PRINCIPLES

of
M.V. CABLE JOINTING AND TERMINATING

CONSTRUCTION OF XLPE
CABLES

Construction of XLPE cables

Conductor Conductor Screen XLPE insulation Insulation Screen Copper Screen Filler Binder tape Bedding Armour Outer sheath

Construction of XLPE cables

Conductor
Carries the load current.

Conductor screen
Ensures smooth and void free interface with insulation

Insulation
Prevents the flow of electricity from the energized conductors to the ground or an adjacent conductor
Withstands the electrical stresses produced by the alternating voltage Withstands superimposed transient voltage stress on the conductor

Construction of XLPE cables

Insulation screen
Ensures that the electrical field is confined within the polymeric insulation Strippable type and bonded type.

Copper Screen
Keeps the insulation screen at Earth potential. Carries the charging current. Serves as a path for earth fault currents.

Filler
Fills gaps between cores Rounds up the cable

Construction of XLPE cables

Binder Tape
Binds the cores & filler together and separates the cores from the next layer

Bedding
Serves as a cushion for the armour
Extruded bedding protects ingress of water

Construction of XLPE cables

Armour
Protects against mechanical stresses Serves as a path for earth fault currents.

Types of armour: Steel Tape Armour (STA) Galvanized Steel Wire (GSW) or (SWA) Galvanized Steel Strip Aluminum wire armour (single core cables).

Construction of XLPE cables

Oversheath
Protects against external impact or pressure Protects against corrosion Protects from water ingress Types of outer sheath PVC PE LSF(LSZH)

Conducting Coating on the outer sheath

Enables to check sheath integrity Graphite coating Extruded semi-conducting layer (For HV cables)

Construction of XLPE cables

BASIC CONCEPTS

Basic Concepts

What is Electrical Stress?

Basic Concepts

V
Max stress 11kV ---- 2.2kV/mm 33 kV---- 3.5kV/mm 132kV--- 8 kV/mm
Uo

Potential Distribution within XLPE insulation

Basic Concepts

Break Down Voltage (BDV)

Voltage

Insulation

Air 3 kV/mm PVC 20-30 kV/mm XLPE - 40-50 kV/mm

Basic Concepts

Air void in solid insulation

Voltage

Stress across air void = V/ t

Basic Concepts

Eliminating air voids in cables

Triple extrusion Super clean XLPE Dust proof extrusion area

Smooth interface between conductor screen and XLPE insulation

Basic Concepts

Nick on XLPE insulation

Insulation screen XLPE Insulation Conductor Screen

Conductor

U0

Basic Concepts

Deep Cut on XLPE insulation

Insulation screen XLPE Insulation Conductor Screen

Conductor

U0

Basic Concepts

Lifting of semi-conducting screen

Insulation screen XLPE Insulation Conductor Screen

Conductor

U0

Basic Concepts
95% 75%

55% 35% 15% Insulation screen XLPE Insulation Conductor Screen

Conductor

U0
Equipotential lines

Flux lines

Stress concentration at the screen termination

Basic Concepts
35% 95% 15% 75% 55% 75% 95%

55% 35% 15% Insulation screen Stress Control Layer Conductor Screen

U0
Flux lines Equipotential lines without control Equipotential lines with control

Stress control layer at the screen termination

STRESS GRADING BY GEOMETRICAL PROFILE

STRESS GRADING IN M-SEAL PUSH-ON

QS-1000 Field Plot

E1 : E2 : E3 : E4 :

1.45 kV / mm 1.66 kV / mm 2.07 kV / mm 2.32 kV / mm

Max. Electrical Stress in Connector Area Max. Electrical Stress in the Insulation Max. Electrical Stress at Semi-con Edge Max. Electrical Stress in the Original Cable

Basic Concepts

IMPORTANT
While preparing the cable: Take care to avoid any damage on insulation The end of semi-conducting screen is the most stressed area of a joint or termination. Take care to avoid any damage or nick on the insulation in this area. While removing strippable type semi-conducting screen, take care not to lift up the edge of the screen termination. After removing the semi-conducting layer,polish the insulation surface with Al. oxide cloth and cleaned with cleaning fluid.

REQUIREMENTS OF JOINTS AND

TERMINATIONS

Requirements of Joints & Terminations

Requirements of Joints
Conductor connection Stress grading Insulation Screen continuity Interface pressure(Elasticity) Earth continuity Sealing Mechanical strength

Requirements of Joints & Terminations

Requirements of Terminations
Conductor connection Stress grading Interface pressure (Elasticity) Creepage Insulation Earth continuity Sealing Resistance against UV light (for Outdoor)