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854

IEEE Transactionson Power Delivery, Vol. 5, No. 2, April 1990


NEW DEVELOPMENTS I N THE FIELD OF H I G H VOLTAGE AND EXTRA-HIGH VOLTAGE CABLES

P o i n t o f View o f a M a n u f a c t u r e r
R.

JOCTEUR, member I E E E [QUES (SILEC)

SOCIETE INDUSTRIELLE DE LIAISONS ELEC 77130 MONTEREAU (FRANCE

LOPE cables grouth in the HV field


ABSTRACT. I n t h i s p a p e r , t h e a u t h o r p r e s e n t s t h e developments i n p r o g r e s s a t t h e p r e s e n t time i n FRANCE c o n c e r n i n g t h e High V o l t a g e ( H V ) and Extra-High Voltage ( E H V ) c a b l e s w i t h s y n t h e t i c i n s u l a t i o n and t h e i r a c c e s s o r i e s up t o t h e 500 kV r a n g e .
W e have a d o p t e d a maximum o p e r a t i n g f i e l d s t r e n g t h a p p r o a c h i n g 1 6 kV/mm (405 V / m i l ) f o r low d e n s i t y p o l y e t h y l e n e (LDPE) i n s u l a t e d c a b l e s . The on-going s t u d i e s s h o u l d a l l o w t o b r i n g t h e maximum o p e r a t i n g f i e l d strength for crosslinked p o l y e t h y l e n e (XLPE) i n s u l a t i o n from 7 t o 10 kV/mm (180 t o 255 V / m i l ) and c a b l e s c o u l d be manufactured more e c o n o m i c a l l y w i t h t h i s material.
500 kV

400 kV

225 kV

751 Irm

instilled
90 to 150 kV

1- INTRODUCTION. 63 kV
HV and EHV c a b l e s w i t h s y n t h e t i c i n s u l a t i o n have been i n s e r v i c e f o r many y e a r s i n F r a n c e .

1
1962 1968

1
1969

-;

instilled installed

560 k m

LDPE i s used f o r a l o n g t i m e . The u t i l i z a t i o n o f HDPE and XLPE is more r e c e n t . Figure 1 illustrates the steps of the n a n u f a c t u r i n g o f LDPE c a b l e s by our company and t a b l e 1 g i v e s t h e d i f f e r e n t stress g r a d i e n t s a d o p t e d by u s . I n P a r i s a l o n e by September o f 1988, 370 km of 225 kV LDPE cables had been installed and 350 t e r m i n a t i o n s and 850 j o i n t s had been mounted. The network is r e p r e s e n t e d i n f i g u r e 2, the first i n s t a l l a t i o n s d a t e from 1969. I n F r a n c e and a b r o a d , t h e t o t a l amount o f 225 kV c a b l e i n s t a l l e d i s a p p r o x i m a t e l y 800 km. Fig. 1 TABLE 1

LDPE c a b l e growth i n t h e HV f i e l d .

O p e r a t i n g stress g r a d i e n t s

I I I I I I I I I

Rated v o l t a g e kV 500
400

225 90 t o 150 63

I 1 I I I I

O p e r a t i n g stress g r a d i e n t s kV/mm 1 V/mil 15.5 14.0 10.0 7-8 6.0

I I

I I I I I I I

395 355 255 180-200 152

I I I I I I I I I

F o r comparison, t h e c u r r e n t A E I C d e s i g n stress l i m i t for 138 kV XLPE c a b l e s , i n s u l a t i o n t h i c k n e s s 21.6 mm, i s 5 . 5 kV/mm (140 V/mil.)

This paper i s t h e second part of t h e general paper New Developments i n France i n t h e f i e l d of High Voltage and Extra-High Voltage Cables, t h e f i r s t p a r t , authored by M. Pays of ELECTRICITE DE FRANCE, is e n t i t l e d The Users Point of View.
; b

-CABLE

ROUTE

89 TD 355-9 P W R D A p a p e r recommended and approved by t h e IEEE I n s u l a t e d Conductors Committee of t h e IEEE Power E n g i n e e r i n g S o c i e t y f o r p r e s e n t a t i o n a t t h e IEEE/PES 1989 T r a n s m i s s i o n and D i s t r i b u t i o n 7 , 1989. Conference, New O r l e a n s , L o u i s i a n a , A p r i l 2 Manuscript s u b m i t t e d December 12, 1988; made a v a i l a b l e f o r p r i n t i n g F e b r u a r y 6 , 1989.

Fig. 2

I n s t a l l a t i o n s i n PARIS o f c a b l e s , t e r m i n a t i o n s and j o i n t s by September o f 1988

0885-8977/90/0100-0$01.MI 0 1990 IEEE

855
In 1984, the 4 0 0 kV level was attained and at present, 19 km of cable, 56 terminations and 6 joints are operating, mainly in nuclear or hydraulic power plants.

2 - DEVELOPMENTS IN PROGRESS CONCERNING THE CABLE 2-1- Nature of the insulation 2-1-1The 500 kV level has just been reached, and the cable's operating field strength on conductor is approaching 16 kV/mm (405 V/mil). Investigation tests were performed in the laboratories of ELECTRICITE DE FRANCE (EDF) on 4 0 0 kV power cable systems, which had already withstood the 4 0 0 kV qualification tests. These complementary tests have been conducted so as to obtain the electrical stresses corresponding to the stresses to be applied when testing a real 500 kV cable. (Table 2: Total of 0 0 kV cable. Table 3: the tests performed on the 4 Stresses corresponding to the complementary test).

Since 1985, the crosslinked polyethylene (XLPE) has replaced polyethylene (PE) more and more in the 60/90 kV networks.

On summary, it can be said that cable manufacturers have mastered the technique of processing EHV cables with synthetic insulation. Although these installations have already been giving satisfaction to end-users for a number of years, new developments are still to come. TABLE 2

EDF tests performed on 4 0 0 kV LDPE cable loops

BDF TESTS PERFORMED UP TO THE 500 KV LEVEL ON 400 KV LDPE CABLE LOOPS
SPaCIFICATION CABLE

I l y h

1
I

I
Accessories

I
I

Nature of the test

1 p,(,:il, j
Level

1 TemperatureI
Duration I

(OC)

on

I
I

1 x 630 nun2 A1

LDPE 4 0 0 kV I Insulation I thickness : 30 mml

30

12 metalclad terminations)- lightning impulses'

I I I

25

I I I

1 1 joint

12

I- AC voltage (50 Hz) I I outdoor terminations I- lightning impulses'

I 1 1425 11.2/50 ps I 1600 11 2/50 s I 5 5 0 1 ' 24' h I


I

1-1 I

I
I

I I I
200

I - AC voltage I
I

(50 Hz)

(2metalclad terminations(- AC voltage (50 Hz) 1 2 joints I

taken I off the I I 200 m I 1 length 1

1 75 1 I I I I I I I I I 1425 11,2/50 ps I 75 I I 1675 11 2/50 s I I I 5 5 0 1 ' 24 h " I I I I !___I -1 I I \ 4 0 0 1 14500 h 180 and 85**) I 4 6 0 I 7700 h (80 and 85*"1
I

1 2 5m

lafter L.D.

1 -!I I 1 X 1200 mm2 Cu I LDPE 4 0 0 kV I Insulation I


thickness
:

I I I

I- lightning impulses' I I- AC voltage (50 Hz)

25

12 outdoor terminations
12 outdoor terminations

I I

I 1425 11.2/50 ps I I 1550 11,2/50 s I I 5 0 0 1 24 hp I 1 24 h I


I--' I
4 0 0

I
75

1- AC voltage (50 Hz)


I

-1 I

I
I

I I I

6400 h

I80 and 8 5 " l

25

27 mml

I
I

1- lightning impulses* I- AC voltage (50 Hz)

I
I

1425
500

I-

II 1-1
30

metalclad terminationsl- lightning impulses' 1425 I 11 joint I I IAC voltage (50 Hz) I 500 1-1 Each cable length passed the above tests without any breakdown or flash-over 10 impulses of + polarity and 10 impulses of - polarity *+ 167 heat cycles 20/80C followed b y at least 83 cycles 2 0 / 8 5 O C Duration of one cycle : 8 h heating 16 h cooling
12

I- lightning impulses' 1- AC voltage ( 5 0 Hz) I I

AC voltage ( 5 0

HZ)

I I I I

460

Il.2/50 ps I 75 I I 24 h I I i 7700 h 180 and e5-i

planned for november 1988 [1,2/50ps

i
75

2 4h

I I

1 I I

Ow 0 1 ' 1 0 ' 1 9 8 8

The underlined values correspond to tests carried to the 500 kV level.

TABLE 3 - Tests performed on a 4 0 0 kV cable at a stress level corresponding to that for testing a 500 kV cable

I
1 I
I
Short term tests Lightning impulses* AC Voltage Long term tests AC Voltage
I

I I
I

75 I (Room temperature1

I
1-2/50 ps 2 4h 6 0 0 0h

\I
I

80 and 85**

I I
I

I I I I
I I

1550 620 500


I

83 33
27

I I I I
I

2110 8 4 0 685

* 10 impulses of + polarity followed by 10 impulses of - polarity ** 167 heat cycles 2O/8O0C followed by 83 heat cycles 20/83"C

856

A sectional drawing of the 630 sc:nm given in figure 3.

~ s b l e is

3- DEVELOPMENT IN PROGRESS CONCERNING THE TERMINATIONS


3-1- 225-400 kV level

'This type of termination is now quite perfected. They are entirely prefabricated and in general, the stress cone is placed in a SF6 atmosphere when outdoor or metal-clad types are used. In case of a metal-clad type there is no insulator (figures 4 and 5).

Fig. 3

Cross-section of 4 0 0 kV cables 1x630 sqmm. left cable : Aluminium wires + lead sheath right cable : Aluminium wires + A1 tape

2-1-2HDPE was developed 10 years later than the LDPE. The 225 kV level has been reached with the same stress gradient as that of LDPE cables (10 kV/mm = 255 V/mil).

- 70 km of cables have been installed up to now. - The 400 kV level is under study.
2-1-3Fig. 4 and Fig. 5 Schematic cross-section view of an outdoor termination and a metal-clad termination (with equipotential lines).

XLPE

The use of HV XLPE cables is relatively recent. Their advantage is a higher allowable operating temperature (90OC for XLPE, 70C for LDPE). But due to the difficulty to obtain a high purity XLPE insulation 6-7 kV/mm we limit the stress gradient to (152-180V/mil). Consequently, at the 225 kV range, LDPE cables operating at lower temperatures but having a reduced insulation thickness, they are at the present time more competitive than XLPE cables. Studies are presently being done to bring the stress gradient to 10 kV/mm (255V/mil) which would make it possible to manufacture 225 kV XLPE cables which would have the same thickness as the PE cables presently used and present the same safety factor.

The use of oil is proscribed in France, but if desired this type of termination can operate in oil. As for the cables, this type of equipment has just attained the 500 kV level.

3-2- 63-110 kV level


Entirely dry outdoor type terminations have just been developed and tests will be started to qualify these products for the 63-90 kV networks. An example is illustrated in figure 6.

2-2-

Specification

New structures have been studied to both reduce costs and make installation easier. 2-2-1 Outer semi-conducting layer Investigations are underway to make this layer strippable so as to facilitate the installation by unskilled workers.

Petticoats of copolymer ethylene propylene

,
E

Linear voltage distribution sl

2-2-2 Aluminium shield Cables with lightened structures comprising an aluminium shield have been developed and qualified for the 63-90 kV range. The shield is generally made of an Alupe tape and a thick HDPE jacket enabling it to withstand the mechanical shocks as prescribed in the standard HN 33-5-52 of ELECTRICITE DE FRANCE. In order to avoid any risk of corrosion in case of cable immersion, the manufacturing of this shield must be carefully controlled to make sure the aluminium tape permanently adheres to the jacket.

Cable shield Cable Ground wires Ground ring

. IIRII
Terminations without insulation for a 63 to 110 kV cable.

Fig. 6

857

This type of termination comprises either a deflector or a field distribution sleeve of the resistive or capacitive type, the utilized product presenting a characteristic U(1) with high non-linearity (U = applied voltage, I = circulating current)

Compared to traditional equipment these terminations present the important advantage of not needing oil, and moreover, they are more economical. All these terminations are available for PE and XLPE cables as well.

4- DEVELOPMENT IN PROGRESS CONCERNING THE JOINTS

As the qualification tests of prefabricated joints for the 225 kV EDF network have recently been terminated, prefabricated joints are now available for the whole voltage range up to 225 kV in France and to 300 kV for exportations. Figure 7 illustrates such a joint. This joint exists also as a cross-bonding type.

. c .. . . . _.

---

3
Fig. 8 and Fig. 9 225 kV cable installations in shafts

Fig. 7 Premoulded 275 kV joint.

..

end to end. Tests will be undertaken to extend this new 225 kV technology to the 4 0 0 kV range. AS the terminations, the joints are available for PE and XLPE cables.

5- DEVELOPMENT CONCERNING THE INSTALLATION METHODS OF EHV CABLES 5-1- Installations in very deep vertical shafts Cables with extruded dielectric are well sui-tau for this type of installation as there is no risk of compound migration and pressure application at the bottom of the feeder.

Of course, this type of installation can be expanded $0 cables of the 400 and 500 kV range. For 0 0 kV cable was installed in a instance, in 1986 a 4 hydraulic power station in a lesser deep shaft of about 30 m.

5-2- Direct burying in the ground in light mix concrete masonry This is an attractive installation method from the economic point of view. Tests were performed by cable manufacturers on 60 to 400 kV cables. The test results checked if the cable had not suffered too much from the compression during heat cycles in service and made sure its electrical properties were not altered.

Two installations of LDPE insulated 225 kV cables have been set up in INDIA and in COLOMBIA in shafts about 200 meters deep. The cables are equipped with an aluminium shield to reduce their weight and with a grooved outer jacket permitting fixation with grooved clamps.
I

5-3- 225 and 400 kV mobile links Examples of installations are shown in figures 8 and 9. 225 kV mobile systems made of prefabricated components have been manufactured and are in service. This principle may be extended with no special problems to the 400 kV range (figure 10).

858

PHASE CONSTITUTION

Porcelain bushing 225 kV Connection SF6 box firmly fixed to the bushing Supporting structure Base plate Connection box firmly fixed to the cable About 6 0 0 m polyethylene insulated 225 kV cable Intermediate joint box Fig. 10 225 kV mobile link.

6- CONCLUSION
This short review demonstrates that the technology of EHV cables with synthetic insulation up to the 500 kV range has been mastered in France. However, improvements are still possible and we have not yet made the most of all of its potientialities. For example, the gradient under a.c. voltage could be increased, the cable weight could be reduced, accessories could be simplified and this type of cable could a l s o be used under d.c. voltage.

4. L. DESCHAMPS, R. MICHEL, J. LEPERS, R. JOCTEUR, E. FAVRIE, G. TERRMORSI, J. MIDOZ, " Results of Tests and Experience in Service, in France, with High Voltage Cables with Synthetic Insulation", CIGRE 1980 Session, Working group 21-06.

5. E. FAVRIE, H. AUCLAIR, "Effect of Water on Electrical Properties of Extruded Synthetical Insulations - Application on Cables", IEEE Trans. Power Apparatus and Systems, vol. PAS-99, pp. 1225-1234, 1980.

R E F E R E N C E S 1. R. JOCTEUR and M. OSTY, "Research and Development in France in the Field of Extruded Polylethylene Insulated High Voltage Cables 'I 1st part "Study concerning the behaviour of polyethylene insulated high tension cable under electric stress", CIGRE 1972 Session, Working Group 21-07. 2. R. JOCTEUR, E. FAVRIE, H. AUCLAIR, "Influence of Surface and Internal Defects on Polyethylene Electrical Routine Test on VHV Cables", IEEE Trans. Power Apparatus and Systems, vol. PAS-96, no. 2, Pp. 513-523, 1977. 3. M. CHAROY, E. FAVRIE, R. JOCTEUR, " Development of Extruded Cables for EHV applications in the Range 138-400 kV", 2nd part '' Development in France of low density polyethylene insulated cables operation with gradients approximating to 15kV/mm : applications 0 0 kV cables", CIGRE 1978 Session, for 225 and 4 Working Group 21-11.

6. R. JOCTEUR, E. FAVRIE, H. AUCLAIR, B. DHUICQ, "Development in France of 63 to 4 0 0 kV Cables with Synthetic Insulation", CHINA Symposium in XIAN, June 1985.
7 . R.

JOCTEUR, "Development Polyethylene Working group

E. FAVRIE, H. AUCLAIR, B. DHUICQ, 0 0 kV Links with Low Density of 4 Insulation", CIGRE 1986 Session, 21-09.

8. H. AUCLAIR, E. FAVRIE, B. DHUICQ, L. BHEEMAN, B7.4 "Installing 225 kV synthetic insulation cables in very deep shafts", JICABLE, September 1987. 9. H. AUCLAIR, B. DHUICQ, E. FAVRIE, A8.5 "Development in France of the 400 kV LDPE insulated cable", JICABLE, September 1987.

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