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    Water Blocking

    Uploaded by

    ramukolaki
    This document discusses water blocked cables and their design. It introduces why water blocking is important to prevent water penetration from damaging cable insulation and components. It then describes various techniques for radially and longitudinally water blocking cables, including using water swellable tapes and powders. The document outlines standard water penetration tests cables must pass and considerations for water blocking cable constructions like conductors, copper tapes and armor. It also notes potential impacts of water blocking on cable lugs and connectors, and the need for further testing to evaluate temperature rises.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Water Blocking

    Uploaded by

    ramukolaki
    259 views24 pages
    This document discusses water blocked cables and their design. It introduces why water blocking is important to prevent water penetration from damaging cable insulation and components. It then describes various techniques for radially and longitudinally water blocking cables, including using water swellable tapes and powders. The document outlines standard water penetration tests cables must pass and considerations for water blocking cable constructions like conductors, copper tapes and armor. It also notes potential impacts of water blocking on cable lugs and connectors, and the need for further testing to evaluate temperature rises.

    Original Description:

    WATER BLOCKING

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    This document discusses water blocked cables and their design. It introduces why water blocking is important to prevent water penetration from damaging cable insulation and components. It then describes various techniques for radially and longitudinally water blocking cables, including using water swellable tapes and powders. The document outlines standard water penetration tests cables must pass and considerations for water blocking cable constructions like conductors, copper tapes and armor. It also notes potential impacts of water blocking on cable lugs and connectors, and the need for further testing to evaluate temperature rises.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    259 views24 pages

    Water Blocking

    Uploaded by

    ramukolaki
    This document discusses water blocked cables and their design. It introduces why water blocking is important to prevent water penetration from damaging cable insulation and components. It then describes various techniques for radially and longitudinally water blocking cables, including using water swellable tapes and powders. The document outlines standard water penetration tests cables must pass and considerations for water blocking cable constructions like conductors, copper tapes and armor. It also notes potential impacts of water blocking on cable lugs and connectors, and the need for further testing to evaluate temperature rises.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 24

    1a

    WATER BLOCKED MV XLPE CABLE

    Testing of water
    blocked cables

    1b

    WATER BLOCKED MV XLPE CABLE


    Introduction
    1. Introduction

    2. Why Water Block Cables?


    3. How to Water Block Cables
    4. Proving Water Blocking
    5. Water Penetration Tests
    6. Aspects of a Water Blocked Cable Design
    7. Impact of Water Blocking on Lugs and Ferrules
    8. Aberdare's Test Rig

    2.1

    WATER BLOCKED MV XLPE CABLE


    Why Water Block Cables?
    Water + Any conductive parts
    This conducts electricity, causing
    Safe surfaces to become live and dangerous.
    Instead of insulating, insulators conduct electricity.
    In PILC electrical trees will form within the insulation.
    Conductive path between phases or from phase to earth =
    Remedies
    Ensure that cables are always dry inside.
    Maintain good insulation radials.
    At cable ends keep insulation surfaces smooth.
    Ensure insulation and sheathing is free of holes!

    2.2

    WATER BLOCKED MV XLPE CABLE


    Why Water Block Cables?
    Water + Electrical stress
    This will attack ANY polymer, causing
    WATER TREES.
    A water tree is a regions of reduced insulation strength.
    This is the ONLY known ageing chemical process for XLPE.

    Eventually a water tree will cause an electrical tree, and


    Remedies
    Exclude all impurities.
    Ensure that the HUMIDITY within the cable is less than 65%.

    2.3

    WATER BLOCKED MV XLPE CABLE


    Why Water Block Cables?
    Water + Oxidizing agents
    Oxidizing agents attack metals, causing
    Armour to corrode, leaving the cable unprotected and unearthed.
    Screens to be interrupted, leading to failure.
    Ci

    Vp

    (Insulation)
    Vs

    Cs

    (Sheath)

    Example: On A 300 mm 11 kV single core unarmoured with an interrupted


    screen, the screen voltage will be 2 kV. This will puncture the sheath, allowing
    water access to the screen.
    Tracking will take place along the outer semiconcuctor.
    The cable will sizzle for a few minute to a few days, then

    3.1

    WATER BLOCKED MV XLPE CABLE


    How to Water Block Cables:
    Radial water blocking
    Generalized
    cable:
    Outer sheath
    Metallic sheath
    Insulation
    Conductor

    Radially water blocked below the impervious layer.


    Use polyethylene for the impervious layer.
    Use metal for the impervious layer.
    Use both.

    3.2

    WATER BLOCKED MV XLPE CABLE


    How to Water Block Cables:
    Longitudinal water blocking
    Generalized
    cable:

    Outer sheath

    Metallic sheath
    Conductor
    Insulation

    Block longitudinal water migration by layer.


    Water swellable powders, yarns or tapes.
    Bitumen.
    Unvulcanized rubber.
    Solid conductor.

    4.3

    WATER BLOCKED MV XLPE CABLE


    Proving Water Blocking:
    Water penetration test
    Defined in SANS 1339, which refers to IEC 60502-2, with an amendment.
    Includes 10 heat cycles, each lasting 8 hours.
    Frequently a poor design will fail within minutes

    5.1

    WATER BLOCKED MV XLPE CABLE


    Water Penetration Tests:
    Standard tests
    Step

    IEC 60502-2

    SANS 60840

    IEC 62067

    SANS 1339

    MV XLPE

    HV XLPE

    EHV XLPE

    MV XLPE

    Initial sample size

    6m

    6m

    8m

    6m

    Condition
    Sample size

    Bend test
    3m

    Bend test
    6m

    Bend test
    8m

    Bend test
    3m

    Stripped ring

    50 mm

    50 mm

    50 mm

    50 mm

    Water head

    1,0 m

    1,0 m

    1,0 m

    1,0 m

    Filling time

    5 minutes

    5 minutes

    5 minutes

    5 minutes

    Standing time
    Heat cycles

    24 hours
    10

    24 hours
    10

    24 hours
    10

    24 hours
    10

    Cycle duration

    8 hours

    24 hours

    24 hours

    8 hours

    Heating duration

    5 hours

    8 hours

    8 hours

    5 hours

    Hold time
    Cooling time

    2 hours
    3 hours

    2 hours
    16 hours

    2 hours
    16 hours

    2 hours
    3 hours

    Conductor temp (min)

    95 C

    95 C

    95 C

    95 C

    Conductor temp (max)

    < 100 C

    < boiling point

    < 100 C

    < boiling point

    Pass criterion

    No leak

    No leak

    No leak

    No leak

    6.1

    WATER BLOCKED MV XLPE CABLE


    Aspects of a Water Blocked Cable Design:
    Techniques
    To water block the complete cable it is imperative that all material interfaces
    are either bonded or have water block material between them.
    Each stage of the design is analysed and all interfaces water blocked.
    Where electrical contact is required semi-conducting materials are used.

    6.2a

    WATER BLOCKED MV XLPE CABLE


    Aspects of a Water Blocked Cable Design:
    Materials

    Tapes and Yarns containing Polyacrylate water swellable material.


    Tapes can be either semiconducting or non-semiconducting.
    Yarns are available in different diameters.
    Bitumen is often used to water block wire armouring and also provides
    corrosion resistance

    6.2b

    WATER BLOCKED MV XLPE CABLE


    Aspects of a Water Blocked Cable Design:
    Materials

    Requirements for water blocking materials:


    Short term stability
    Long term stability
    Repeatability of water blocking action
    Compatibility between cable materials

    6.2c

    WATER BLOCKED MV XLPE CABLE


    Aspects of a Water Blocked Cable Design:
    Materials
    Water Swellable tapes

    Performance of superabsorbent materials:


    Swell Height
    Swell speed

    6.2d

    WATER BLOCKED MV XLPE CABLE


    Aspects of a Water Blocked Cable Design:
    Materials
    Swelling of Superabsorbent materials

    6.3a

    WATER BLOCKED MV XLPE CABLE


    Aspects of a Water Blocked Cable Design:
    Conductors
    Water blocking of conductors is achieved
    using a swellable yarn in the centre and
    swellable tapes over each layer of
    wires.
    Aberdare has completed type tests with
    this design.

    6.3b

    WATER BLOCKED MV XLPE CABLE


    Aspects of a Water Blocked Cable Design:
    Conductors
    Wetting water blocked conductor.

    6.4

    WATER BLOCKED MV XLPE CABLE


    Aspects of a Water Blocked Cable Design:
    Copper Tapes
    Water blocking of copper tapes is achieved by applying a semi-conducting
    swellable tape under the copper tape, which provides electrical contact
    between the core screen and copper tape.
    Over the copper tape could be water blocked with swellable yarns applied as
    a filler during lay up, if required.

    6.6

    WATER BLOCKED MV XLPE CABLE


    Aspects of a Water Blocked Cable Design:
    Armour
    Water blocking of the armour is achieved by flooding the armour with bitumen
    which seals the interstices between the armour wires and enhances the
    corrosion resistance of the armour wires.

    6.7

    WATER BLOCKED MV XLPE CABLE


    Aspects of a Water Blocked Cable Design:
    Other issues
    Special Manufacture
    Lead time for materials
    Cost increase

    7.1

    WATER BLOCKED MV XLPE CABLE


    Impact of Water Blocking on Lugs & Ferrules:
    Concern
    Water blocking tape between the layers of a stranded conductor prevents
    current from flowing freely between layers.
    Over a long length of conductor this is no problem because there is no useful
    radial component to current.
    It is a concern in the case of lugs and ferrules where there is a significant
    radial component to current.
    In the steady state the heat sink effect of metals in contact will prevent
    dangerous temperatures.

    In the transient adiabatic situation short duration high temperatures could


    occur.

    7.2

    WATER BLOCKED MV XLPE CABLE


    Impact of Water Blocking on Lugs & Ferrules:
    Test method
    Comparative testing is carried out between bare conductors without water
    blocking components and bare conductors with water blocking components.
    Each sample is terminated using lugs, and jointed mid-span with a connector
    (ferrule).
    The temperatures in the connector, adjacent to the contact between conductor
    and connector, as well as of the conductor away from the connector, is
    measured.
    The conductors are loaded to specific conductor temperatures and the
    connector temperatures are measured.
    Any increase in the connector temperature for the same conductor
    temperature indicates that there is some resistance to radial current at the
    connector.

    7.4

    WATER BLOCKED MV XLPE CABLE


    Impact of Water Blocking on Lugs & Ferrules:
    Conclusion
    Early indications are that there may be a slight increase in resistance to radial
    current.
    The likelihood of this causing damage to the insulation is low during a fault,
    because no insulation should be present at hot spot.
    Never-the-less water blocking materials should be removed from conductors
    inserted into connectors and lugs, until proven that this is not necessary.

    8.4

    WATER BLOCKED MV XLPE CABLE


    Aberdares Test Rig

    Thank you

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