W e lcom e !

to the Presentation fro m

Proton Products Ltd

“Manufacture of Triple Layer

Medium to High Voltage Cables”
Presented by:
Paul Sives, Tapio Hahko
& Jukka Karppo

Intercable meeting October 2001

Final solutions for medium voltage
power cable production

• Conductor stranding
and Screening Line
• Cabling Line

• Sheathing Line

• CV Line
1 – 66KV

• Auxiliary Equipment
 Medium Voltage up to 66KV Application

• Power Transmition over short

distances for medium sized
power consumption (city and area
distribution).

• Factory Power Transition for

Internal distribution.

• High Power consumption

equipment
 Requirements for medium voltage power
cables

1. Longevity
2. Resistance to Water Ingress
3. Should have some resilience to Rodent Damage
4. Environmental conditions must be considered (vibration,
temperature variation, contact with chemically active
components)
1. Thermal and fire Resistance
Typical example of Medium voltage Power
cable construction

PVC or HDPE
outer sheath
Cu wires
screen

Semiconductive
material tape

Outer semiconductive layer

with Al screen
Insulation

Insulation

Outer conductor layer Conductors inner

layers

Inner semiconductive layer

Conductor central
element
 CV against Silane process

CV- lines
• Simple Process
• Ready Mixed Materials
• One Step Finished Process
Curing Complete at Take Up
• Curing Quality confirmed
Immediately
Silane - lines
• Long Running Capability
• Silane dosing critical to process
• Proven Technology
• Two step curing process
• No Water Penetration to
(Insulation / Sauna)
Insulation
• Continuous production is
limited
• Due to curing technique, water
Penetration occurs
• Quality confirmation is delayed
• Limited Production range
•Hard requirements for safety during using
Silane and extra special equipment
 Technical characteristics CCV Line for
power cables 1-35 KV

•Conductor Cross section 25~630 mm2 (copper)

35~800 mm2(Aluminium)
• Diameter of the conductor 6~40 mm
• Diameter of the finished Cable 14~65 mm
• Voltage class 1~35 kV
• Max. weight of the cable 10 kg/m
• Line speed ~50 m/min
• Maximum temp of curing tube 450 C
• Working pressure 1~1.6 Mpa
• Wall thickness of inner semi-conductor 0.3~2 mm
• Wall thickness of insulation 2.5~12 mm
• Wall thickness of outer semi-conductor 0.3~2 mm
• Power consumption of the line 700 kVA
•Peroxide curing in an inert atmosphere Nitrogen
 Typical configuration of CV line for
MV power cable production
Main components and elements
ƒPay off stand (traversing on rails) type TF2500
ƒAccumulator S1600
ƒGuide roller
ƒCapstan RTE2000
ƒInner semi-conductor extruder type E65/20
ƒInsulation extruder type E150/25
ƒOuter semiconductor extruder type E90/20
ƒTriple layer cross head PROMAC-6
ƒHydraulic splice box
ƒCuring tube and support stand
ƒHeating and cooling system for the curing tube
ƒ Sag control device BRT 100
ƒ End sealing device
ƒ Caterpillar TR1800
ƒ Cooling trough PCT14-A
ƒ Belt type caterpillar TR1800
ƒ Tension control device
ƒ Take up stand (traversing on rails) type TS3200
ƒ Water level control device and pump
ƒ Electrical equipment and control system PROREG 2000
ƒ Nitrogen Station
 Portal pay offs type TF
(Driven or Non Driven)

Technical features

• Diameter range 6 ~40 mm

• Reel Types Din 1600 ~ 3200
• Max. weight 10 tons
• Traversing on rails base
• DC Drive Siemens / Eurotherm
• PLC Siemens or Mitsubishi

•Exact centring of pintles

•Wide range of reels width
•Up / Down lifting by DC motor
•Friendly design operator panel

Portal pay off type TF1800

 Accumulators type S

• Technical features

• Type horizontal
• Capacity 80-200 m
• Pulley Diameter 1200 -2400 mm
• Horizontal moving speed 2 - 4 m/min

Horizontal type accumulator S1600

•Easy loading
•Special material of grove surface
 Wheel capstan RTF

Technical features
• Diameter range 6 ~40 mm
• Pulley Size 1600 - 2500 mm
• Tractive Force 16 - 32 kN
• DC Drive Siemens / Eurotherm

•Easy loading and service

•Based on high quality roller bearings
•Built in accurate tension control system
Wheel capstan RTE2000
Inductive High Frequency Preheaters CAP

Technical features
Type induction, horizontal
Conductor diameter 6 - 40 mm
Power 100 - 130 кVA
Heating temeperature
- Al conductors till 120 С
- Cuconductors till 180 С

Induction preheater
CAP 100 •Increase adgesion
•Increase line speed for 10-12 %
 Extrusion cross head for triple layer
insulation type PROMAC
Technical features
• Conductor diameter 40 mm
• Diameter over insulation 80 mm
• Number of heating zones 3
• Heating / Cooling by water or oil

Scope of supply include

• Adapters for three extruders
• One set of Tools (according to customer’s size)
• Tool Extraction Device
• Pre-centering device
• Fluid tempering device included

•Carefully designed flow channels from Tip of Screw to the

die prevents dead flow spots avoiding scorching.
3-layer extrusion cross-head PROMAC-6
•Easy serviced
•Moving platform for dismountling of cross-head
 Extrusion group Е
Extruder 1 - E60-20 D
(inner semiconductive layer)
Extruder Е90-20D Screw diameter 60 mm
Screw length 20 D
Screw rotation speed 6- 60 r\min
Zones heating: 4х3.2kWт+5kW+1.4RkW
Output 45 kg\h
E Power consumption 30 кVА
x Extruder 2 (main) -E150-20 D
t
r (insulation apply)
u Screw diameter 150 mm
d Screw length 24 D
e
r
Screw rotating speed 9-45 r\min
Zones heating: 4х12kW+6.5kW+3kW+2.5kW+0.8kW
Output 250 kg\h (XLPE)
E150-24D Power consumption 160 кVА
Extruder 3 - E90-20D
(outer semiconductive layer)
Screw diameter 90 mm
Screw length 20 D
Extruder Е60-20D Screw rotation speed 6- 60 r\min
Zones heating: 4х4.3kW+6.8kW+2.1kW
Ooutput 65 kg\h
Power consumption 50 кVА
•Special design of screw geometry (patented by Protom Products)
•Exact temperature and presure control of mass for each zone
•Easy service
Curing tube and splice box
Curing Tube
Number of heating / cooling zones up to 8 (depend from
products and standards
requirements
(Independent thermocontrol for each zone)
Position detection Induction coil detectors over
lenghth of the line
Inside tube atmosphere Nitrogen
Working presure 1.5 - 1.8 mPa
(Presure control in accordance with EU standards )
Cooling water
Heating induction
Tube material I Cr18Ni9Ti

Splice box
Angle 15-21
Construction telescopic,
hydraulicaly operated
Water consumption 4 l \min
Working presur 6.3 - 6.8 мPa
Actual moving length 800 mm
 Nitrogen Production

The Nitrogen Station generates

a sufficient flow of Nitrogen for one
CCV Production line. It comprises:

•Pumping station

•Nitrogen storage tank

•Nitrogen creation unit.

Nitrogen station
 Caterpillars TR

Technical features

• Max cable diameter 75 mm

• Max puling force 17кN
• Actual pressing length 1800 - 2800 mm
• Number of cylinders 6 - 10 pair
• Cylinders type pneumatic
• DC Drive Siemens / Eurotherm
• PLC Siemens / Mitsubishi

•Belt profile and material provide long using time and

eliminate any slipping of the cable
•Include length /speed measuring system
•Have safety device against big insulation lumps

Belt caterpillar TR1800

 Portal Take ups TS

Technical features
• Reel Size Range 1.6 m – 3.6m
• Maximum weight 18 tons
• Cable Diameter Range 5 - 75mm
• Traverse Range 5 – 78mm
• Traverse method on rails base
• Drive DC Siemens / Eurptherm
• PLC Siemens / Mitsubishi

• Exact centring of pintles

Portal take up TS 2500
•Wide range of reels width
•Up / Down lifting by DC motor
•Friendly design operator panel
•Accurate winding of the cable as result of using
positioning traversing detectors
Measurement systems
SIKORA

Technical features
Measuring parameters
- Diameter
- Wall thickness
- Eccentricity
Cable diameter range 50 - 160 mm
Accuracy +- 50 microns
Scan frequency 250 scan\sec
 Electrical equipment and Control system
PROREG 2000
•Electrical equipment include complete set of electrical
cabinets with drives and main line power distribution
system

Control system PROREG 2000

•Monitoring of stability of technological parameters and immediate
reaction for the changes
- Zones temperature control of extruders
- Section control of temperature profile in curing tube
- Control of rotation speed of screw for 3 extruders for sure of
stability of the triple layer insulation process
- Tension control
- Position control of the cable in curing tube
- Cable diameter, etc.

Control
•Provide 100 % synchronisation of line parts depending from value of
technological parameters and their changes
system
PROREG 2000 •Monitoring and alarm system for case of technological parameters
achieving their critical value or parts of line fault

•System of creating and storage technological recipes using

built in computer data bases

•Operator panel - “Touch screen” with friendly designed interface and

3-level enter to the system

•Automatic calculation of cure rates for different products

 Conductor
• Successful cable manufacturing begins of a good conductor.
• Construction has to be correctly dimensioned according to standards, Since the
standards define the maximum resistance of each cross-section it takes some
learning to find a right compacting degree after each cage in the strander to
minimize the use of metal.
• The conductor must be kept clean from oil and water and other dirt.
• Outer layer should be as tight as possible.
• Especially dangerous are thorn-like protruding chips from surface.
• Good quality reels are important to maintain the conductor in good condition.
In wooden reels must be no spikes or resin.
• In certain cases, say, with short lengths, if it is not possible to make a
conductor tight enough or if there is other surface defects, it can be wound with
semicon tape.
• Different conductor constructions.

• (See the next page pictures for better view )

 Conductor construction

Normal lay-up Compacted Solid shaped conductor

Low loss conductor for Circular Stranded shaped

oil-filled cables hollow conductor,
(Milliken conductor) compacted
 Extrusion

After successful manufacturing of the conductor, it will require three

layers extruded around it. Two semi conductive, inner and outer and
one insulation layer between them.

• The layers can be extruded in tandem or in triple head in one go, which
is mostly used nowadays because of its obvious benefits.

(See the next page pictures for better view )

Three Layer insulation cable construction
 Semi Conductive Materials

• Semi conductive materials are used to control electrical field on both conductor
and insulation outer surface.

• Material is copolymer, highly hygroscopic, containing 30 to 40 % carbon black.

Therefore it has to be maintained dry and usually dried before use.

• Border between the semicon and insulation layer must be smooth as ever to
avoid electric field concentration.
 Field strength Factor

F ield S tren g th F acto r F

20

18 a. c
b
2 2
16 a c
F 1
14 r c
b
12
a a
r = 0.01
10
F

r = 0.09

8 0.5
r
c a. 1
a
6

4 Insulation
d Conductor (a c)
2
b 0.5 ln
Semi-Conductor (a c)
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4

a mm
 Insulation Materials

Most of the high voltage cables are insulated nowadays by polyethylene, only a minor
portion uses other material like rubber.

Polyethylene is a partially crystalline substance created by polymerizing long

hydrocarbon molecules. It is rather pure hydrocarbon. In some manufacturing
processes ash content may be under 0,01 % of weight.

Polyethylene’s can be divided by density in to LD and HD. Also it’s possible to make
a division in to linear and branched types.

The latter division describes the molecular structure and it has a connection point
with a former division. The crystallization degree of polyethylene grows along with a
density of PE and the crystals form over-structures, spherulites. These have
apparently important part to the properties of polyethylene as penetration of gases or
liquids, mechanical and electrical strength, and chemical resistance e.t.c.
Polyethylene Structure
 Affect of temperature
on Material properties

45 175
Q 96 D E N S IT Y H E A T C O N D U C TIV ITY S P E C IFIC H E A T
150
40

Q 91 125
1 1 1
35
2 2 2
100
Q 86
30 CP
ρ
λ 75

Q 81
25 50

Q 76 20 25
20 60 100 140 180 25 50 75 100 125 150 360 370 380 390 400 410

ϑ°C ϑ°C  °K

As attached pictures indicate, are both LD and HD polyethylene’s density, specific heat,
elasticity and heat conductivity quite considerably dependent on temperature.
 Different types of insulation defects
Defect
• Protrusions on the semiconductive layers
(conductor or insulation shield)
• Stripping void between the insulation and
semiconductive layers (conductor and insulating
7
6 1
shields)
1 2 • Voids
8
2
Moisture
9 Impurities (Metal, Amber)
3
9
4
Examples of deterioration resulting from defects
9
• Water tree from conductor shield
5
• Water tree from insulator shield
• Electrical tree caused by partial discharge

Insulation material has to be handled carefully too, dirt kept away and water condensation prevented
in cold climate after taking the bags into a warm• space.
There are quite a number of possibilities to make considerable mistakes in extrusion process which
may cause damage to cable construction immediately or after some time in use. In the picture are
gathered the most typical ones.
 Breakdown field as a function of
temperature by various polymers
1600

1400

1200

PVA
PM M A
1000
P V C -A C
PVC
V o lts/m m

PS
800 LO P E
P IB
E -P
600 A pp
PA6
Ip p

400

200

0
-200

-180

-160

-140

-120

-100

100
-80

-60

-40

-20

20

40

60

80
T em p C 0

Attached picture indicating the breakdown voltage for various materials confirms the excellence of
PE. The values are of course theoretical and cannot be used in cable designing.
 Vulcanising
Various methods are known for vulcanizing (X-linking) of the cable insulation. Like steam and oil
curing systems. Also so-called long die system is used and even x-ray systems.

Dry curing method using pressurized nitrogen inert gas inside the tube is most commonly used today.
Pressure is needed in order to avoid bubble forming in the insulation.

The reason why we want to go with this kind of laborious and expensive method is that the
mechanical strength of the LDPE can be increased in higher temperatures. E.g. an operational
temperature of the conductor is raised from 70 to 90 deg C and 5 sec short circuit temperature will be
250 deg C.

The material used for cross linking today is organic peroxide which is mixed with polyethylene.
When PE is heated up peroxide starts decomposing forming radicals, which from their part create
chemical bonds with previously seen molecules . The reaction is so called first degree chemical
reaction meaning that in certain temperature dependant half-life, half of the remaining peroxide
decomposes. (See the picture of “Affect of chemical reaction” )
The temperature dependency of the half-life is given in the picture of “Half-life of Vul-cap vs
Temperature” , e.g. where at 160 C it is c. 10 min and in 182 C it is c. 2 min.

In the successful vulcanizing process, every point of the cable cross-section in the insulation should
reach 4 to 5 half- lives when the amount of decomposed peroxide is c.95%
In order to define the connection between the time and the temperature in different layers of the
insulation, we need to have a some sort of a calculation method.

As a curiosity of this from early 1970ies, can be shown measurement curves of an arrangement of an
analogic calculation in which electric resistance resembles of heat transfer resistance and a capacitor of
heat mass. (See the picture of “Heat transfer Resistance” )

Currently computers are used for the calculations.

Heat transfer calculations are done so that the cable is divided into coaxial layers. Between those
layers heat transfer is calculated. (See the picture of “Grid for calculation of temperature in the insulation” )

With given formulas it is possible to solve temperature distribution in relation to time.

As seen from the formulas, we need to know the material parameters as, density, specific heat and heat
conductivity. As shown previously, the parameters are temperature dependent.
This means that the calculation must take into account the prevailing temperature at each point and
choose corresponding value of each parameter curve.

As far as said parameters are correct, the calculation is fairly simple providing that the cable
surface temperature is known or predicted.

In the dry curing process heat transfers to the surface of the cable from hot tube by two means, by
radiation and by convection. Theoretically taken, the radiation can be calculated quite exactly.

However, since there is nitrogen inside the tube as a protective inert gas, there forms eddies which
can not be calculated. (See the picture of “Eddy Current” )
Moreover these eddies change the temperature distribution in the cross section of the tube. Thus
the basis of the radiation calculation changes too.

It has been observed up to 50 deg C temperature differences This is significant because the
radiation energy follows the 4th power of temperature. Therefore, even the most refined calculation
software’s are only giving direction and every new cable type run has to be carefully tested as to
it’s vulcanization degree.

When cable layers temperature has been calculated and are now known by function of time , it is
possible to calculate the amount of decomposed peroxide
 Affect of chemical reaction

% of Original Peroxide Decomposed

Number of Half-Lives or % of ultimate Cure State
1 50
2 75
3 87.5
4 93.75
5 96.9
6 98.4
7 99.2
8 99.6
9 99.8
10 99.9
 Half-life of Vul-cup
vs Temperature
100

10
Half-Life, Min

PE,EVA
EPDM,EPM
NBR
SOLUTION

0.1
280 300 320 340 360 380 400
Temperature, C
 Heat transfer resistance
2 00

1 80 R0 R1 R2 R3 R4 R5

1 60
U0 C0 C1 C2 C3 C4 C5 U1 U2
1 40

1 20
Tem p C

1 00

80

60

40

20

0
WATER
0 0 .5 1 1 .5 2 2 .5
T im e S e cs
Grid for the calculation of temperature
in the insulation

l+2
r0 l+1
l
rL z
l-1
r

__
n=0 n=1n=2 N T NT+1
_
Insulation
Core
 Eddy Currents

Eddy current scan

Definition of Vulcanizing Degree by Extract Test

The picture “Decomposition vs Gel Content” indicates the amount of gel content in relation to
decomposed peroxide.

When peroxide decomposes various by-products will emerge.

Non of those substances have been proven to be hazardous to health. For example, one of the
major component is known to be used in perfumes. Just vulcanized cable may contain 1% of
those by-products. It takes a long to time to get the gases extracted from the cable in the ambient
temperature.

Every time when cable run is started one must check the physical dimensions and make the hot-
set test to the insulation.
 Decomposition vs Gel Content
100

90

80

70
Gel Content %

60

50

40

30

20

10

0
0 20 40 60 80 100

Decomposition %
 Post vulcanizing cooling

Extruder
80-90 °C
Trap
Water

After the vulcanizing process cable has to be cooled before it comes out from the tube. The lower
voltage cables are cooled with water and higher voltage cables by nitrogen. The most important
criteria of cooling is the maximum conductor temperature at the outlet, Being typically 80 to 90 deg
C.
 Cable Structures
As in every electrical appliance, also in the cables, water penetration poses dangers.

Before prevailed a belief that PE made an exception in this respect. Therefore people neglected
proper designing of the cables. Two pictures illustrate the difference of the construction of the
same factory from 70ies to 90ies. (See the picture of “Cable contruction-1970s” & “French
contruction cable” )

It did not take for long before it was noted that the influence of external moisture to unprotected
cables increased the break-down frequency drastically.

Because of the capacitive currents, the cable has to be clad by metal coating. Therefore it should
be carefully considered how it can be made to prevent water penetrating inside the cable.

One good example is French construction. (See the picture of “French contruction cable” ).
In this triple-insulated conductor insulation is grooved from outer surface and is powdered with
swelling powder before laying-up of a longitudinal aluminum tape. When overlapping is also
sealed with hot melt, the cable becomes almost hermetical.

Some countries are using CU-band wrapped around the cable but this does not make the cable
water impervious.

In actual high water cables only extruded or welded hermetical metal sheath is accepted.
Cable construction - 1970s
 French construction cable
PVC sheath
Sealed Lacquer
Al. Foil

Swelling powder

Strippable insulation
shield

Insulation

20KV XLPE cable of the French EDF Conductor screen

Al. conductor
Typical example of Medium voltage Power
cable construction

PVC or HDPE
outer sheath
Cu wires
screen

Semiconductive
material tape

Outer semiconductive layer

with Al screen
Insulation

Insulation

Outer conductor layer Conductors inner

layers

Inner semiconductive layer

Conductor central
element
 Examples of cable medium voltage cables
construction

Copper wire screen, Copper wire screen, Lead sheath Copper tape screen
standard design water tight design

The cable standards do not usually cover the construction after the triple insulation,
only national standards exist. Example of different cable constructions.
 Standards

The following review concerns European standards. (Pict.39)

The standards determine the insulation thickness only up to 30 kV. They are:

- 10 kV = 3,4 mm
- 15 kV = 4,5 mm
- 20 kV = 5,5 mm
- 30 kV = 8,0 mm

The thicknesses for higher voltages are only determined nationally.

Because it is the field strength in the insulation, which is a primary factor for break-downs in the
cable, it can be seen that the given thickness values are fairly big in
comparison to power transmission figures of higher voltage cables. E.g. 20 kV cable may
typically have a transmission capacity of 10 MW whereas 400 kV cable has 1000 MW capacity.

So the importance to power transmission economy is 100 bigger in case of 400 kV cable. But as
seen in the picture St 1, the field strength in this more important cable is 4 times higher exposing
it to higher damage risk.
 Electrical Stress in service
400

275

220
Rated Voltage KV

150

132

110

60

30

20 Emean

Emax
10

0 2 4 6 8 10 12 14
Service stress E [KV/mm]
 Thank You
for Your attention !

Proton Products
10, Aylesbury End
Beaconsfield
Bucks, UK
Phone: +44 1494 670 606
Fax: +44 1494 670 808