Medium Voltage Cables
Medium Voltage Systems A worldwide leading player in the cable industry As a leading player in the high technology business of energy and telecom cables & systems, the Prysmian group has a strong position in higher added value market segments. It develops, designs, produces, supplies and installs a wide range of cables addressing the most diverse applications in both the energy and telecoms sectors. Specialising in the development of products and systems designed on the basis of clients’ specific requirements, Prysmian’s main competitive strengths include its focus on research and development (over 3,000 granted and filed patents overall), the ability to innovate its products and production processes, and the use of its own advanced proprietary technologies.
A global presence With its two businesses, Energy Cables and Systems (cables and systems for underground and submarine power transmission and distribution, for industrial applications and for the distribution of electricity to residential and commercial buildings) and Telecom Cables and Systems (optical cables and fibres and copper cables for video, data and voice transmission), Prysmian boasts a global presence with subsidiaries in 35 countries, 54 plants in 21 countries, 7 Research and Development centres in Europe, USA and South America and employs more than 12,000 people worldwide. This broad and diverse geographical distribution of manufacturing facilities allows Prysmian to respond more efficiently and effectively to the needs of local markets and customers.
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Cables from Delft With cable manufacturing experience since 1913, Prysmian Cables and Systems B.V. designs, manufactures, distributes and installs a wide range of cables and systems for the transmission and distribution of power at low, medium, high and extra high voltage for both land and submarine applications and for special industrial applications, together with a wide range of accessories for applications all over the world. Prysmian Cables and Systems B.V. initiated and patented pioneering developments related to extruded cable systems, such as the prefabricated stress cone and joint body (1965), the in-line cross-linking of extruded cables (1970), the Click-Fit accessories range (1990), the introduction of the environmentally friendly HPTE (High-performance Polypropylene Thermoplastic Elastomer) insulated medium voltage cables in the Netherlands (2010) and the production of HVDC land cables (2011) to name but a few. Furthermore Prysmian Cables and Systems B.V. can offer extended after sales Services such as: - 24/7 Emergency and Condition Based Maintenance; - On-site Fault Localization; - Diagnostics and Assessments; - Material Qualification; - Testing in our own HV Laboratory.
Environment and sustainability Management of its business on an environmentally sustainable basis is not just an ethical commitment for the Prysmian Group but a key factor in its very business competitiveness. Prysmian is constantly seeking not only to develop products with an ever lower environmental impact, but also to implement management and production processes that help improve the environmental sustainability of its business. In keeping with the contents of the specific policy document, approved and supported by the Chief Executive Officer in 2007, since then Prysmian systematically and continuously pursued all the fundamental activities for managing issues relating to the environment and the health and safety of its employees, introducing a few improvements to the instruments used for fulfilling these tasks. Prysmian has also set up a special committee, the Environmental and Safety Committee (ESC), which acts at management level by deciding objectives for improvement on the basis of information provided by the Health Safety & Environment (HSE) department
Prysmian products are designed to comply with all major national and international standards (e.g. NEN, IEC, CENELEC, BS, CEI, DIN VDE, ICEA, IRAM, NBR, NF, SABS, SFS, TSE, UNE, UTE, NBN, AEIC, ANSI, AS/NZS etc.) and with customer’s specific requirements.
The XLPE and HPTE cables produced at Prysmian Cables and Systems B.V. are environmentally friendly and safe to use. Furthermore the reduction of electrical and magnetic fields induced by the currents flowing through the conductors is minimized in smart system designs.
Thanks to an undisputed expertise developed over decades in servicing all major utilities anywhere in the world, Prysmian relies on a long-standing tradition of participation and on a strong presence within international scientific bodies– IEC, CENELEC and AEIC among others – to develop relevant standards, technical recommendations and guidelines.
Prysmian sets high standards
Innovation and quality
Prysmian Cables and Systems B.V. is certified in accordance with ISO9001:2000 Quality and ISO 14001 Environmental Management System standards for its activities.
The objectives of Prysmian’s Research & Development function are identifying innovative products and technologies, introducing new products onto the market services designed to expand the range on offer, and cutting production costs. The quality of Prysmian products is assured by means of strict monitoring of all phases of the production process, from raw material procurement to the delivered product, through a highly-developed control system for each specific phase of the cycle. The controls during the raw material procurement stage concern supplier selection and quality checks of the individual supplies, which have to be accompanied by special certificates proving that they conform to the standards specified during the contractual phase.
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Medium Voltage Systems Medium Voltage XLPE cable production The extrusion and curing of XLPE insulated medium voltage cables is performed in three separate steps, i.e.: In the first step, thermoplastic polyethylene with a catalyst already added to the mix is fed into the extruder. During this extrusion process the conductor-screen, insulation and insulation-screen are produced in one go inside the extrusion head. Then this combination of conductor and insulation is cooled to room temperature and placed on a drum. In the second step this combination of conductor and insulation (called a core) is placed inside a water tank at 80ºC, where cross-linking occurs. The main advantages of this type of processing are high extrusion speed, low odour level, storage stability and low equipment costs. In the third and last step the cable finishing is placed on the cable core. In case of medium voltage cables this is usually a copper wires screen and a polyethylene outer sheath.
Cable finishing Prysmian Cables and Systems B.V. offers a wide variety of cable finishings based on customer’s requirements, which includes the following: Single core medium voltage utility cables: - copper wires screen; - copper wires screen and laminated aluminium foil; - copper wires screen and laminated copper foil. Three core medium voltage utility cable: - copper wires screen. Single core industrial medium voltage cables: - lead alloy sheath; - steel wire armouring; - steel tape armouring; - welded aluminium sheath; - aluminium wire armouring. Three core industrial medium voltage cables: - lead alloy sheath; - steel wire armouring; - steel tape armouring. Apart from the standard PE outer sheath the following optional finishing can be produced by Prysmian Cables and Systems B.V. as well: - LSOH outer sheath; - PVC outer sheath. Some of the abovementioned finishings may also be combined, e.g.: Steel tape armour with a lead alloy sheath. If you have specific wishes concerning cable constructions and/or test regimes, please do not hesitate to contact us.
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Conductor types and range
Please note that the requirements of the NEN 3620 are more severe and the test program is extended to include more tests than listed in IEC 60502-2.
The maximum conductor size per material and type is as follows:
Routine tests
The conductor sizes mentioned in the tables are commonly used types.
Solid Stranded Milliken
Copper - 800 2500
Aluminium 1600 1600 2500
The minimum conductor size per type and voltage class is as follows: 10kV and 15kV Solid Stranded
Copper - 35
Aluminium 25 95
20kV Solid Stranded
Copper - 35
Aluminium 50 95
30kV Solid Stranded Milliken
Copper - 95 1000
Aluminium 150 95 1600
Special designs:
Besides offering special arrangements in accordance with customer requirements, each cable length is subjected to a final routine testing procedure based on NEN3620 before release, consisting of: - Measurement of the electrical resistance of the conductor; - High voltage test; - Partial discharge test. Insulation quality and life expectancy of a cable are related to the magnitude of partial discharges that might occur in a cable. The reliability of measuring results for these partial discharges greatly depends on the noise level caused by the surrounding environment. The discharge detection limit is improved by using an electromagnetically shielded room (Faraday’s-cage) for the execution of the partial discharge test.
Sample tests
Sample tests are performed in accordance with NEN3620 and/or customer requirements.
- Large conductor cross-sections up to and including 2500mm2 copper or aluminium Milliken constructions; - Oxidized wires for copper conductors; - Large solid round aluminium conductors up to and including 1600mm2; - Enamelled wires for copper conductors.
Test regimes As part of our quality system extensive tests are performed to guarantee our products fulfil the highest demands. Type tests reveal our cable designs to be outstanding and routine and sample tests prove that our cables conform to the highest standards.
Type tests
Prysmian Cables and Systems B.V. continuously performs type tests on MV cables according to the following Dutch standard: Middenspanning kunststof (MS): NEN 3620 (2003), “Kabel geïsoleerd met vernet polyetheen voor spanningen van 6kV tot en met 30kV”. This document is based on CENELEC HD620 S2, Part 10, Section J.
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Medium Voltage Systems P-Laser Product evolution During the years, after the undisputed supremacy held by impregnated paper, the evolution of insulation technologies and materials for Medium Voltage cables headed for extruded materials, at first thermoplastic PVC (soon given up because of reduced dielectric properties) and eventually cross-linked polyethylene. Introduced on the market in the early ‘80s, cross-linked polyethylene (XLPE), in particular, has completely replaced, since the early ‘90s, the still excellent impregnated paper insulation and is nowadays a fully consolidated technology, which relies on outstanding overall characteristics and performances (electrical, thermo-mechanical and installation) and a well-proven track record at all voltages. It appeared difficult, therefore, to find out something new, which could guarantee equivalent (if not improved) performances and introduce innovations and simplifications, given the technological goals achieved with XLPE. Prysmian, in its capacity as innovation leader, has taken up the challenge put forward by a mature technology as XLPE. The Company has therefore developed, thanks to its R&D facilities and a know-how acquired in more than 130 years of activity, an equally reliable new technology, with excellent mechanical, electrical and physical features and properties: P-Laser. The P-Laser technology, in addition to ensuring the same performances, the same excellent reliability and handling characteristics equivalent to the traditional XLPE cables, provides: - innovation for the network upgrading; - optimization of the Supply Chain and of the Total Cost of Ownership; - full recyclability of the product with lower environmental impact; - full compatibility of the cable with the existing network and the standard accessories. Furthermore, the product is conceived according to a modular architecture, which allows various design configurations depending on the specific customer’s requirements.
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Benefits and main characteristics Innovative product in terms of materials and production process: - High reliability and improved thermo-mechanical performances; - On-line protection of cable core during manufacturing process; Delivery time reduction and optimisation of Total Cost of Ownership: - Production process based on a single and uninterrupted line; - No degassing treatment needed, due to the new materials used; Eco-compatibility of the product and strong reduction of carbon footprint: - Fully recyclable materials and no gas emission in the atmosphere; - Lower soil occupation and reduced power consumption; Full compatibility with the existing electrical network and standard components.
Industrial process The product P-Laser uses a High Performance Polypropylene Thermoplastic Elastomer (HPTE) developed by Prysmian’s R&D laboratories and covered by patents and patent applications. P-Laser can be manufactured on a single and uninterrupted production line. Therefore, it is characterised by the complete product/ process integration, which allows to significantly streamline the supply chain and to considerably reduce the factory lead time, thus providing customers with remarkable advantages in terms of service, in addition to the excellent intrinsic characteristics of the product itself. The P-Laser cable can also be produced according to different metallic screen and outer sheath configuration requirements.
Technical Specifications XLPE
HPTE
Operating temperature
90°C
90°C (up to 110°C)
Emergency temperature
105°C
130°C
Dielectric losses
Tan∂(@90°C; 15 kV/mm) 185mm2 Three core cables 1.04 1.03 1.0 0.98 0.96 0.95 0.94
Rating factors for variation of installation depth for cables installed in ducts Installation depth [m] 0.5 0.6 0.8 1 1.25 1.5 1.04 1.02 1.0 0.98 0.96 0.95 Single core cables: ≤185mm2 1.05 1.03 1.0 0.97 0.95 0.93 Single core cables: >185mm2 Three core cables 1.03 1.02 1.0 0.99 0.97 0.96
S
Axial seperation of circuits Thermal resistivity [K.m/W] S Rating factors for variation of thermal 0.7 S resistivity of the soil and groups of direct 0.8 D buried single core cables, where the 0.9 S circuits are spaced 400 mm apart 1.0 D S S 1.5 2.0 2.5 S S D 3.0
1.75 0.94 0.92 0.95
Number of parallel cable circuits 1 2 3 4 1.37 1.21 1.08 1.03 1.3 1.14 1.03 0.98 70mm 1.24 1.09 0.98 0.93 1.19 1.05 0.94 0.89 70mm 1.00 0.88 0.79 0.75 0.88 0.77 0.70 0.66 0.79 0.70 0.62 0.59 0.73 0.64 0.58 0.55 70mm 70mm
S 0.7 1.25 250mm1.15 Rating factors for variation of thermal 0.8 1.21 70mm 1.11 resistivity of the soil and groups of single 0.9 1.17 250mm1.08 S core cables installed in ducts, where the 1.0 1.14 1.05 circuits are spaced 400 mm apart 1.5 1.00 0.92 S 70mm 2.0 0.90 0.83 S 250mm 2.5 0.83 0.76 3.0 0.77 0.71 S S
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Rating factors for variation of thermal resistivity of the soil and groups of direct buried three core cables, where the circuits are spaced 400 mm apart Rating factors for variation of thermal resistivity of the soil and groups of three core cables installed in ducts, where the circuits are spaced 400 mm apart
S S S
S
S S
S = axial separation of groups of cable D = cable diameter
S
1.06 1.03 0.99 0.97 0.85 0.77 0.71 0.65
1.03 0.99 0.96 0.93 0.82 0.74 0.68 0.63
1.05 1.01 0.98 0.94 0.82 0.74 0.67 0.62 0.99 0.97 0.95 0.94 0.85 0.78 0.73 0.69
1.01 0.97 0.94 0.91 0.79 0.71 0.65 0.60 0.96 0.93 0.92 0.90 0.82 0.75 0.71 0.66
70mm
0.7 0.8 0.9 1.0 1.5 2.0 2.5 3.0 0.7 0.8 0.9 1.0 1.5 2.0 2.5 3.0
1.28 250mm1.15 1.23 70mm 1.11 1.19 250mm1.07 1.15 1.04 1.00 0.9 0.90 70mm0.81 0.82 250mm0.74 0.76 0.68 1.17 1.08 1.14 1.05 1.12 1.03 1.10 1.01 1.00 0.92 0.92 0.85 0.86 0.79 0.81 0.75
Rating factors for single and three core medium voltage cables based on NPR3626 Rating factors for variation of ambient air temperature: Ambient air temperature [ºC] Value
15 1.14
20 1.1
25 1.1
30 1
35 0.95
15 1.0
20 0.92
25 0.83
40 0.90
Rating factors for variation of ground temperature Ground temperature [ºC] Value
5 1.14
10 1.07
S
Axial seperation of circuits Thermal resistivity S S [K.m/W] D 70mm S 0.5 Rating factors for variation of thermal 0.75 resistivity of the soil and groups of SS single core cables in flat 1.0 direct buried D S 70mm 1.2 D formation 70mm 1.5 S S
1 70mm 250mm Rating factors for variation of thermal 0.5 1.11 resistivity of the soil and groups of direct 70mm S core cables in trefoil 0.75 1.00 buried single 70mm 250mm 1.0 0.94 250mm 1.2 0.91 1.5 0.88 SS S Rating factors for variation of thermal resistivity of the soil and groups of direct 0.5 1.11 70mm buried three core cables 0.75 1.00 S 250mm 1.0 0.94 S 1.2 0.91 1.5 0.88 70mm
Number of parallel cable circuits 1 2 3 1.11 0.89 0.79 1.00 0.80 0.71 0.94 0.76 0.67 0.91 0.73 0.65 0.88 0.70 0.62 Number of parallel cable circuits 2 3 S pacing between trefoils [mm] 70 250 70 250 0.87 0.93 0.75 0.82 0.78 0.84 0.68 0.74 0.74 0.79 0.64 0.70 0.71 0.77 0.62 0.68 0.69 0.73 0.59 0.65 70 250 70 250 0.87 0.93 0.75 0.82 0.78 0.84 0.68 0.74 0.74 0.79 0.64 0.70 0.71 0.77 0.62 0.68 0.69 0.73 0.59 0.65
70mm 250mm 250mm
S
S S
S
S S
Disclaimer While reasonable care has been used in collecting and displaying information contained herein, Prysmian provides no express or implied warranty as to its accuracy, completeness, usefulness, use in any manner by users and disclaims any liability for errors or omissions herein. Information may be changed or updated without notice. Prysmian may also make improvements and/or changes in the products or information described in this brochure without notice. Prysmian assumes no liability, express or implied of whatsoever nature with respect to the use of any content thereof.
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Also available High and extra high voltage cable systems
150kV connection Connection Black Circuit length: ~4250 meter
Substation
Joint pit 1 ~725m
Joint pit 2 ~725m
Joint pit 3 ~685m
Transformer
Joint pit 4
Joint pit 5
~665m
~730m
System design
Complete system supply
We supply a complete range of accessories and fittings for splicing and terminating as well as tools and mequipment, for all of the high and extra high voltage classes. Combined with our planning and supervision of the overall system package and after sales services, you will not find a more suitable partner anywhere else.
Research, development and quality
The introduction of new cable systems with XLPE cables and accessories is preceded by an extensive mresearch and development program. Not only type tests, but also qualification tests and development tests are performed according to relevant standards and specifications. Of course all of these tests are performed in accordance with PRYSMIAN CABLES AND SYSTEMS B.V.’s quality system (ISO 9001:2000) and environmental system (ISO 14001). Prysmian Cables and Systems B.V. has prequalified its product range for the EHV voltage class in accordance with IEC62067, up to 500kV.
Contact
For more information concerning high and extra high voltage cable technology or our brochure concerning high voltage cables or Click-Fit accessories, please feel free to contact us via the information on the back of this brochure.
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Surface 1000mm
For each (E)HV project a specific design is created that fits the customers’ needs and fulfils any specific constraints: - Cable design; - Accessories design; - Functional requirements; - Standards; - Environmental conditions; - Thermo-Mechanical design; - Metallic sheath bonding arrangement; - Laying configuration.
~720m
1200mm
Prysmian Cables and Systems B.V. has been at the cutting edge of the of high voltage cable systems technology for several decades. We have experience not only in medium voltage cable systems but also supplying all types of high voltage cable systems throughout the world with full turnkey capability.
Components Symbol
Description
Type
High voltage cable
Qty
EYLKrvlwd 87/150 kV 1x1600Alrm
8000m
Earthing cable
1x185mm² Cu PE insulated
300m
Outdoor termination
OTC-170-X
3
Dry type termination
CFC-170
3
Joint with sheath interruption
CFJX-170
6
Straight-through joint
CFJ-170
9
Cross-bonding box
6SX-FS
2
300mm American projection
Scale: n.a. Dimensions in m 16-11-‘10
Drawn: M.R.H. Oltmans Dept. System Engineering Checked: J. van Rossum Customer
Po box 495, 2600 AL Delft Netherlands
150kV Cable connection
Drawing : SD10-41 Version: 1 quotation no.
Format:
520.10.0001/0
A3
Diagnostic & Testing Services Prysmian offers accessible solutions for corrective- and preventive maintenance, monitoring, services and emergencies, including: - (E)HV Site Acceptance Testing with Prysmian’s own mobile resonance test systems; - On-site dielectric diagnostics of MV, HV and EHV cable systems with: - Resonance testing; - Sinusoidal Damped AC (DAC) testing; - 24/7 emergency service; - Qualified personnel and expert equipment for jointing and maintenance of any existing HV cable system; - Qualified personnel and expert equipment for fault localisation and on-site diagnostics; - Knowledge and expertise in fault analysis and risk assessment; - Training in condition assessment and maintenance of cable systems; - Oil leak localization equipment; - Mobile oil refilling units for LPOF cable systems; - Oil degassing; - Contracts with suppliers and (civil) contractors for emergency services outside office hours; - Extensive emergency stock of cables and accessories; - Expertise in XLPE and LPOF cable systems; - Extensive knowledge and information concerning existing cable circuits; - Qualified personnel and equipment at Prysmian’s own High Voltage Research Laboratory (HRL), Material Laboratory (MLE) and Oil Research Laboratory in Delft (NL); - Close cooperation with the Delft University of Technology with respect to specialists and specialist equipment; - Cable load prediction system (CLPS); - Sheath Voltage Limiter (SVL) Monitoring System.
Contact
For more information concerning corrective- and preventive maintenance, monitoring, services and emergencies or our brochure concerning Diagnostic & Testing Services, please feel free to contact us via the information on the back of this brochure.
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Prysmian Cables and Systems B.V. | Schieweg 9 | Postbus 495 | 2600 AL Delft | Tel. 015 260 52 60 | Fax 015 261 38 08 | E-mail
[email protected] | www.prysmian.com
