIGRE Technical Brochure 338, Statistics of Underground Cables in Power Networks, Working
Group B1.07, December 2007.
41
EPRI Underground Transmission Systems Reference Book: 2006 Edition, EPRI Palo Alto,
CA:2007. 1014840.
42
Khajavi M.B, and Zenger W, Design and Commissioning Test of a 230-kV Cross-linked
Polyethylene Insulated Cable System, Paper A.1.1, Jicable Conference, 2003, Versailles.
43
Mikkelsen S.D and Argaut P, New 400 kV Underground Cable System Project in Jutland
(Denmark), Paper A.4.3, Jicable Conference, 2003, Versailles.
44
Jensen C and Argaut P, 400 kV Underground Cables in Rural Areas, Paper B1-211, CIGRE
Conference, 2006, Paris.
45
Rendina R, Posati A, Rebolini, Bruno G, Bocchi F, Marelli M and Orini A, The New Turbigo-Rho
380 kV Transmission Line: An Example of the Use of Underground XLPE Cables in a Meshed
Transmission Grid, Paper B1-302, CIGRE Conference, 2006, Paris.
46
Vavre J and Wanda M, 400 kV Vienna -The Vienna 400 kV North Input, Paper B1-101, CIGRE
Conference, 2006, Paris.
47
Matallana J, Gahungu F, Duvivier M, Dubois, D and Mirebeau P, 400 kV 2500 mm2 XLPE Cable
System Prequalification and Type Test for Middle East Environment, Paper A.1.6, Jicable Conference,
2007, Versailles.
48
Koreman C.G.A, Aanhaanen G.L.P, Van Rossum J.C.M, Koning R.F.F, Boone W and De Wild F.H,
Development of a New 380 kV Double Circuit XLPE Insulated Cable System in the Netherlands,
Paper B1-107, CIGRE Conference, 2006, Paris.
49
CIGRE Technical Brochure 379, Update of Service Experience of HV Underground and Submarine
Cable Systems, Working Group B1.10, April 2009.
50
Electra 151, Recommendations for Electrical Tests Prequalification and Development on Extruded
Cables and Accessories at Voltages of Greater than 150 kV and Less than Equal to 400 kV, CIGRE
WG 21.03, December 1993.
ER 381
51
CIGRE Technical Brochure 303, Revision of Qualification Procedures for HV and EHV AC
Extruded Underground Cable Systems, Working Group B1.06, August 2006.
52
Bolsa A et al, 'Prequalification Test Experience on EHV XLPE Cable Systems', Paper 21-104,
CIGRE Conference, 2002, Paris.
53
Technical Brochure 218, Gas Insulated Transmission Lines (GIL), CIGRE Joint Working Group
23/21/33.15, February 2003.
54
EPRI Underground Transmission Systems Reference Book, Chapter 7, Cable Constructions:
Special Applications, 2006 Edition, EPRI, Palo Alto, CA:2007.1014840.
55
Feldmann D et al, Development of a Directly Buried 400 kV Gas Insulated Line Technology, Paper
21/23/33-02, CIGRE Conference 2000, Paris.
56
Nojima T et al, Installation of 275 kV- 3.3 km Gas-insulated Transmission Line for Underground
Large Capacity Transmission in Japan, Paper 21/23/33-01, CIGRE Conference 1998.
57
J M Delcoustal, A Very large GIL Project: PP9, IEEE PES Summer Meeting Panel Session on GIL,
July 1997, Berlin.
58
J Alter et al, N2/SF6 Gas-Insulated Line of a New GIL Generation in Service, paper 21-204, CIGRE
Conference, 2002, Paris.
59
V. Piputvat et al, 550 kV Gas-Insulated Transmission Line for High Power Rating in Thailand,
Paper B1-107, CIGRE Conference, 2004, Paris.
60
P. Coventry et al, New Generation of GIL Characteristics and Applications, Paper B1-103, CIGRE
Conference, 2004, Paris.
61
D Kunze et al, Gas-Insulated Transmission Lines Underground Power Transmission Achieving a
Maximum of Operating Safety and Reliability, Paper A 3.6, 2007 Jicable Conference, Versailles
62
M. Tinkham, Introduction to Superconductivity, unabridged republication of Second Edition, 1997,
by Dover 2004, ISBN 0-486-43503-2.
63
BICC Cables, Electric Cables Handbook, Third Edition, Chapter 44, Introduction to
Superconductivity, Chapter 45, High Temperature Superconductors and Chapter 46, High
Temperature Superconducting Power Cables, Blackwell Science, 0-632-04075-0.
64
Technical Brochure 229, High temperature Superconducting (HTS) Cable Systems, CIGRE
Working Group 21.20, June 2003.
65
A Geschiere et al, Optimizing Cable Layout for Long Length High Temperature Superconducting
Cable System, Paper B1-307, CIGRE Conference, 2008, Paris.
66
A Geschiere et al, Installing a Long Distance HTS Cable, Paper A 3.3, 2007, Jicable Conference,
Versailles.
67
S Norman et al, Design and Development of Cold-Dielectric (CD) High-temperature
Superconducting Cable System for Bulk Power Transmission at Voltages up to 225 kV, Paper 21-205,
CIGRE Conference 2000, Paris.
68
M Nassi et al, Design Development and Testing of the First Factory Made High Temperature
Superconducting Cable for 115 kV 400 MVA, Paper 21-202, CIGRE Conference 1998, Paris.
69
J Ostergaard and O Tonnesen, Design, Installation and Operation of Worlds First High
Temperature Superconducting Power Cable in a Utility Power Network, Paper 21-205, CIGRE
Technical Conference 2002, Paris.
ER 381
70
S. Honjo et al, Verification Tests of a 66 kV High-TC Superconducting Cable System for Practical
Use, Paper 21-202, CIGRE Technical Conference, 2002, Paris.
71
M. Ichikawa et al, Demonstration and Verification Test Results of 500-m HTS Power Cable, Paper
B1-104, CIGRE Conference, 2006, Paris.
72
S.I. Jeon, et al, Development of Superconducting Cable System for Bulk Power Delivery, Paper
B1-06, CIGRE Conference, 2006, Paris.
73
HM Jang et al, Type Test Results for 22.9 kV 50 MVA HTS Cable System in Korea, Paper B1108, CIGRE Technical Conference, 2008, Paris.
74
D Lindsay et al, Installation and Commissioning of TRIAX HTS Cable, paper A.3.2, Jicable 2007
Conference, Versailles.
75
D Lindsay et al, Operating Experience of 13.2 kV Superconducting Cable System at AEP Bixby
Station, Paper B1-107, CIGRE Conference, 2008, Paris.
76
J-M Saugrain et al, Superconducting Cables Status and Applications, Paper A 3.1, Jicable 2007
Conference, Versailles.
77
F Schmidt et al, Development and Demonstration of a Long Length Transmission Voltage Cold
Dielectric Superconducting Cable to Operate in the Long Island Power Authority, Paper A.3.4. 2007
Jicable Conference, Versailles.
78
Argaut P, Bjorlow-Larsen K, Zaccone E, Gustafsson A, Schell F, Waschk W, Large Projects of
EHV Underground Cable Systems, Paper A.2.1, Jicable Conference, 2007.
79
Canadian Electricity Association. Forced Outage Performance of Transmission Equipment 2007.
80
IEC 60287-3-1: 1999. Electric Cables Calculation of the Current Rating Part 3-1: Sections on
Operating Conditions Reference Operating Conditions and Selection of Cable Type, Item 4.3.
81
Appendix 608 Technical Specification for the 240 kV Transmission Cable, Accessories and
Installation, Supply and Install Transmission Cable and Accessories for the Downtown Edmonton,
240 kV Supply Line. Item 8.3, page 10.
82
CEGB Design Memorandum 099/56, Current Rating Requirements for Buried Cables, 132, 275 and
400 kV Systems, Section 10, November 1968.
83
IEC 60287--1: 2006. Electric Cables Calculation of the Current Rating Part 1-1: Current rating
equations (100 % load factor) and calculation of losses General.
84
International Commission on Non-Ionizing Radiation Protection, Guidelines for Limiting Exposure
to Time-varying Electric, Magnetic, and Electromagnetic Fields (up to 300 GHz), (ICNIRP
Guidelines) Health Physics, Volume 74, Number 4, April 1998.
ER 381
APPENDICES
Appendix : Economic comparison of scenarios for the 500 kV underground cable feasibility
report
AESO
Revenue requirement
System energy loss
Discount rate used in net present value calculations
February, 2010
Distribution:
ER 381
Teshmont
Underground Cable Project. Case Study for Underground Cable Sections on the 500 kV AC Lines
Between Two Stations, Station A and Station B Heartland
Technical Memorandum 2074-002-147-Rev11
2010 February 10
Study Report Sections:
Executive Summary
1. Introduction
2. Shunt compensation
3. Study details (criteria and scenarios)
4. Network data
5. Results
6. Reactor requirements
7. Voltage profiles
Appendix A: Evaluation of Losses on the 500 kV AC Lines Between Station A and Station B
Appendix B: Case Study: Analysis of Scenarios without Shunt Compensation
ER 381
AESO
Transmission System Requirements, Heartland Project,
February 11, 2010
Appendix: Analysis of the minimum winter temperatures recorded on the 240kV DESS
circuit in Edmonton in 2009
ER 381
ER 381
ER 381
ER 381
---------------------------------End