The Invisible Supply of Reliable Power Power Cables MV, HV & Ehv

THE INVISIBLE SUPPLY OF
RELIABLE POWER
POWER CABLES
MV, HV & EHV
NIGEL HAMPTON
LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004
CONTENTS
DEFINITIONS
CABLES IN POWER TRANSMISSION
HISTORICAL PERSPECTIVE
KEY TECHNICAL ISSUES
LOSSES, TEMPERATURE OF OPERATION, PARTIAL DISCHARGES
RELIABILITY
HOW DO WE MEASURE IT
WHAT REDUCES IT
EFFECT OF WATER TREES ON MV RELIABILITY

EFFECT OF CONTAMINANTS ON SIZE OF HV CABLES
CONCLUSIONS
DEFINITIONS
MEDIUM VOLTAGE
6 - 36kV
MV
HIGH VOLTAGE
36 - 161kV
HV
EXTRA HIGH VOLTAGE

>161kV
EHV
45
40
EUROPE - ALL VOLTAGES
35
30
25
20
15
19
59
19
64
19
69
19
74
19
79
19
84
19
89
19
94
19
95
19
96
19
97
19
98
19
99
AMMOUNT OF ENERGY
TRANSMISSION UNDERGROUND
(%)
CABLE USAGE INCREASES
SOURCE: ICF
FAULT STATISTICS - NORDEL 1990 - 1999

2000
CABLES
OVERHEAD
1500
OTHER
1000
STATION
EQUIPMENT
LINE FAULTS
CABLE FAULTS
<0.8% OF LINE FAULTS
500
DENMARK, FINLAND, ICELAND, NORWAY, SWEDEN

ENGERGY LOSS STATISTICS - NORDEL 1990 TO 1999

6%
3%
47%
44%
OVERHEAD
STATION EQUIPMENT
OTHER
CABLE
DENMARK
FINLAND
ICELAND
NORWAY
SWEDEN
IF CABLES ARE SO GOOD WHY ARE THERE SO

FEW?
COST CABLES HAVE HIGHER CAPITAL COST
CAPITAL
LIFETIME COST
OHL = 1
OHL = 1
CABLES = 3 10
CABLES = 0.9 4
CURRENT RATING CABLES HARDER TO COOL THAN OVERHEAD LINES,

THUS MORE CONDUCTOR REQUIRED FOR THE SAME CURRENT APPROX
2 CABLES= 1 OHERHEAD LINE
AVAILABILITY FAULT RATE & REPAIR TIME
CABLE SYSTEM
OHL SYSTEM
FAULT RATE
#/YR/100KM
0,1
15
REPAIR TIME
DAYS
7
0,01 - 0,1
AVAILABILITY
DAYS/YR/100KM
0,7
0,15 - 1,5
CABLE VOLTAGE (kV)
POWER CABLE DEVELOPMENT

550
500
450
400
350
300
250
200
150
100
50
0
FIRST CABLE
USED TO BLOW
UP A FORTRESS
DC CABLES INSULATED
IN RUSSIA
WITH STRING
1800
RUBBER CABLES
FIRST
OVERHEAD
LINE
PAPER
1820
1840
1860
1880
1900
1920
1940
CABLE VOLTAGE (kV)

FIRST SCREENED CABLE HOCHSTADTER
550
PRESSURISED
500
FERRANTI PAPER CABLES
450
400
10kV
350
TUBULAR
300
CABLE
250
WITH
200
PAPER
150
100
50
0
1880
1900
1920
1940
FIRST USE OF PVC IN GERMANY

WIDESPREAD COMMERCIAL
USE OF PVC
PAPER
POLYTEN
PEX
1960
1980
2000
2020
HIGHEST VOLTAGE IN
HYDRO PLANTS
PAPER - GRAND COULEE
XLPE - DACHAOSHAN
CABLE VOLTAGE (kV)

550
500
450
400
350
300
250
200
150
100
50
0
EUROPEAN
EHV GRID
1940
PAPER
EHV IN
EUROPE
EHV IN JAPAN
PE & XLPE
WONDER
MATERIAL
WTR - US
COPOLYMER - EUROPE
POLYTEN
PEX
1950
WATER TREES - MV
CONTAMINANTS - HV
1960
1970
1980
1990
2000
2010
3 CORE
SUBSEA
CABLE
ARMOUR
FILLERS
NO METAL SHEATH
SO IT IS CALLED
A WET TYPE
ALUMINIUM CONDUCTOR
COPPER WIRES TO CARRY

LOSS AND FAULT CURRENT
ALUMINIUM FOIL TO
KEEP OUT MOISTURE
CAPACITANCE
C = 2 r / ln (R/r)
units - Farads/m F/m

= 8,854 E 12
F/m
r = relative permittivity
6-7
3,5
2,3
PVC
EPR
XLPE
DIELECTRIC LOSSES
W = C U2 TAN
x
units - Watts/m W/m

0,08
0,004
0,0003
0,003
PVC
EPR
XLPE
PAPER
LOSSES 1
1000SQMM CABLE
LOSS (W/m)
25000
EPR
PAPER
XLPE
HIGH LOSS XLPE
20000
15000
10000
5000
0
0
10
20
30
40
50
60
70
AVERAGE STRESS (kV/mm)
LOSSES 2
MAX
INSULATION
TEMPERATURE
TEMPERATURE DIFFERENCE
MAX
GROUND
TEMPERATURE
CABLE
SURFACE
BEDDING
SOIL
OR
AIR
CONDUCTOR INSULATION
METAL SHEATH
ARMOUR
LOSSES 3
= (2R + W)
CONDUCTOR
R = CONDUCTOR RESISTANCE
DIELECTRIC
R = R/ ( 1 + S + R)
R/ = R20 (1 + (20))
W = DIELECTRIC LOSS
W = C U2 TAN
T = THERMAL RESISTANCE
T = (/2) LN (1 - (R-r)/r)
= THERMAL RESISTIVITY
RATINGS LIMIT
THE LENGTH OF CABLES
LOSSES 6
3,0E+08
2,5E+08
DIELECTRIC
10kV/mm
TOTAL
2,0E+08
1,5E+08
1,0E+08
TOTAL
5,0E+07
150
140
130
110
100
90
80
70
60
50
40
30
20
10
0,0E+00
120
DIELECTRIC
5kV/mm
LOSSES (W)
DC NEEDED FOR LONG LENGTHS
CIRCUIT RATING
LENGTH (km)
RELIABILITY
IMPULSE
GENERATOR
HIGH VOLTAGE
AC TEST SET
TEST
TERMINATIONS
BREAKDOWN - 400kV 1600mm2 25mm XLPE JICABLE 1995 A1.4

AC
710
805
860
655
710
710
IMPULSE
1575
1675
1725
1850
1900
GENERAL FORM OF ANALYSIS IS WEIBULL ANALYSIS
WEIBULL DISTRIBUTION
(E E loc )
Pfailure = 1 exp
EC
WHERE:
PFAILURE - CUMULATIVE PROBABILITY OF FAILURE
E
- APPLIED ELECTRICAL STRESS
ELOC
- OPTIONAL LOCATION PARAMETER;
OFTEN REFERRED TO AS THE THRESHOLD STRESS
EC
- SCALE PARAMETER; THE STRESS WHICH
GIVES A PROBABILITY OF FAILURE OF 63%
- SHAPE PARAMETER; THE GRADIENT OF THE

WEIBULL CURVE
AC
TAT @ 2Uo
463kV
0,26% CHANCE
OF FAILING
IMPULSE
TAT
1425kV
1,6% CHANCE
OF FAILING
PROBABILITY OF FAILURE
ENDURANCE TESTS
0,99
50kV/mm
33kV/mm
0,66
0,33
MODEL
TRANSMISSION
CABLES
0
0,1
10
100
1000
10000 100000
TIME TO FAILURE (HOURS)
100
FAIL ON TEST
NO FAIL ON TEST
80
60
40
1,E+06
1,E+05
1,E+04
1,E+03
1,E+02
1,E+01
1,E+00
1,E-01
20
1,E-02
MEAN ELECTRICAL STRESS

(kV/mm)
ENDURANCE CURVE - COLD - MODEL TRANSMISSION CABLES
TIME (HOURS)
CABLE VOLTAGE (kV)
RELIABILITY - WATER TREES

500
400
300
200
100
0
1950
PE & XLPE
WONDER
MATERIAL
1960
WATER TREES - MV
CONTAMINANTS - HV
1970
1980
1990
INVESTMENTS IN CABLE QUALITY

BRING HIGHER RELIABILITY
STEAM CURE
GRAPHITE SCREEN
PVC SHEATH
STRIPPABLE
SCREENS
NO STEAM CURE
4
PE SHEATH - NO PVC
AL FOIL
00
20
98
19
96
19
94
19
92
19
90
19
88
19
86
19
84
19
82
19
80
19
78
19
76
19
74
19
72
19
70
0
19
CABLE FAILURE RATE

(# / 100km / YEAR)
XLPE CABLE FAILURE RATE
YEAR OF MANUFACTURE
12 & 24kV CABLES, SINTEF, NORWAY
ASTM D 6097 Ashcraft Test

Largest Vented Trees After 30 Days at Room
Temperature
CLASSIC
0.750 mm STREAMER TREE
ENHANCED
0.300 mm CONSTRAINED TREE
WHAT CAUSES THE PROBLEM?
HIGH LOCAL FIELDS TREES GROW FASTER CONTAMINANTS

WATER
IN APPROPRIATE MATERIALS
TEMPERATURE GRADIENTS
TRANSIENTS
HOW DO WE KNOW THAT THE PROBLEM IS SOLVED??

ACCELERATED TESTING
HOW DO WE KNOW THAT WE ACCELERATE THE RIGHT MECHANISM?
BREAKDOWN STRENGTH (Uo)
USEFULNESS OF 2 YEAR CENELEC TEST

35
MEURER ET AL, JICABLE03
30
FAREMO ET AL, JICABLE 03
25
20
15
10
5
0
NEW
1 YEAR
2 YEAR
21
19
Breakdown [U/Uo]
Monthly average
Year average
17
15
13
11
9
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999
Production year of the cables
Results of the cable production monitoring in Germany according to DIN-VDE 0276-620
F. MERSCHEL, Kabel seminar, Hannover 2002, updated presentation
SMALLER SIZE (HIGHER STRESS) BUT SAME

RELIABILITY - CONTAMINANTS
SIZE > CAPITAL & INSTALLATION COST
SIZE > 1/TEMP > 1/RATING > OPERATING COST
SIZE > 1/HANDLABILITY > INSTALLATION COST
THICKNESSES OF TRANSMISSION CABLES
THICKNESS (mm)
25
20
15
10
66
132
154
5
0
1965
1970
1975
1980
1985
1990
1995
2000
2005
ELECTRIC FLUX / ELECTRIC FIELD ENHANCEMENTS

SURFACE ROUGHNESS AND
DISCONTINUITIES IN THE INSULATION
AFFECT WHERE THE ELECTRIC FLUX LINES GO
IN SOME AREAS THEY ARE CLOSER IN SOME
THEY GET FURTHER APART
THE AVERAGE DENSITY IS ALWAYS THE SAME
WHEN THE ELECTRIC FIELD GOES UP
IN ONE AREA IT MUST GO DOWN IN ANOTHER
WHY WORRY ABOUT THIS IF IT GOES UP IN

ONE AREA BUT IS COMPENSATED IN ANOTHER?
PARTICLES INSIDE CABLE INSULATION
BREAKDOWNS INSIDE CABLES
BREAKDOWN STRENGTH vs SIZE OF CONTAMINANTS

Cable breakdown strength 63% probability [kV/mm]
300
250
IMPULSE
200
150
AC
100
50
0
20
40
60
Contaminant size (microns)
80
100
CONTAMINANT CONCENTRATION & CABLE BREAKDOWN

Probability
ofof
Failure
Probability
failure(%)
CDF%
90
W/rr
70
63,3
50
30
20
IMP 5
AC 5
10
5
IMP 25
2
1
AC 25
10
100
Breakdown stress kV/mm
1000
MODEL CABLE DATA
STRESS ENHANCEMENT - SHAPE & PERMITTIVITY

20
Field increase factor [n]
R
16
2a
R/a=0.01
12
R/a=0.1
R/a=1
4
0
1
Feature permittivity
100
Size Affects Electrical Requirement

8
7
Average stress
6
5
4
Volume
3
Requirement
2
1
0
12
14
16
Wall thickness
18
20
22
Reference case - 2000mm2 150kV

MORE INFORMATION
ADVANCED POWER CABLE TECHNOLOGY, TANAKA & GREENWOOD
ELECTRICAL DEGRADATION & BREAKDOWN IN POLYMERS, DISSADO &
FOTHERGILL
ELECTRIC CABLES HANDBOOK (3RD EDITION)
IEEE Guide for the Statistical Analysis of Electrical Insulation Voltage Endurance
Data, ANSI / IEEE std 930 - 1987.
The New Weibull Handbook (1996), Abernethy RB, ISBN 0-9653062-0-8.
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THE INVISIBLE SUPPLY OF

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

EFFECT OF WATER TREES ON MV RELIABILITY

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

EXTRA HIGH VOLTAGE

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

EUROPE - ALL VOLTAGES

CABLE USAGE INCREASES

FAULT STATISTICS - NORDEL 1990 - 1999

DENMARK, FINLAND, ICELAND, NORWAY, SWEDEN

ENGERGY LOSS STATISTICS - NORDEL 1990 TO 1999

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

IF CABLES ARE SO GOOD WHY ARE THERE SO

CURRENT RATING CABLES HARDER TO COOL THAN OVERHEAD LINES,

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

CABLE VOLTAGE (kV)

POWER CABLE DEVELOPMENT

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

CABLE VOLTAGE (kV)

POWER CABLE DEVELOPMENT

FIRST USE OF PVC IN GERMANY

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

CABLE VOLTAGE (kV)

POWER CABLE DEVELOPMENT

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

COPPER WIRES TO CARRY

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

units - Farads/m F/m

units - Watts/m W/m

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

AVERAGE STRESS (kV/mm)

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

DC NEEDED FOR LONG LENGTHS

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

BREAKDOWN - 400kV 1600mm2 25mm XLPE JICABLE 1995 A1.4

GENERAL FORM OF ANALYSIS IS WEIBULL ANALYSIS

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

- SHAPE PARAMETER; THE GRADIENT OF THE

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

MEAN ELECTRICAL STRESS

ENDURANCE CURVE - COLD - MODEL TRANSMISSION CABLES

CABLE VOLTAGE (kV)

RELIABILITY - WATER TREES

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

INVESTMENTS IN CABLE QUALITY

CABLE FAILURE RATE

XLPE CABLE FAILURE RATE

ASTM D 6097 Ashcraft Test

0.750 mm STREAMER TREE

0.300 mm CONSTRAINED TREE

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004

WHAT CAUSES THE PROBLEM?

HIGH LOCAL FIELDS TREES GROW FASTER CONTAMINANTS

HOW DO WE KNOW THAT THE PROBLEM IS SOLVED??

LECTURES ON HIGH VOLTAGE TECHNOLOGY CHALMERS 2004