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XLPE Cable Systems Users Guide.pdf

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XLPE Cable Systems User´s guide rev. 2 CONTENT XLPE Cable Systems Page Page Introduction........................................................................... 3 Cable drums..........................
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   XLPE Cable Systems User´s guide rev. 2  2  ABB CONTENT  XLPE Cable Systems Page  Introduction ...........................................................................3   XLPE cable systems - design, installation and testing  .......4 XLPE cables ......................................................................... Cable accessories ................................................................. Installation of XLPE cable systems ......................................5 Testing of XLPE cable systems .............................................   XLPE cable and cable system standards  ............................6 IEC ..................................................................................... CENELEC ............................................................................. ICEA .....................................................................................   ISO Standards ......................................................................  XLPE cable system configurations  ......................................7 Trefoil and flat formation ........................................................ Bonding of metallic screens ..................................................  Current rating for XLPE cable systems  ...............................8 Current rating for three-core cables, ampères ...................... Current rating for single-core cables, ampères ...................9 Rating factors ...................................................................11 Rating factor for cross section area of metal screen .......... Rating factors for ground temperature ............................... Rating factor for cables in pipes in the ground ...............12 Rating factor for cables installed in air ............................... Example of the use of rating factors .................................. Overload ............................................................................... Short-circuit currents ............................................................ Maximum short-circuit currents due to thermal restrictions .13 Dynamic forces at short circuits ............................................   Page  Cable drums ........................................................................14 Selection of cable drum ........................................................ Sizes and weights of wooden drums and steel drums .......15 Large and special drums .......................................................  Testing of XLPE cables  ..........................................................  Cable handling  ........................................................................ Minimum bending radius ....................................................... Maximum pulling forces ........................................................  XLPE Cable Design  ..............................................................16  Conductors ............................................................................ Standards - IEC and ICEA..................................................... Conductor water sealing .......................................................  Insulation  ................................................................................. Conductor screen ................................................................. XLPE insulation .................................................................17 Insulation screen ...................................................................  Metallic screen ........................................................................ Copper wire screen, standard design.................................... Copper wire screen, water tight design ................................. Lead sheath .......................................................................... Copper tape screen ..............................................................  Non-metallic outer sheath .................................................18  Conductive outer layer ..........................................................  Flame retardant outer layer   ....................................................  Fire behavior   ...........................................................................  Technical data for cables in the ABB XLPE cable system  .....19  Formulae  .............................................................................26 Support .................................................................................27  Checklist for Cable Inquiry  .................................................28 To make sure you have the latest version of this brochure, have a look at  www.abb.com/cables   ABB 3 Introduction Interfaces you can trust  ABB manufactures underground and submarine power cables up to the highest voltages available. Furthermore, we produce associated joints, terminations and other accessories for all types of cables. The products are designed to work perfectly together. Thus, we know  what we connect. Experience you can rely on  We have extensive experience of cable projects all over the  world, encompassing every aspect from planning to commis-sioning, including engineering, route surveys, cable-laying, installation and final testing. Very few manufacturers can point to such a long tradition in the high voltage field as ABB.  We delivered our first electrical cable in 1883 and introduced triple-extruded XLPE cables around 1970. In the early 1970s  we started to supply cables for over 100 kV and our first 245 kV XLPE cable was put into service in 1978. ABB has since then supplied more than 7,300 km of XLPE cables above 100 kV. Experience you can rely on. Research and development  ABB has always been a pioneer in the high voltage field and we have many world’s first and world records among our references. But there are no shortcuts to success. Maintaining our position calls for innovative research and development, backed up by the wealth of know-how we have accumulated over the years. One of the driving forces for our R&D is to meet the new and constantly increasing requirements from the power industry and a deregulated market. Today we aim to develop the solutions our custo-mers will need tomorrow. State-of-the-art manufacturing lines Experience and state-of-the-art expertise go hand in hand for us. We have been manufacturing cables for over 120  years and have since the beginning been one of the leading producers. Our factories are among the most modern in the world and our advanced quality system leaves nothing to chance. Every cubic millimeter of the cable has to be perfect. We design and produce cables in accordance with internationally approved standards or/and according to our customers’ specifications.This guide presents XLPE cables and systems for under-ground applications mainly. INTRODUCTION  XLPE Cable Systems  4  ABB  XLPE cable systems – design, installation and testing  XLPE cables Single- or three-core XLPE cables consist of the following components:ã Conductor - Copper (Cu) or Aluminium (Al) stranded compacted conductor or - Cu segmental conductor or - Cu or Al conductor with key-stone shaped profiles - Longitudinal water sealing of conductorã Triple extruded and dry cured XLPE insulation systemã Metallic screen Copper wire screen Copper tape screen Radial water sealing - Al or Cu laminate solidly bonded to outer polyethylene jacket or - Lead sheath Longitudinal water sealing of metallic screenã Non-metallic outer sheath - PE - PVC - Halogen free flame retardant - Co-extruded conductive layer over the sheath for special sheath testingã Armour - Single wire armour - Double wire armour Cable accessories  ABB’s line-up of cable accessories for ABB XLPE cable systems includes:ã Straight joints and joints with integrated screen separation for cross bondingã Transition joints for connection of  XLPE to fluid- filled cablesã Outdoor terminations with porcelain or composite insulatorsã Screened separable connectors for switchgears and transformersã Cable terminations for transformers and Gas Insulated Switchgears (GIS)ã Link boxes for earthing and cross-bondingã Distributed Temperature Sensing (DTS) Systems with integrated optical fibre in metallic tube (FIMT)ã Integrated optical fibre cable for control and communication, as an alternative to separately installed optical fibre cable. Especially suitable for 3-core submarine cables and for cables with a copper wire metallic screen. More information about our accessories is available on www.abb.com  XLPE CABLE SYSTEMS - DESIGN, INSTALLATION AND TESTING
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