Professional Documents
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User´s guide
XLPE cable systems - design, installation and testing........ 4 Selection of cable drum..................................................... 14
Sizes and weights of cable drums...................................... 15
XLPE cables........................................................................ 4
Large and special drums.................................................... 15
Cable accessories................................................................ 4
Installation of XLPE cable systems....................................... 5 Testing of XLPE cables........................................................ 15
Testing of XLPE cable systems............................................. 5
Cable handling..................................................................... 15
XLPE cable and cable system standards............................. 6
Minimum bending radius.................................................... 15
IEC .................................................................................... 6 Maximum pulling forces..................................................... 15
ICEA and AIEC..................................................................... 6
XLPE cable design................................................................ 16
ISO Standards..................................................................... 6
Conductors ......................................................................... 16
XLPE cable system configurations....................................... 7
Standards - IEC and ICEA.................................................. 16
Trefoil and flat formation....................................................... 7 Conductor water sealing.................................................... 16
Bonding of metallic screens................................................. 7
Insulation.............................................................................. 16
Current rating for XLPE cable systems................................ 8 Conductor screen.............................................................. 16
Current rating for single-core cables, amperes .................... 9 XLPE insulation.................................................................. 16
Insulation screen................................................................ 16
Rating factors.................................................................... 11
Rating factor for cross section area of metal screen....... 11 Metallic screen..................................................................... 17
Rating factors for ground temperature............................ 11 Copper wire screen, standard design................................. 17
Example of the use of rating factors............................... 12 Copper wire screen, water tight design.............................. 17
Overload............................................................................ 12 Lead sheath....................................................................... 17
Copper tape screen........................................................... 17
Short-circuit currents......................................................... 12
Maximum short-circuit currents due to thermal restrictions..13 Non-metallic outer sheath . ................................................ 18
Fire behavior........................................................................ 18
Support .................................................................................. 22
ABB
INTRODUCTION
Introduction
ABB
XLPE CABLE SYSTEMS - DESIGN, INSTALLATION AND TESTING
XLPE cables
Single- or three-core XLPE cables consist of the following
components:
• Conductor
- Copper (Cu) or Aluminum (Al) stranded compacted
conductor or
- Cu segmented conductor or
- Cu or Al conductor with key-stone shaped profiles
- Longitudinal water sealing of conductor
• Triple extruded and dry cured XLPE insulation system
• Metallic screen
Copper wire screen
Copper tape screen
Radial water sealing
- Cu or Al laminate solidly bonded to outer
polyethylene jacket or
- Lead sheath
Longitudinal water sealing of metallic screen
• Non-metallic outer sheath
- PE
- PVC
- Halogen free flame retardant
- Co-extruded conductive layer over the sheath for
special sheath testing
• Armour
- Single wire armour
- Double wire armour
Cable accessories
ABB’s line up of cable accessories for ABB XLPE cable systems
includes:
• Straight splices and splices with integrated screen
separation for cross bonding
• Transition splices for connection of XLPE to fluid-
filled cables
• Outdoor terminations with porcelain or composite
insulators
• Screened separable connectors for switchgears and
transformers
• Cable terminations for transformers and
gas insulated switchgears (GIS)
• Link boxes for earthing and cross-bonding
• Distributed Temperature Sensing (DTS) Systems with
integrated optical fibre in metallic tube (FIMT)
• 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
ABB
XLPE CABLE SYSTEMS – DESIGN, INSTALLATION AND TESTING
Sample tests
Sample tests are carried out with a frequency according to
applicable standards.
• Conductor examination
• Electrical resistance of conductor
• Check of dimensions
• Capacitance test
• Hot set test
• Electrical tests
ABB
XLPE CABLE AND CABLE SYSTEM STANDARDS
ABB´s XLPE cable systems are designed to meet requirements ICEA and AEIC
in international and/or national standards. Some of these are In North America, cables are often specified according to
listed below. ICEA (Insulated Cable Engineers Association, Inc.):
IEC S-97-682
XLPE cable systems specified according to IEC Standard for utility shielded power cables rated 5-46 kV.
(International Electrotechnical Commission) are among
many other standards accepted. IEC standards are conside- S-108-720
red to express an international consensus of opinion. Standard for extruded insulated power cables rated above
46 through 345 kV.
Some frequently used standards are:
IEC 60228 or AEIC (Association of Edison Illuminating Companies):
Conductors of insulated cables.
IEC 60287 CS7-93
Electric cables - Calculation of the current rating. Specifications for cross-linked polyethylene insulated
shielded power cables rated 69 through 138 kV.
IEC 60332
Tests on electric cables under fire conditions. ISO Standards
IEC 60502 ABB has well-developed systems for quality and environ-
Power cables with extruded insulation and their accesso- mental management which put the needs and wishes of
ries for rated voltage from 1 kV (Um=1,2 kV) up to 30 kV the customer first. Our systems comply with the requi-
(Um=36 kV). rements of ISO 9001 and ISO 14001 and are certified by
Bureau Veritas Quality International.
IEC 60840
Power cables with extruded insulation and their accessories
ISO 14001 and ISO 9001 - Certificate of Approval
for rated voltage above 30 kV (Um=36 kV) up to 150 kV
(Um=170 kV). Test methods and requirements.
IEC 60853
Calculation of the cyclic and emergency current rating of
cables.
IEC 61443
Short-circuit temperature limits of electric cables with rated
voltages above 30 kV (Um=36 kV)
IEC 62067
Power cables with extruded insulation and their accessories
for rated voltage above 150 kV (Um=170 kV) up to 500 kV
(Um=550 kV). Test methods and requirements.
ABB
XLPE CABLE SYSTEM CONFIGURATIONS
Both-ends bonding
A system is both ends bonded if the arrangements are such
that the cable sheaths provide path for circulating currents
at normal conditions. This will cause losses in the screen,
which reduce the cable current carrying capacity. These
losses are smaller for cables in trefoil formation than in flat
formation with separation.
Single-point bonding
A system is single point bonded if the arrangements are
such that the cable sheaths provide no path for the flow of
circulating currents or external fault currents. In such case,
a voltage will be induced between screens of adjacent
phases of the cable circuit and between screen and earth,
but no current will flow. This induced voltage is propor-
tional to the cable length and current. Single-point bonding
can only be used for limited route lengths, but in general
the accepted screen voltage potential limits the length.
Cross-bonding
A system is cross-bonded if the arrangements are such that
the circuit provides electrically continuous sheath runs from
earthed termination to earthed termination but with the
sheaths so sectionalized and cross-connected in order to
eliminate the sheath circulating currents. In such case, a volt-
age will be induced in between screen and earth, but no
significant current will flow. The maximum induced voltage
will appear at the link boxes for cross-bonding. This method
permits a cable current-carrying capacity as high as with sin-
gle-point bonding but longer route lengths than the latter. It
requires screen separation and additional link boxes.
ABB
CURRENT RATING FOR XLPE CABLE SYSTEMS
The XLPE cable should at least have a conductor cross section Phase location in duct banks
adequate to meet the system requirements for power trans-
mission capacity. The cost of energy losses can be reduced by Fig.1a
using a larger conductor.
Load losses in XLPE cables are primarily due to the ohmic loss-
es in the conductor and the metallic screen. XLPE cables can
be loaded continuously to a conductor temperature of 90°C.
Dielectric losses in XLPE cables are lower than for EPR and
fluid-filled cables.
Fig.2
ABB
CURRENT RATING FOR XLPE CABLE SYSTEMS
kcmil kcmil A A A A A A A A A A A A
750 180 535 440 545 440 455 365 585 485 590 485 510 415
1,000 180 625 495 635 490 530 405 685 545 690 540 595 460
1,250 180 700 530 715 530 595 435 770 590 775 585 670 495
1,500 180 775 565 785 560 655 460 850 630 855 620 735 525
1,750 180 835 590 850 585 705 480 920 665 930 650 795 545
2,000 180 885 610 900 605 745 495 975 685 985 675 845 565
2,500 180 980 650 1,005 640 825 520 1,085 730 1,100 715 935 595
3,000 180 1,060 675 1,085 665 890 540 1,170 765 1,190 750 1,010 620
Table 2
Rated voltage 138 kV (and 115 kV), copper conductor - 180 kcmil screen
kcmil kcmil A A A A A A A A A A A A
750 180 680 515 690 510 580 420 740 550 750 560 650 475
1,000 180 790 560 800 555 670 455 860 625 870 615 755 520
1,250 180 880 595 890 590 745 480 965 665 975 655 840 550
1,500 180 955 625 970 615 810 500 1,050 700 1,065 690 910 575
1,750 180 1,020 650 1,040 640 865 520 1,125 730 1,140 715 975 595
2,000 180 1,165 695 1,190 685 985 550 1,290 785 1,310 770 1,115 635
2,500 180 1,295 730 1,325 715 1,090 575 1,430 825 1,465 805 1,240 665
3,000 180 1,405 755 1,440 740 1,185 595 1,550 860 1,595 840 1,345 690
ABB
CURRENT RATING FOR XLPE CABLE SYSTEMS
Table 3
Rated voltage 345 kV (and 230 kV), aluminum conductor - 500 kcmil screen
kcmil kcmil A A A A A A A A A A A A
1,000 500 615 505 625 510 525 415 675 560 685 560 590 470
1,250 500 690 545 705 545 585 445 760 610 770 610 660 510
1,500 500 760 580 775 580 640 470 835 650 850 650 725 540
1,750 500 820 605 835 605 690 490 905 680 920 680 780 565
2,000 500 870 630 885 625 730 505 960 705 975 705 830 580
2,500 500 965 665 985 665 805 530 1,065 750 1,085 745 920 615
3,000 500 1,060 695 1,070 685 880 550 1,175 790 1,190 780 1,000 635
3,944 500 1,160 730 1,175 720 960 570 1,290 830 1,310 815 1,095 665
4,931 500 1,245 755 1,270 745 1,035 590 1,395 865 1,420 850 1,185 685
Table 4
Rated voltage 345 kV (and 230 kV), copper conductor - 500 kcmil screen
kcmil kcmil A A A A A A A A A A A A
1,000 500 775 580 790 580 660 470 850 650 860 645 740 540
1,250 500 865 620 880 620 730 500 950 695 965 690 825 575
1,500 500 940 645 960 640 790 520 1,035 730 1,050 725 895 600
1,750 500 1,005 670 1,025 670 845 535 1,105 755 1,125 750 960 620
2,000 500 1,145 715 1,170 710 960 565 1,265 810 1,295 805 1,095 655
2,500 500 1,270 750 1,305 745 1,060 590 1,405 850 1,440 840 1,215 685
3,000 500 1,400 775 1,425 760 1,165 605 1,560 885 1,590 870 1,330 705
3,944 500 1,550 810 1,590 790 1,290 625 1,730 925 1,775 910 1,480 730
4,931 500 1,680 840 1,740 825 1,400 645 1,890 970 1,955 945 1,615 760
10 ABB
CURRENT RATING FOR XLPE CABLE SYSTEMS
Rating factors
Table 5, 115-138 kV cable with 180 kcmil screen Table 6, 230-345 kV cable with 500 kcmil screen
Rating factor for tables 1 and 2 Rating factor for tables 3 and 4
Conductor kcmil Copper screen kcmil Conductor kcmil Copper screen kcmil
Al Cu 45 90 180 360 500 Al Cu 90 180 360 500
750 1.06 1.03 1 1.00 1.02 1,000 1.01 0.98 0.98 1
1,000 1.06 1.03 1 1.00 1.02 1,250 1.01 0.98 0.98 1
1,250 750 1.06 1.03 1 1.00 1.02 1,500 1,000 1.01 0.98 0.98 1
1,500 1,000 1.10 1.04 1 1.00 1.02 1,750 1,250 1.02 0.98 0.98 1
1,750 1,250 1.10 1.04 1 1.00 1.02 2,000 1,500 1.02 0.98 0.98 1
2,000 1,500 1.10 1.04 1 1.00 1.02 2,500 1,750 1.02 0.98 0.98 1
2,500 1,750 1.12 1.05 1 0.99 1.02 3,000 2,000 1.03 0.98 0.97 1
3,000 2,000 1.12 1.05 1 0.99 1.02 3,944 2,500 1.03 0.98 0.97 1
2,500 1.12 1.05 1 0.99 1.02 3,000 1.03 0.98 0.97 1
3,000 1.15 1.07 1 0.98 1.02 3,944 1.03 0.98 0.97 1
4,931 1.03 0.98 0.97 1
Ground temperature °C 10 15 20 25 30 35 40 45
Rating factor 1.11 1.07 1.04 1 0.96 0.92 0.88 0.83
ABB 11
CURRENT RATING FOR XLPE CABLE SYSTEMS
12 ABB
CURRENT RATING FOR XLPE CABLE SYSTEMS
Maximum short circuit currents due to thermal restrictions Copper screens may reach a temperature of 250oC without
The thermal energy developed during a short-circuit is damaging adjacent insulating material. With an initial tempe-
determined by the short-circuit magnitude and duration. rature of 50oC this corresponds to a current density of 83A/
For design purposes, an equivalent short-circuit current kcmil during 1s. (Both higher and lower current densities may
with a duration of 1 sec is used according to formula be allowed if other conditions apply.)
below. This formula is valid for a short-circuit duration of Lead sheath temperatures of up to 210oC are permitted in
0.2 to 5.0 sec. connection with short circuit events. With an initial tempe-
rature of 50oC this corresponds to a current density of 14
A/kcmil during 1 s.
Table 9
Ish= short-circuit current [kA] during time tsh
I1 = short-circuit current rating during 1 second. See the 1- Max short-circuit current on the screen during 1 s kA
second value in Table 8 for the conductor and in Table 9 Metallic screen Metallic screen temp
for the metal screen. cross section kcmil before the short circuit
tsh= short-circuit duration (sec) Copper Lead 50°C 70°C
45 311 3.7 3.5
For XLPE insulated conductors the maximum allowable 90 621 7.5 7.0
short circuit temperature is 250oC.
180 1,242 14.9 14.0
ABB 13
CABLE DRUMS
Cable drums
Wooden drums/reels are standardized. For certain purposes steel drums/
reels are applicable. Both wooden and steel-drums can be obtained for
special purposes with other dimensions than stated below.
Table 10
Selection of cable drum
Cable lenghts in feet on standard drum K22 - K30 and Steel drum St 28 - St 43
Cable Wooden drum Steel drum
dia.
inch K22 K24 K26 K28 K30 St 28 St 30 St 32 St 34 St 35 St 36 St 37 St 38 St 39 St 40 St 43
3.0 1,050 1,312 1,969 2,657 3,970 2,986 3,707 5,217 6,004 6,857 6,857 7,710 8,645 8,645 9,580 11,549
3.1 755 1,066 1,640 2,657 3,330 2,986 3,707 4,462 6,004 6,037 6,857 7,710 7,776 8,645 9,580 11,549
3.2 755 1,066 1,542 2,543 3,330 2,904 3,576 4,298 5,052 5,840 6,660 6,660 7,530 8,399 8,399 10,302
3.3 689 984 1,542 2,165 3,330 2,887 3,576 4,298 5,052 5,840 6,660 6,660 7,530 7,579 8,399 10,302
3.4 689 902 1,444 2,018 2,756 2,067 2,690 4,003 4,692 4,692 5,446 6,201 6,201 7,021 7,021 8,760
3.5 689 902 1,444 2,018 2,756 2,067 2,690 4,003 4,692 4,692 5,446 5,479 6,201 7,021 7,021 8,760
3.6 1,165 1,919 2,625 2,001 2,575 3,182 4,528 4,528 5,249 5,249 6,020 6,020 6,791 8,465
3.7 1,066 1,919 2,625 2,001 2,575 3,182 3,871 4,528 4,560 5,249 6,020 6,020 6,791 7,677
3.8 1,066 1,591 2,100 1,903 2,477 3,051 3,707 4,364 4,364 5,052 5,052 5,774 5,774 7,349
3.9 1,066 1,493 2,100 1,903 2,477 3,051 3,707 3,740 4,364 4,396 5,052 5,774 5,774 7,349
4.0 1,837 2,379 2,953 3,543 3,543 4,199 4,199 4,888 4,888 5,610 6,332
4.1 1,263 1,739 2,264 2,822 3,412 3,412 4,035 4,035 4,692 4,692 6,102
4.2 1,247 1,739 2,264 2,822 3,412 3,412 4,035 4,035 4,692 4,692 6,102
4.3 1,247 1,739 2,264 2,822 3,412 3,412 4,035 4,035 4,692 4,692 6,102
4.4 1,198 1,657 2,165 2,690 3,248 3,248 3,248 3,871 3,871 4,495 5,151
4.5 1,181 1,657 2,165 2,690 2,690 3,248 3,248 3,871 3,871 4,495 5,151
4.6 1,132 1,575 2,051 2,575 2,559 3,117 3,117 3,675 3,675 3,675 4,921
4.7 1,115 1,575 2,051 2,575 2,559 3,117 3,117 3,117 3,675 3,675 4,921
4.8 1,115 1,575 2,051 2,575 2,559 2,592 3,117 3,117 3,675 3,675 4,331
4.9 1,066 1,476 1,952 1,952 2,428 2,428 2,953 2,953 2,953 3,510 4,101
5.0 1,066 1,476 1,476 1,952 2,428 2,428 2,461 2,953 2,953 3,510 4,101
5.1 1,066 1,476 1,476 1,952 2,428 2,428 2,461 2,953 2,953 3,510 4,101
5.2 1,001 1,001 1,411 1,837 1,837 2,297 2,297 2,789 2,789 2,789 3,904
14 ABB
CABLE DRUMS | TESTING | CABLE HANDLING
Table 11 A
Sizes and weights of standard drum K22 - K30
Wooden drum
K22 K24 K26 K28 K30
Shipping volume ft3 217.2 259.9 372.9 490.2 605.6
Drumweight incl. battens lbs 1246 1378 2524 3219 4012
a Diameter incl. battens inch 89.6 97.4 106.3 114.2 122.0
b Flange diameter inch 86.6 94.5 102.4 110.2 118.1
c Barrel diameter inch 55.1 55.1 59.1 59.1 59.1
d Total width inch 46.8 47.2 57.0 65.0 70.9
e Spindle hole diameter inch 5.2 5.2 5.2 5.2 5.2
Table 11 B
Sizes and weights of drum St 28 - St 43
Steel drum
St 28 St 30 St 32 St 34 St 35 St 36 St 37 St 38 St 39 St 40 St 43
Shipping volume ft3 727.5 829.9 939.4 1,020.6 1,115.9 1,179.5 1,243.1 1,306.6 1,373.7 1,444.4 1,663.3
Drumweight incl. battens lbs 3,307 3,748 4,850 5,732 5,952 6,173 6,614 6,834 7,275 7,716 8,818
a Diameter incl. battens inch 115.4 123.2 131.1 139.0 142.9 146.9 150.8 154.7 158.7 162.6 174.4
b Flange diameter inch 110.2 118.1 126.0 133.9 137.8 141.7 145.7 149.6 153.5 157.5 169.3
c Barrel diameter inch 78.7 78.7 78.7 78.7 78.7 78.7 78.7 78.7 78.7 78.7 78.7
d Total width inch 94.5 94.5 94.5 94.5 94.5 94.5 94.5 94.5 94.5 94.5 94.5
e Spindle hole diameter inch 5.9 5.9 5.9 5.9 5.9 5.9 5.9 5.9 5.9 5.9 5.9
ABB 15
CONDUCTORS | INSULATION
Insulation
16 ABB
INSULATION | METALLIC SCREEN
Metallic screen
Copper wire screen, standard design
A polymeric sheath covers the copper wire screen.
Lead sheath
Radial water sealing achieved by a corrosion resistant lead
sheath. Longitudinal water sealing is achieved by using a
water swelling material applied under the lead sheath.
ABB 17
N O N - M E T A L L I C O U T E R S H E A T H | C O N D U C T I V E O U T E R L AY E R | F L A M E R E T A R D E N T O U T E R L AY E R | F I R E B E H AV I O R
Fire behavior
This relates to cables in buildings and tunnels.
18 ABB
TECHNICAL DATA FOR CABLES IN THE ABB XLPE CABLE SYSTEM
Cross- Diameter Insulation Diameter Cross- Outer Cable Cable Capaci- Charging Inductance Surge
section of con- thickness over section diameter weight weight tance current impe-
of con- ductor insulation of of cable (Al-con- (Cu-con- per ** * dance
ductor screen ductor) ductor) phase
at 60 Hz
kcmil mil mils inches kcmil inches Lb/ft Lb/ft μF/ A/ mH/ mH/ Ω
1000 ft 1000 ft 1000 ft 1000 ft
Table 15
Table 16
ABB 19
TECHNICAL DATA FOR CABLES IN THE ABB XLPE CABLE SYSTEM
Cross- Diameter Insulation Diameter Cross- Outer Cable Cable Capaci- Charging Inductance Surge
section of con- thickness over section diameter weight weight tance current impe-
of con- ductor insulation of of cable (Al-con- (Cu-con- ** * dance
ductor screen ductor) ductor)
kcmil mil mils inches kcmil inches Lb/ft Lb/ft μF/ A/ mH/ mH/ Ω
1000 ft 1000 ft 1000 ft 1000 ft
Table 17
Table 18
** Inductance trefoil in duct w 9” horisontal and vertical distance (10” from 3,000 kcmil)
*Inductance flat formation with distance c/c 10,1” between cables (11,2” from 3,000 kcmil)
20 ABB
FORMULAS
Formulas
Formula for electric stress Formula for maximum short circuit currents
Conductor screen:
ABB 21
SUPPORT
Support
The transmission network in most countries is very large and
complex. It may incorporate many different types of transmis-
sion circuits, including AC and DC over-head lines, fluid-filled
cable systems and extruded cable systems, etc. Also, many
modern networks contain extensive underground and sub-
marine cable systems for supply of major metropolitan areas
and for interconnection with neighboring countries.
ABB’s experienced project managers, technical specialists and
other staff will give their professional support in evaluating
suitable solutions. We aim to offer the most optimal solution
and we can supply the complete underground or submarine
cable system which can include:
22 ABB
CHECKLIST FOR CABLE ENQUIRY
ABB is always prepared to work closely with our customers below data checklist is submitted with each inquiry (if some of
to develop optimized and cost effective cable system design the requested data is not available at the time of the inquiry
solutions. In order for us to identify the best overall design or does not appear applicable, just insert N/A in the cor-
solution for a specific application, we kindly request that the responding data cell).
ABB 23
For additional information please contact you local ABB Sales Office
Brochure issued by:
2GM 5007 US.pdf Elanders, Västerås 0610