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Advanced Design of Metal Laminated Coverings:

Recommendation for Tests, Guide to Use, Operational Feed
Back
Working Group
B1.25
February 2011
Advanced design of metal laminated coverings
Recommendation for tests
Guide to use
Operation feed back
Working Group
B1.25
Members
Pierre MIREBEAU (France) - (Convener), Jean BECKER (Belgium) - (Secretary),
Bruno FAINARU (Israel) - Tommy JOHANSSON [Johan KARLSTRAND] (Sweden),
Matthias KIRCHNER (Germany), Frank MIDDEL (Netherlands), Giovanni POZZATI (Italy),
Giao ROINEL [Pierre ARGAUT - Matthieu SURDON] (France),
Kenichiro TANIMOTO (Japan), Kenneth BOW (USA), Hans MAYER (Australia),
Bjorn SANDEN [first year only] (Norway)
Corresponding members
Aloisio LIMA (Brazil), S. RAMAPRASATH (India)
Copyright © 2010
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company network is forbidden”.
Disclaimer notice
“CIGRE gives no warranty or assurance about the contents of this publication, nor does it accept any
responsibility, as to the accuracy or exhaustiveness of the information. All implied warranties and conditions are
excluded to the maximum extent permitted by law”.
,6%1
1
Table of contents
FOREWORD: ............................................................................................................. 4
INTRODUCTION: ....................................................................................................... 5
1 DEFINITIONS ...................................................................................................... 7
1.1 Metal laminated covering:....................................................................................................................... 7
1.2 Design types: ............................................................................................................................................. 7

1.2.1 Combined Design; ................................................................................................................................. 8
1.2.2 Separate Design: .................................................................................................................................... 9
1.2.3 Separate semi-conductive Design: ....................................................................................................... 10
Conclusion on laminated covering designs: ...................................................................................................... 11
2 RECOMMENDATION FOR TESTS: .................................................................. 11
2.1 Development tests................................................................................................................................... 12

2.1.1 Tests on cable ...................................................................................................................................... 12
2.1.1.1 Impact test ................................................................................................................................... 12
2.1.1.2 Abrasion test: .............................................................................................................................. 14
2.1.1.3 Sidewall pressure test.................................................................................................................. 15
2.1.1.4 Long term ageing of the adhesive bonds of the components of the laminated covering: ........... 17
2.1.1.5 Mechanical properties of the welding (case of CD design): ....................................................... 18
2.1.2 Tests on cable system .......................................................................................................................... 20
2.1.2.1 Short circuit test .......................................................................................................................... 20
2.1.2.2 Corrosion at the accessories ........................................................................................................ 23
2.1.2.3 Thermal cycle test and Thermo-mechanical test ......................................................................... 23
2.2 Type tests ................................................................................................................................................ 24

2.2.1 Tests on cables ..................................................................................................................................... 24
2.2.1.1 Bending test ................................................................................................................................ 24
2.2.2 Tests on cable system: ......................................................................................................................... 24
2.2.2.1 Type test following IEC standard: .............................................................................................. 24
2.3 Sample test .............................................................................................................................................. 25

2.3.1 Adhesion and peel strength of the laminated metal foil ...................................................................... 25
2.3.2 Electrical properties and dimension: ................................................................................................... 27
2.4 Routine tests ........................................................................................................................................... 27
2.5 After installation tests ............................................................................................................................ 27
2.6 Tests from earlier recommendation no more considered ................................................................... 28

2.6.1 Tests on cables:.................................................................................................................................... 28
2.6.1.1 Fatigue (2.1.2 from Electra 141): ................................................................................................ 28
2.6.1.2 Radial moisture penetration (1.1 from Electra 141):................................................................... 28
2.6.1.3 Spike test (6.3.3 and appendix E from BS 7970): ....................................................................... 29
2.6.1.4 Thermal cycle test (2.1.2 from Electra 141): .............................................................................. 29
2.6.1.5 Screen contact resistance (1.1 from Electra 141): ....................................................................... 29
2.6.2 Tests on cable system .......................................................................................................................... 29
2.7 Conclusion: ............................................................................................................................................. 30
2
3 GUIDE TO USE: ................................................................................................ 32
3.1 Purchasing: ............................................................................................................................................. 32
3.2 Storage: ................................................................................................................................................... 32
3.3 Laying conditions: .................................................................................................................................. 32

3.3.1 Sidewall pressure: ................................................................................................................................ 32
3.3.2 Direct burying:..................................................................................................................................... 32
3.3.3 Ducts and Tunnels, galleries and shafts: .............................................................................................. 32
3.4 Electrical design vs. Circulation current: ............................................................................................ 33

3.4.1 Connection of copper wires with the laminate: ................................................................................... 33
3.4.2 Long spans: .......................................................................................................................................... 33
3.5 Installation:............................................................................................................................................. 33
3.5.1 Stiffness of the cables .......................................................................................................................... 33
3.5.2 Designs to be avoided .......................................................................................................................... 33
3.5.2.1 Cable construction ...................................................................................................................... 33
3.5.2.2 Screen connection at the accessories .......................................................................................... 34
3.5.2.3 Direct burying of SscD ............................................................................................................... 34
3.6 Repairing: ............................................................................................................................................... 34
3.7 Maintenance: .......................................................................................................................................... 34
4 THE EXPERIENCE WITH CABLES WITH LAMINATED COVERINGS: .......... 36
4.1 World survey: ......................................................................................................................................... 36

4.1.1 Use of cables with advanced laminated coverings: ............................................................................. 36
4.1.1.1 Examples of CD design installation: ........................................................................................... 36
4.1.1.2 Examples of SD design installation: ........................................................................................... 41
4.1.2 Cable designs and market share ........................................................................................................... 42
4.1.3 Questions and feed back received from utilities .................................................................................. 43
4.1.3.1 Experience in service .................................................................................................................. 43
4.1.3.2 Question to CD Design: .............................................................................................................. 43
4.1.3.3 Design SD and CD:..................................................................................................................... 43
4.1.3.4 Design SD and SscD: .................................................................................................................. 43
4.1.3.5 All types (CD + SD + SscD): ...................................................................................................... 44
A.1. FUNCTIONAL ANALYSIS .......................................................................... 45
A.2. BIBLIOGRAPHY ......................................................................................... 61
3
Foreword:
This brochure has been ordered by CIGRE study committee B1 to update the report:
"Guidelines for tests on high voltage cables with extruded insulation and laminated protective
coverings" WG 21.14 published in ELECTRA no141 [1] in April 1992. Further taken into
account by IEC 60840 [3], 62067 [7] and the Technical Report 61901 [6] published in 2005.
Numerous technical improvements appeared on laminated coverings since 1992 in parallel
with service experience.
The present brochure replaces Electra 141.
The Terms of Reference are the following:

To review and update the tests on cables with extruded insulation and laminated protective
coverings taking into account the system view, i.e. the installation of accessories. Tests on
cable, on accessories and on the system itself should be addressed, including the short
circuit one
• To issue a Guide to Use for non experts explaining what could be the different cable
designs
Scope of work:
• Extruded cable systems only
• AC cable systems only with a focus above 36 kV
• Land cables
Deliverables:
The output should be an updated recommendation for tests on high voltage cables with
extruded insulation and laminated protective coverings that includes a guide (for non-
technical readers) with the aim to get customers to reference this guide. Moreover, the WG
will provide an Electra article and a Tutorial for presentation at CIGRE conferences and
workshops.
NOTE: Cables with traditional screen (extruded or corrugated) and plastic oversheath are
excluded
4
Introduction:
The WG began his work by writing a questionnaire to perform a world survey of the use of
laminated coverings. 13 countries answered, which gives a sound overview of the designs
and operation feed back.
Three successful designs are today covering the market:
Combined Design - combined mechanical and electrical properties:

• XLPE Insulation system
• Semi-conductive bedding (water swellable if required)
• Thick metal foil either welded or glued, that carries the full short circuit current
o coated
o and bonded to the outer sheath (usually HDPE)
Additional wires can eventually be added to match the short circuit requirement
The metal foil is mainly aluminium; copper can be used as well.
Separate Design - separated mechanical and electrical properties:

• XLPE insulation system
• Copper or aluminium wires
• Water swelling tapes to block the screen area
• Coated laminated metal foil i.e. for example Al 0,2 mm + 0,05 mm coating on
one side.
• Oversheath (usually MDPE or HDPE )
Metal is mainly aluminium, copper or other metal laminated foils can be used.
Separate semi-conductive Design – separated electrical and water tightness properties

with semi-conductive plastic coated foil.
• Round copper wires screen, non swelling semi-conductive tape below
• thin lead or Al foil (0,05 mm typical) with glue on one side, inner side (screen
side) coated with typically 0,05 mm thick semi-conductive plastic
• Over-sheath (usually PVC)
The operation feed back relative to the use of these three designs as a function of the length
to be laid, the installation method (ducts, directly buried…), the environment, the connection
and grounding of the screen (single point, cross bonding, double point) made it possible for
the WG to write the present brochure.
The First part is the recommendation for tests that replaces the one of ELECTRA 141 [1].
The Second part is a guide to use.
The Third part is the operational feed back.
A functional analysis of the laminated covering is given in the Appendix.
5
PART 1: RECOMMENDATION FOR TESTS
6
1 Definitions
1.1 Metal laminated covering:
A metal laminated covering consists of several layers of plain (not corrugated) metal and
plastic materials bonded together to get a special set of properties: bending ability, radial
water tightness.
It can be used to carry the capacitive, circulating and short circuit currents, according to the
cable system design.
1.2 Design types:

The WG has identified three main cable designs:
7
1.2.1 Combined Design;
In the eighties power cables had a lead sheath. The first driver to introduce laminated
covering instead of lead was to get lighter and cheaper cables. The first studies about the
use of aluminium laminated screens started in the late eighties. Nowadays, also
environmental reasons support this choice (CIGRE 2004).
Copper and other metal-plastic laminate are also used.
Combined Design (CD) - combined mechanical and electrical properties:

• XLPE Insulation system
• Semi-conductive bedding (water swellable if required)
• Thick metal foil either welded or glued, that carries the full short circuit current
o coated
o and bonded to the outer sheath (usually HDPE)
Additional wires can eventually be added to match the short circuit requirement
The metal foil is mainly aluminium; copper can be used as well.
Note : In case copper wires are used in combination with a welded aluminium foil, it is recommended to put a non metal tape
between them to avoid possible corrosion
A CD cable picture is shown in figure 1.
Figure 1: Combined Design 500kV cable
8
1.2.2 Separate Design:
This design was introduced in the eighties when the necessity of a radial moisture barrier
became apparent in cables only having a wire screen and a PE and PVC jacket as water
trees generated and led to cable faults. The principle of the laminated moisture barrier was
taken over from telecommunication cables.
Separate Design (SD) - separated mechanical and electrical properties:

• Copper or aluminium wires
• Water swelling tapes to block the screen area
• Coated laminated metal foil i.e. for example Al 0,2 mm + 0,05 mm coating on
one side
• Oversheath (usually MDPE or HDPE)
Metal is mainly aluminium; copper or other metal laminated foils can be used.
A SD cable picture is shown in figure 2.
Figure 2: Separate Design 400kV cable
9
1.2.3 Separate semi-conductive Design:
This design was introduced in Japan in the eighties when the necessity of a radial moisture
barrier became apparent in cables only having a wire screen and a PVC jacket as water
trees generated and led to cable faults.
First cables used a lead laminated foil. Now Aluminium laminate is introduced as well.
Separate semi-conductive Design (SscD) – separated electrical and water tightness

properties with semi-conductive plastic coated foil:
• Round copper wires screen, non swelling semi-conductive tape below
• thin lead or Al foil (0.05 mm typical) with glue on one side, inner side (screen
side) coated with typically 0.05 mm thick semi-conductive plastic
• Over-sheath (usually PVC)
A SscD cable picture is shown in figure 3.
Figure 3: Separate semi conductive Design 275kV cable
10
Conclusion on laminated covering designs:
As compared to extruded sheaths, the use of laminated coverings (specially when using
aluminium) decreases the weight and diameter of the cable, allows for improvement in
pulling techniques, and also achieves longer delivery lengths on a drum, which, in turn,
decreases the number of joints in a circuit link.
Potentially, a significant impact on cost reduction of the cable system can be achieved.
Since the late nineties, in many countries, the aluminium laminate screen bonded to the PE
oversheath has progressively superseded the lead sheath and the PVC oversheath.
2 Recommendation for tests:
The tests are divided in several classes. They cover the needs of the functional analysis (see
appendix A1), and the technical issues raised by utilities (see world survey 4.1.2):
Development Tests: Tests made during the development of a cable design.
Prequalification Tests: Tests made before supplying on a general commercial basis a cable
design covered by the recommendations in this document. These tests demonstrate the
satisfactory long-term performance of the complete cable system.
Type Tests: Tests that are conducted on cables and accessories, before they are supplied
on a commercial basis, for a cable system covered by the recommendations of this
document. These tests are conducted to verify the properties of a cable system prior to
supplying that particular system.
Sample Tests: Tests that are conducted on samples of complete cables or components, at a
specified frequency, to verify that the product meets the design and manufacturing
specifications.
Routine Tests: Tests made by the manufacturer on every manufactured component (length
of cable or accessory) to demonstrate the integrity of the manufactured component.
Tests after Installation: Tests made on a completed cable system, after installation and
prior to use, to demonstrate system integrity.
11
2.1 Development tests
2.1.1 Tests on cable
2.1.1.1 Impact test

There are 3 classes for resistance of the cable sheath to mechanical impact depending on
the design and installation conditions of the cable:
In case of the CD design the concern is that mechanical impact to the laminated covering
could damage the metal component and alter the electric functionality of the screen;
therefore, the impact resistance of the laminated covering must be the highest.
In case of the SD design there is not a concern that mechanical impact to the metal
component of the laminated covering will alter the electric functionality of the screen. The
cable can be operated with short circuit capability provided by the presence of the screen
wires. However, the impact resistance of the laminated covering should be high enough to
preserve the radial water tightness function provided by the laminated covering.
In case of the design SscD, In case of the design SsdD, there is no need for the impact test
as the cable is designed to be installed in duct or tunnel, not directly buried, see 3.3.2.
Table 1: impact test requirements
Impact test Design CD Design SD Design SscD
Height (m) 0,27 1 n/a

Weight (kg) 27 5 n/a
R (mm) 1 2 n/a
Number of impacts 4 at the same location 1 impact at 5 different n/a
points more than
100mm apart
Figure 4: Test apparatus for the impact test

Sample:
A piece of cable, at least 1m in length
12
Test:
a) Test on CD design
The cable should be installed on a rigid metal base.

The test should be undertaken at 20±15 °C using a weighted metal of 27 kg wedge falling
onto the cable from a height of 0,27 m. The wedge should have a radius R of curvature of
1mm at the point of impact and its axis should be perpendicular to that of the cable (figure 4).
The requirements for the impact test are presented in Table 1.

The impact test shall be performed at 4 locations along the cable, at 150 mm distance from
each other. For investigation during development, one impact is performed at position 1, two
at position 2, three at position 3, and for the test assessment four at position 4 (Figure 5).
The test shall be performed on the overlap or on the welded seam (Impact Point A) as on the
opposite side of the cable (Impact Point B).
≥ 250 150 Dim in mm
A A1 A2 A3 A4
B B1 B2 B3 B4
75 ≥ 250
525
Figure 5: Positions of the points of impact
Result: Visual inspection and measurement of impact depth.

After the impacts the sample shall be cut longitudinally along two lines at 90° from the points
of impact. The inner side of the metal screen or metal sheath shall be examined with normal
vision.
- There should be no puncture at the points of impact A4 and B4.
- A longitudinal cut shall be made through the fourth points of impact, A4 and B4 (Figure 6).
The semi-conductive screen should not be deformed by more than 1 mm and should not
show a deflection having a sharp angle into the insulation at the point of impact. See
distance d in the illustration of the impact point.
Over sheath
Screen or metal sheath
Outer semi-
conductive layer
d
Penetration into the insulation
Figure 6: Deformation at the impact points to be examined
13
b) Test on SD design
The impact test on the SD design is carried out as per IEC 61901 [6]
The cable, at least 1 m in length, should be installed on a rigid metallic base. The test should
be undertaken at 20±15 °C using a weighted metal wedge of 5 kg falling onto the cable from
a height of 1 m. The 90° wedge should have a 2 mm radius of curvature at the point of
impact and its axis should be perpendicular to that of the cable (figure 4).
An impact should be successively made at five different points along the cable; the distance
between any two impact points should be at least 100 mm.
Result - visual inspection:

A 1 m sample should be dissected and visually examined. Examination of the samples with
normal or corrected vision without magnification should reveal no cracks or separation of the
metal foil of laminated protective coverings or harmful damage to other parts of the cable.
c) Test on SscD design

No test is needed due to the specific installation conditions (see part 2).
2.1.1.2 Abrasion test:

In the case of cables with laminated coverings, the over sheath has a function of preventing
abrasion which could expose the metal component leading to corrosion of the metal foil. The
abrasion test is considered of high functional importance as a first line of defence against
corrosion.
The abrasion test shall be carried out if the oversheath material is not of type ST2 (PVC) or
ST7 (MDPE – HDPE) of IEC standards 60840 [3] and 62067 [7], where the world survey
(4.1.2) has provided feedback of satisfactory performance against abrasion.
The abrasion test should be performed on new materials, where satisfactory feed back on
abrasion resistance from operation has not been provided.
The test procedure:

A complete piece of cable shall be tightly fixed to a metal base.
A conical test piece shall be applied to the upper surface line of the cable. The conical
piece shall have a radius of curvature at its point of contact of 1 mm and the angle to
the surface line of the cable shall be 90°. The mass of the piece shall be of 48 kg. The
conical surface shall be smooth.
The conical piece shall be subjected to a motion to and fro, at constant speed,
between the marks A and B as shown in Figure 7:
48 kg
90 °
A B
Figure 7: Test arrangement for the abrasion test
14
The characteristics of the test shall be:
- Distance between A and B: 50 cm ± 10 cm

- Speed of the conical piece between points A and B: 0,3 m/s with a tolerance of
± 15 %
- 4 motions to and fro of the conical piece
At the end of the test, it shall not be possible to see, with normal or corrected vision
and without amplification, the metal screen under the over sheath between the A and
B marks.
Case of SscD design

No test is needed due to the specific installation conditions (see part 2 paragraph 3.3.2).
2.1.1.3 Sidewall pressure test
The current installation practice allows for a sidewall bearing pressure test, according to the
table below, when the over sheath materials are ST2 or ST7 as mentioned in 2.1.1.2.
The test shall be carried out if the designed value of sidewall pressure during installation is
expected to be higher than the one indicated in Table 2, provided the cable has successfully
passed the impact (2.1.1.1) and abrasion (2.1.1.2) tests (these tests govern the wall
thickness of the oversheath).
Table 2: Maximum acceptable sidewall pressures
Design CD/ST7 CD/ST7 + wires SD/ST7 SscD/ST2
T/R (DaN/m)* 2500 1000 1000 750
*T= tensile stress on the cable, R= Bending radius
In case of special cable design (i.e. where optical elements are integrated into the power
cable structure), it is recommended to carry out the test even if the sidewall bearing pressure
during installation does not exceed the above values in Table 2.
15
The test procedure:
The proposed test arrangement and procedure is according IEC TR 61901 [6], paragraph
5.2.
A cable sample 15 m in length should be tested using a test arrangement such as that shown
in Figure 8 A.
Fixed wheel
50 m
Winch
Hydraulic pulling device

Tensioner
A B
Figure 8: Sidewall pressure test arrangements
The cable should be subjected to one pass forward and one pass backward around a fixed
wheel under the assigned sidewall pressure (T/R), calculated using the tension in the steel
wire (T) and the wheel radius (R). The radius should not be greater than the radius used for
the bending test (see IEC 60840 [3], 12.3.3). The cable should be in contact with the wheel
for at least 90° during the test. Lubricant should be applied at the contact point on the wheel.
The test may be made by other means, for example by pulling a cable 180° around a fixed
wheel (figure 8 B). A number of small diameter rollers (50 mm to 100 mm) can also be used.
The use of rollers may result in very high localised pressure. The amount of pressure
depends on many parameters: diameter of the rollers, bending radius, distance between
rollers, cable stiffness, etc. The method/rule to define the diameter of the rollers and the
distance between the rollers has to be set according to the practice of the cable
manufacturer and the information presented in CIGRE TB 194 [28].
Result - visual inspection:

A 1 m sample subjected to the sidewall pressure should be dissected and visually examined.
Examination of the samples with normal or corrected vision without magnification should
reveal no cracks or separation of the metal foil of laminated protective coverings or harmful
damage to other parts of the cable.
16
2.1.1.4 Long term ageing of the adhesive bonds of the components of the laminated covering:
Temperature:
In close trefoil formation the actual sheath temperature in operation can reach 80 °C when
the conductor temperature is 90 °C; so the recommended temperature for the long term
ageing of the bonding is 80 ±3 °C(1).
The test has to be performed on the three cable designs.
Test conditions:
A 1 m sample bent in 2.2.1.1 shall be placed in a solution of 1 % NaCl, 1 % Na2SO4 with

NaOH added to adjust a pH of 8,5 ± 0,5. The solution shall be maintained at (80 ± 3) °C
during the test. The cable with both ends sealed shall be immersed at a depth of at least 0,5
m.
The cable sample shall be removed from the solution after 3000 h of immersion and shall
comply with the following requirements.
Requirements:
The adhesion strength and peel strength of the metal foil shall be measured at room
temperature in accordance with 2.3.1. The results should comply with the table 3
requirements.
A 1 m sample shall be dissected and visually examined. Examination of the sample with
normal or corrected vision without magnification should reveal no cracks, no corrosion and
no harmful damage to other parts of the cable.
(1)
As compared to 70 °C in case of the corrosion test of Electra 141.
17
2.1.1.5 Mechanical properties of the welding (case of CD design):
General :
The elongation at break of the welded metal should be checked as it indicates the quality of
the welding process. This test has to be carried out in case of longitudinal welding as well as
in case of transverse welding when two laminates are jointed together.
Test arrangement :
The test arrangement is described figure 9. The test samples are prepared by either by
decreasing the sheath thickness down to 0,5 mm, so the metal surface is not altered and the
mechanical contribution of the sheath remaining thickness is negligible as compared to the
metal laminate, or taking the samples just before extrusion of plastic sheath. The edges of
the samples must be smoothed or LASER cut to avoid initiation of cracks from a cutting
defect.
The test shall be performed at ambient temperature. The distance between grips is about
100mm; the sample width is between 10mm and 50mm. The separation rate of the grips of
the tensile testing machine shall be 20 mm/min. The test is performed on 5 samples
including the welded zone and on 5 samples not including a welded zone. The break should
be out of the welded zone.
Two marks are drawn on the sample, one on each side of the welding. Reference marks
have to be taken at not less than 10 mm from the welding, at each side, as shown in Fig. 9.
18
Results
The median values of tensile strength and elongation at break are calculated.
The median elongation at break and the median tensile strength of the samples with the
welding should be respectively more than 70% and 80% of that of the non welded samples,
measured between the two marks.
Figure 9: Test arrangement for the measurement of the mechanical properties of the
welding, dimensions in mm.
19
2.1.2 Tests on cable system
2.1.2.1 Short circuit test
In the case of a single phase short circuit, the current can flow through the metal screen, the
metal screen / accessory connection, the ground lead of the joint or the termination.
The following test has been designed to test these components and connections in a simple
way. It simultaneously tests the cable, the connection to accessories, the accessories, the
grounding connection, and the grounding cables.
The electric parameters of this test have been chosen to be such that the test capabilities are
available in many laboratories at an acceptable cost.
If the requested short current is higher than 50 kA and no suitable equipment is available, the
applied current may be minimum 50 kA and the time longer to reach the calculated temperature.
This test supersedes the short circuit test on cable previously recommended by ELECTRA
141 [1].
Sample:
The length of the sample of cable is about 5 m with a joint and/or the termination connection.
There is at least 2 m of cable on each side of the joint and earth connection and ground
connection.
If two different metal foils are connected together inside the cable length during
manufacturing, such a metal foil connection should be included in the test.
Test arrangement
In figure 10, the short circuit test arrangement is given for three kinds of joints:
o Straight through joint
o Joint with earth connection
o Sectionalised joint
20
Figure 10: Short circuit test arrangement for three kinds of joints
Rating:
The short circuit rating has to be determined by calculation.

The maximum short circuit duration is 5 s.
Asymmetry is free.
Calculation of the short circuit rating for design CD:
Calculations shall be performed following IEC 60949 [4]:

- For the calculation of the non adiabatic factor for over sheaths, the formula of
paragraph 6.1 shall be taken.
- The factor F (factor to account for imperfect thermal contact) is 0.9.
- The maximum temperature during short circuit considered in IEC 61443 [5] is
200 °C (ST2) or 180 °C (ST7). However, higher temperatures have been
specified in national standards or manufacturer’s specifications.
- According to the operation and tests feed back, a temperature of 250 °C is
acceptable. A higher temperature is not recommended.
21
Short circuit rating for design SD or CD + wires:

- The current share between the two different metal screen components is
equal to the inverse ratio of their respective resistances.
- For the calculation of the non adiabatic factor for over sheaths, the formula of
paragraph 6.1 shall be taken.
- The factor F (factor to account for imperfect thermal contact) is 0.9 for the
laminated covering and 0.7 for the screen wires.
- The short circuit temperature considered in IEC 61443 [5] is 200 °C (ST2) or
180 °C (ST7) for the laminated covering. The most demanding limit shall be
adopted. However, depending on the specific design, national standards or
manufacturer’s specifications might supersede these values.
- According to the operation and tests [31] feed back, a temperature of 250 °C
at the screen wires is acceptable.
Note : when there is a layer thermally separating the screen wires from other materials in the cable, a temperature of 350°C is
allowed
Short circuit rating for design SscD:

- The current share between the two different metal screen components is
equal to the inverse ratio of their respective resistances.
- For the calculation of the non adiabatic factor for over sheaths the formula of
the paragraph 6.1 shall be taken.
- The factor F (factor to account for imperfect thermal contact) is 0.9 for the
laminate and 0.7 for the screen wires.
- The short circuit temperature considered in IEC 61443 [5] is 200 °C for the
laminated covering. National rules or manufacturer’s recommendations might
supersede these values.
Test:
Five short circuits shall be applied successively to the assembly:

• Before the short circuit test, the cable conductor shall be heated and stabilised for at
least 2 h at a temperature 90 to 95 °C.
• The short circuits are separated by an interval of time long enough to cool down the
cable screen within 5 K of its initial temperature.
Result - visual examination and integrity of the laminate:

A 1 m cable sample including the metal foil connection if any, should be dissected and
visually examined. Examination of the samples with normal or corrected vision without
magnification should reveal no cracks or separation of the metal foil of laminated
protective coverings or damage to other parts of the cable.
There shall be no sign of harmful deterioration of the cable / joint screen connection,
neither at the cross bonding leads nor at the grounding connections.
The adhesion strength and peel strength should be according to 2.3.1 table 3.
22
Extension of qualification rule:
The cable system design will be qualified for other cross sections and voltages provided that
the calculated temperature at the end of the short circuit and the maximum current, if lower
than 50 kA, are both lower or equal to the one tested.
2.1.2.2 Corrosion at the accessories
This test was added as corrosion at accessories was a concern during the world survey. It
has to be performed on the three cable designs.
The test has to be performed with the same equipment as the one defined in IEC 62067 [7b]
or 60840 [3b], appendix G: "Test of outer protection for buried joint".
The test is carried out using natural or tap water. Deionised water is not allowed.
The test assembly shall be immersed in water to a depth of not less than 1 m at the
highest point of the outer protection. This may be achieved by using a header tank
connected to a sealed-off vessel containing the test assembly.
A total of 20 heating/cooling cycles shall be applied by raising the water temperature
to within 15 K to 20 K below the maximum temperature of the cable conductor in
normal operation. In each cycle the water shall be raised to the specified temperature,
maintained at that level for at least 5 h and then be permitted to cool to within 10 K
above ambient temperature. The test temperature may be achieved by diluting the
water with water of higher or lower temperature. The minimum duration of each
heating cycle shall be 12 hours and the duration for raising the water temperature to
the specified temperature shall be as much as possible the same as the duration for
cooling the water equal to or less than 30 °C or 10 K above ambient temperature.
Result – examination:
There should be no sign of corrosion of any metal part of the accessory: connection of the
cable to the accessory, accessory screen, accessory bonding leads.
2.1.2.3 Thermal cycle test and Thermo-mechanical test

The thermal cycles and thermo-mechanical tests are addressed, if needed, in the relevant
cable standards IEC 60840 [3] and IEC 62067 [7] and cover all the development
requirements of advanced laminated coverings
23
2.2 Type tests
2.2.1 Tests on cables
2.2.1.1 Bending test

This test is a lead test for various tests, that is:
• long term ageing of the adhesive bonds of the components of the laminated covering
• electric tests
The cable sample shall be bent around a test cylinder (for example, the hub of a drum) at
ambient temperature for at least one complete turn and unwound, without axial rotation. The
sample shall then be rotated through 180° and the process repeated. This cycle of
operations shall be carried out three times in total.
The diameter of the test cylinder shall not be greater than:
• 20(D+d) for CD
• 25(D+d) for SD and CD + wires
• 10Ds for SscD
Where 2
D is the nominal overall diameter of the cable,
d is the nominal diameter of the conductor.
Ds is the nominal diameter of the shielding layer
Result:
One sample of 3m length shall be examined. There shall be no delaminating, folding of the
metal foil, radial buckling or crossing of the screen wires.
Adhesion and peel tests shall comply with the requirements of table 3 of paragraph 2.3.1.
In the case of SccD, no delamination shall occur.
2.2.2 Tests on cable system:
2.2.2.1 Type test following IEC standard:

The tests and sequence of tests are following the relevant IEC standard (IEC 60840 [3] or
62067 [7]) but the bending test is replaced by the one defined in 2.2.1.1.
The examination at the end of the type test should include a piece of cable, to show that
there is no delaminating, folding of the metal foil, radial buckling or crossing of the screen
wires.
2
This definition is the same as the one in paragraph 6 of IEC 62067
24
2.3 Sample test
2.3.1 Adhesion and peel strength of the laminated metal foil
In case of the CD design the concern is that delaminating could damage the metal
component and alter the electric functionality of the screen; therefore, the adhesion strength
and peel strength of the laminated covering must be the highest.
In case of the SD design there is not a concern that delaminating will alter the electric
functionality of the screen. The cable can be operated with short circuit capability provided by
the presence of the screen wires. However, the adhesion strength and peel strength should
be high enough to preserve the laminate from folding and buckling.
In case of the design SscD, the test cannot be performed because the metal foil is so thin
that it breaks during the adhesion or peeling strength test.
Table 3: Minimum acceptable adhesion or peel strength forces
Type of screen
Adhesion or CD SD SscD
Peel Strength
N/mm Copper 1.5 Copper 1.0 Lead NA*
N/mm Alu 1.5 Alu 1.0 Alu NA*
N/mm Overlap 1.5 Overlap 1.0 Overlap NA*
*test cannot be performed
Test: Adhesion strength

The test specimen shall be taken from the cable covering where the metal foil adheres
to the oversheath.
The length and width of the test specimen shall be 200 mm and 10 mm respectively.
One end of the test specimen shall be peeled between 50 mm and 120 mm and
inserted in a tensile testing machine by clamping the free end of the oversheath or the
insulation screen in one grip. The free end of the metal foil shall be turned back and
clamped in the other grip as shown in Figure 11.
25
Grip
Oversheath
Metal foil
Grip
Figure 11: Adhesion of metal foil
The specimen shall be maintained approximately vertical in the plane of the grips
during the test by holding the specimen.
After adjusting the continuous recording device, the metal foil shall be stripped from
the specimen at an angle of approximately 180° and the separation continued for a
sufficient distance to indicate the adhesion strength value. At least one half of the
remaining bonded area shall be peeled with a speed of approximately 50 mm/min.
NOTE: When the adhesion strength is greater than the tensile strength of the metal foil so that the
latter breaks before peeling, the test should be terminated and the break point should be recorded.
Test: peel strength of overlapped metal foil
Procedure
A sample specimen 200 mm in length shall be taken from the cable including the
overlapped portion of the metal foil. The test specimen shall be prepared by cutting
only the overlapped portion from this sample as shown in Figure 12.
Specimen
Oversheath
Metallic foil or
laminated metallic foil
Figure 12 − Example of overlapped metal foil
The test shall be conducted in the same manner as described for the Adhesion
strength. The arrangement of the test specimen is shown in Figure 13.
26
Grip
Oversheath
Metal foils
Grip
Figure 13 − Peel strength of overlapped metal foil
2.3.2 Electrical properties and dimension:

The DC resistance of the screen and the dimensions of the metal part of the laminated have
to be checked in accordance with the relevant standards.
2.4 Routine tests
There is no specific routine test to be associated with advanced laminated coverings. The
relevant standard is to be applied.
2.5 After installation tests
There is no specific after installation test to apply. The relevant standard is to be applied.
27
2.6 Tests from earlier recommendation no more
considered
2.6.1 Tests on cables:
2.6.1.1 Fatigue (2.1.2 from Electra 141):

Aluminium based laminated coverings:
There has been a long experience with corrugated aluminium screen Self Contained Oil
Filled cables. This design has given a satisfactory fatigue result for more than 30 years, ref
JICABLE 07 B-44 [60].
It well known that the laminate design (bonding of layers together) improves the fatigue
properties of the metal foil.
Experiments have been carried out on cables with advanced laminated covering of SccD
design (JICABLE 03 A-1-5 [45]). They confirmed that no issue about fatigue was to be feared
for conventional laying distances (< 13km), and state of the art installation design.
No fatigue issue was reported from the world survey.
The successful completion of a type test (including the examination of the cable after the
bending test and at the end of the type test, looking to delaminating, folding of the metal foil
and radial buckling or crossing of the screen wires) should assess the quality of the cable
design and consequently the absence of fatigue issue during installation and operation.
Other metals:
Copper is known to be as good as aluminium. For other metals, an investigation should be
performed.
2.6.1.2 Radial moisture penetration (1.1 from Electra 141):

This test was "under development" in Electra 141 [1].
A simple test, adapted from ASTM E 96 by Tokyo Electric Power Company has been
included in some specification and performed in France, Japan, Korea, and Taiwan.
Results showed that there is no detectable radial penetration of water in the case of metal
laminated coverings. Ref JICABLE 07 C5111 [59]
.
A high sensitivity test was reported at "Power Technology International 1993 [61] »:
A piece of 24 kV hollow cable with overlapped aluminium foil bonded to over-sheath was
introduced in a carefully closed steel chamber filled at 50 °C with water containing hydrogen
isotope tritium. Exposed length was 246 mm. Water permeates into the centre of the cable
and is collected in a vial. The quantity of tritium is detected by liquid scintillation analysis,
which is 109 times more sensitive compared to classical method.
The measured permeation rate of the laminated covering, SD type, was around 1,5 ng m-2 s-
1
, i.e.1000 times less than what permeates through a 2 mm thick PE sheath without metal
barrier.
The long term ageing test of 2.1.1.4 validates the cable design in reference to the moisture
penetration.
28
2.6.1.3 Spike test (6.3.3 and appendix E from BS 7970):
This test proves that the cable can transit the short circuit current during the required time in
case of internal failure.
It has been prescribed in British Standard 7970 [12].
Results have been published in Jicable 1999 A2-6 [37]. No problem was reported.
The WG is not aware of any problem in operation.
This costly test has then been removed from the recommendation.
2.6.1.4 Thermal cycle test (2.1.2 from Electra 141):

In ELECTRA 141 [1], 100 cycles were to be performed, then the cable examined.
Two alterations could happen:

• The fatigue, that has proven to be not an issue see 2.6.1.1.
• The decrease of the peeling strength, which could happen in case of bad design, and
is checked in 2.1.1.4.
Moreover, a system test, as recommended in CIGRE brochure TB 303 [29], is included in the
IEC 62067 [7a and b], and is likely to be included in IEC 60840 [3b],. This test requires 180
load cycles. It will give credibility to the system design.
Note : In the case there is not a system test in IEC 60840 (cond screen stress < 8kV/mm or ins. screen stress < 4kV/mm), the
sheath shrinkage could be measured over 80 load cycles according to CIGRE brochure 303.
2.6.1.5 Screen contact resistance (1.1 from Electra 141):

The issue was the contact between the copper wires and the aluminium foil.
This test was under development in ELECTRA 141 [1]
No specific test has been proposed since then.
The problem has been solved through the system design.
2.6.2 Tests on cable system

There was no test on cable system in ELECTRA 141 [1].
29
2.7 Conclusion:
The recommendation for tests has been written taking into account:
• The cable designs as pointed out by the world survey

• The tests of ELECTRA 141 [1] that are considered as relevant to evaluate the quality
of the system by the cable manufacturers.
• The cable system design.
• The questions raised by the operation feed back. New tests are proposed when
needed.
Cable systems validated in reference to the recommendation should be sound.
30
PART 2: GUIDE TO USE
31
3 Guide to use:
The Guide to use section is dealing with the specificities of cables with laminated metallic
coverings. For a general guidance
• on the selection of high voltage cables, refer to IEC 60183 [2],
• on laying practices, refer to CIGRE TB 194, (2001) [28].
3.1 Purchasing:
The cables with laminated coverings are lighter and smaller in diameter than the ones with
extruded screen.
A longer length between joints can be achieved.
Depending on the circuit characteristics the most adequate design (CD, SD or SscD) is to be
selected.
3.2 Storage:
Cables with aluminium laminated coverings are sensitive to moisture ingress. A special
attention, as for other high voltage cables, must be paid to the protection of the cable ends
during storage and installation works.
3.3 Laying conditions:
3.3.1 Sidewall pressure:

When the cables are pulled from one end of the span, the sidewall pressure should be lower
than the one of the table in 2.1.1.3, depending on the cable design. If not, the acceptable
level should be measured.
3.3.2 Direct burying:

Design SscD should be avoided.
The direct burial of cables is described in the CIGRE brochure TB 194 [28], paragraph 3.2.2.
There is no special limitation regarding the use of design SD or CD.
A special attention must be paid to the homogeneity of the soil properties, as for any directly
buried HV link.
3.3.3 Ducts and Tunnels, galleries and shafts:

All designs can be used.
A semi-conductive layer over the sheath is highly recommended to be able to perform the
after installation sheath integrity test (DC test between screen and outer semi-conductive
layer).
32
3.4 Electrical design vs. Circulation current:
3.4.1 Connection of copper wires with the laminate:

The good electrical contact between the copper wires and the metal foil should be effective
during the complete life of the cable.
It can be achieved either at accessories, either by design along the cable length.
In the case of SD design, the contact with the metal foil may be distributed over the full
length of the cable depending on the cable detailed design.
The WG recommends connecting the metal foil to the accessories metal screen whatever the
particular realisation of the SD design (so called open and closed design).
3.4.2 Long spans:

When there are long spans with circulating currents, a particular attention has to be paid to
the endurance of the screen contact at the accessories (see 3.5).
Pressed contacts have led to negative feedback in this condition, while their performance is
satisfactory when single point grounding is used.
For voltages equal or higher than 150kV, due the expected high short circuit current and
time, pressed contacts are not recommended whatever the circuit electrical design.
3.5 Installation:
3.5.1 Stiffness of the cables

No reported problem regarding the Stiffness of any of the designs DC, SD, SscD. The
bending diameters are lower than the ones recommended for the extruded jackets.
3.5.2 Designs to be avoided
3.5.2.1 Cable construction
When a design with two metal elements, e.g. Cu wire screen and Al foil is used, there must
be a good electrical contact between the Cu wires and the Al foil. A semi-conductive tape
between Cu wires and Al foil is not good enough because in case of short circuit, the short
circuit current will flow only over the Cu wire screen and will induce a voltage difference
between Cu wire and Al foil. Depending on the cable length the voltage can be high enough
to create a breakdown through the semi-conductive tape. The resulting electric arc will
damage the outer semi-conductor of the cable core and destroy the cable (see
Elektrizitätswirtschaft, Jg. 89 (1990), Heft 11 [62]). For this design it is necessary to have
either:
1. an electrical connection between Cu wires and Al foil at each end of each cable
section (i.e. at joints and terminations).
2. direct electrical contact between Cu wires and the Al foil in the cable: no tape, partly
no tape or special tape e.g. Cu woven tape etc, (see Elektrizitätswirtschaft, Heft 7/92,
Seiten 353 – 356 [63]).
33
3.5.2.2 Screen connection at the accessories
Spring rolls can give rise to hot spots in connection zone at high currents. They should
therefore be avoided when the designed screen current is above 200 A. Welding gives no
hot spots in connections between Al foils and screen strands and should be used. Screen
wires should be spread out, as when bunched together, they lead to higher temperatures.
3.5.2.3 Direct burying of SscD
There is no experience of direct burying of SscD. In case direct burying of this design is
considered, an evaluation similar to the ones performed for design SD will be performed.
3.6 Repairing:
The laminated coverings are very robust (see requirements of paragraph 2.1.1.1 impact test,
2.1.1.2 abrasion test, 2.1.1.3 sidewall pressure test) and a repairing work is seldom needed
when state of the art laying techniques are used.
If there is damage to the outer sheath only, the repair works must rebuild all laminated layers
i.e. glue and oversheath.
If there is a puncture in the metal foil:

• When the cable is still dry (for instance the accident happens during the installation),
it can be repaired and all layers have to be rebuilt. This is a delicate work that needs
training and qualification of the operator. The functionality of the laminated covering
(metal and plastic layers) has to be checked during the repair works.
• When there is moisture in the cable (for instance the accident happen during the
operation and the cable is directly buried), the cable has to be changed over the
length submitted to moisture ingress.
The after installation test of the sheath should be performed after the repair.
3.7 Maintenance:
No special action as compared to extruded metal sheath is required. A periodic test of the
sheath integrity is to be performed once a year as recommended by contribution B1 PS1 Q6
from CIGRE 2004 by K. Bjorlow-Larsen [64].
34
PART 3: OPERATION FEED BACK
35
4 The experience with cables with laminated coverings:
4.1 World survey:
In addition to the 9 countries contributing to the WG, The group has prepared a questionnaire
to assess the feed back of the use of the laminated coverings:
Question 1: Identification of the utility

Question 2: Installed circuit length by voltage range of designs D1, D2, D3 and traditional
extruded cable designs.
Question 3: Trends in volume in the different designs by voltage range
Question 4: Issues regarding cable quality
Question 5: Issues regarding installation and accessories
This questionnaire has been sent to all CIGRE B1 members, they have handed over to their
respective utilities.
We got answer from a total of 13 countries
There are 3 times more SD than CD circuit lengths, mainly due to the large experience of
Germany, and larger than that of SscD. The trend is to increase the number of circuits with
laminated coverings as compared to other designs.
4.1.1 Use of cables with advanced laminated coverings:

Installation:
The survey showed that designs CD and SD are installed in all conditions: tunnels, ducts,
surface through, directly buried.
4.1.1.1 Examples of CD design installation:
4.1.1.1.1 Elancourt France RTE 225kV 2000mm² aluminium:
Description of the route:
Transmitted power: 530 MVA

The route is 11.7km long and includes 7 horizontal drillings.
Accessories:
 6 outdoor terminations
 18 straight joints
 15 cross bonding joints (12 with SVL and 3 directly grounded)
36
Pulling of the cables Installation in ducts
Controlled backfill (weak concrete) Warning lattice
37
4.1.1.1.2 Nanterre Nourotte RTE 225kV 1600mm² copper:
Transmitted power: 470 MVA
The route is 21km long and includes 3 horizontal drillings.
60 joints and 6 outdoor terminations
Cable pulling Pushing caterpillar

(push and pull laying)
4.1.1.1.3 Turbigo-Rho 2000mm² copper 400kV Italy:

Technical details
Transmitted power: 1050 MVA per circuit.
In order to make crossing of some villages possible and to obtain quick permission in an
area having important natural reserves, the under grounding of the last 8.4 km of the total 28
km long line was necessary. To fulfil the thermal power rating of the overhead line, it was
necessary to install two underground 380 kV cables per phase having a 2000 mm² copper
conductor.
The two cable circuits were directly buried in trench at a depth of 1.5 m, one circuit per trench
with cables laid flat spaced 350 mm and a distance between trenches of 6 m, to provide a
continuous rating of each circuit of 1600 A. Each circuit was composed of 12 cable spans
and 4 cross bonding sections.
Outdoor terminations were installed in the overhead/underground transition compound.
Continuous temperature monitoring with a DTS system and continuous partial discharge
monitoring at joints was also applied.
Special magnetic field shielding has been provided where necessary for some part of the
route in order to comply with Italian legal requirements.
38
Construction Issues
The Turbigo-Rho Italian 400 kV Project The Turbigo-Rho Italian 400 kV Project
Two trenches
The undergrounding of part of

40 km long line led to the
speeding up of authorisation Power station
2560 MW
procedures. The line was Milan
Existing OHL 380 kV
necessary for the reinforcement
Overhead line 380 kV
Underground cable 380 kV
County borders
of the transmission grid in a

Transition stations
very congested area avoiding Timeline:

the risk of future blackouts. • 1991Start of discussions
• 1994-2004 Discussions blocked
The max. power rating of the • June 2004 – Decision on partial undergrounding
circuit is 2.2 GVA • Mar 2005 – Construction started
• May 2006 – Activation of the line
4 3
4.1.1.1.4 Madrid Airport “Barajas” 400 kV 2500 mm² copper:

Madrid Barajas airport has been re-developed in 2003 with the construction of two new
runways and terminal and satellite areas. Intrusion of a nearby double circuit 400 kV
overhead line on airport operations and possible radio interference with automatic navigation
systems has led to under-grounding of part of the line. The underground cables are laid in a
12.8 km long prefabricated tunnel. Cable and GIL solutions were compared and XLPE cable
selected as the most competitive solution. The overhead line rating per circuit (1390 MVA
summer / 1720 MVA winter) can be met using one cable per phase equipped with forced
cooling. The two cable circuits are in the same tunnel.
39
Thermal requirements
The high rating of the circuits requires a 2500 mm2 copper conductor and a forced cooling
system, which includes 5 fan stations, distributed temperature sensing (DTS) to measure
circuit and tunnel temperatures and a real-time thermal rating (RTTR) system that
commands and integrates all subsystems. The forced cooling system is designed for a
summer air intake temperature of 35 ºC, maximum tunnel air temperature of 50 ºC and
maximum air speed of 5 m/s. The limiting parameter is the temperature of the 400 kV cable
joints. The tunnel temperatures (air at the top of the tunnel and hottest cable) are
continuously monitored by the fibre optic DTS system. The RTTR interfaces with the DTS
and controls the cooling fan speeds. Circuit parameters, such as load, temperatures,
surrounding environmental conditions, etc. are continuously monitored by the RTTR system
to calculate in real time the maximum loads (steady state and short term overload) that could
safely be applied to the circuits. Cable sheath bonding consists of a combination of 5 x 3
cross-bonded sections 810 m long and two single point bonded lengths at the ends (300 m at
one end and 400 m at the other). This configuration ensured the manufacturing of 90 drums
of identical length and eventual route changes adopted during civil works construction have
been absorbed by these cable ends.
Installation details
The technical solution that meets project electrical and thermal requirements consists of a 2
m x 2.25 m tunnel buried at an average depth of 2 m. The cable circuits, supplied by two
manufacturers, are laid in a vertical configuration, one at each tunnel side with a phase
separation of 0.5 m. Due to high mechanical stresses present in the cables with load
variations, a flexible cable laying (snaking system) was chosen to minimize longitudinal and
radial stresses on cable and accessories. Cables are fixed on metallic supports fixed to
tunnel walls every 6 m. The cables rest on saddles and brackets and are tied together by
means of three phase spacers at the 3 m intermediate point between two supports. Spacers
are used to reduce electro dynamic forces generated during a short circuit. Sag applied to
cables after laying is equal to 0.25 m. All metallic supports used for cable laying have been
designed to resist maximum electro dynamic forces during a short circuit.
40
4.1.1.2 Examples of SD design installation:
4.1.1.2.1 Diagonal BEWAG Berlin Germany 400kV 1600mm² copper:

In 1994, Bewag's insular existence came to an end when it was connected to the supra-
regional interconnected grid (VEAG Wolmirstedt). Part of this connection consists of a new
380 kV overhead power transmission line and a new 380 kV oil-filled cable system which
was used to provide an inner city link-up with the Reuter substation in Spandau district. A
380 kV connection (overhead line and oil-filled cable) between the Reuter and Mitte
substations, which had come into operation as early as 1978, enabled power to be supplied
from the grid to the city centre of Berlin.
The entire 380 kV diagonal link
The extension of the 380 kV cable network to connect Mitte and Friedrichshain substations
was originally to be carried out by analogy with conventional cut-and-cover methods, as had
been the case with the 380 kV grid link-up. The envisaged extension route ran mostly along
public highways and cuts across various major construction sites (Potsdamer Platz, new
government precinct, Friedrichstraße) and urban development areas at several points. For all
these reasons a feasibility study was carried out to establish whether it would be possible to
have the planned 380 kV cable system installed in a tunnel linking the two substations. The
position of the tunnel was then determined on the basis of geological reports, existing test
drills and realized depth drills. The tunnel runs at a depth of approx. 25 to 30 metres beneath
the land surface. Its outside diameter is 3.6 metres and the inside width 3 metres. The tunnel
is approx. 6.3 km long. The run is approx. 1.1 km shorter than it would have been if
conventional construction methods had been used.
380 kV connection between Friedrichshain and Marzahn substations
The fourth section of the 380 kV diagonal connection between the 380 kV substation in
Friedrichshain and the new substation in Marzahn stretches over a distance of approx. 5.2
km.
The new connection, which completed the diagonal link-up, went into operation in autumn of
the year 2000.
41
4.1.2 Cable designs and market share
Table 4 is limited to the answers received and it shows that the feedback is significant..
Table 4: summary of installed lengths of CD, SD and SscD design in the countries that
gave an answer to the questionnaire
Voltage Range XLPE cable with metal laminated covering XLPE cables with
extruded metal
screens
U (kV) installed circuit (km) installed circuit (km)
Combined Separate Separate E.g. corrugated metal

Design Design SC Design sheaths,
lead sheaths
IT – IR – Be –
IT – IR – Be – DE - AU – DK –
AU – MEX – NL MEX – NL – NZ IT - IR - Be - AU - JP
– NZ – NO – SE – NO – SE – CN DK – MEX – NL – NZ
– CN - FR – FR – USA JP – NO – SE – CN - FR
50 - 109 355 92 6178 8629
110 – 219 286 2573 571 790
220 – 314 109 38 27 1881
315 - 500 33 48 0 167
TOTAL 783 2660 6776 11467
The global trend is an increase of the market share of the laminated coverings, and a
decrease of traditional screens extruded lead, and corrugated metal screens.
Special cases:
Germany, all cables with metal laminated covering are of SD design; this adds 400 km a year
of this type of cable.
In France, all cables are of CD design; this adds 200 km a year of this type of cable.
42
4.1.3 Questions and feed back received from utilities
4.1.3.1 Experience in service

All types (CD + SD + SscD):
Nothing to report
4.1.3.2 Question to CD Design:

Q: Risks of damage to insulation when soldering or welding during installation of the Al tube.
A: When it is performed by qualified fitters, there is no issue. No reported problem up to now
Q: Detection of seam defects.

A: The welding seam is monitored during the manufacturing process, the monitoring must be
recorded. The repair of defects in the manufacturing process is part of the quality procedures
of the supplier.
Q: Sealing against moisture at joints

A: this point is addressed with a specific test in section 2.1.2.2
Q: Occurrence of wrinkles and creases of laminates because of a bad adhesion in the

overlap of the laminate, and bad quality of glue.
A: The quality procedures of the supplier, from the purchasing of the materials, through the
production process, to the final tests, should consider these points. An adhesion and peel
strength of the laminate has been introduced as sample test 2.3.1.
4.1.3.3 Design SD and CD:

Q: Corrosion of aluminium foil
A: In spite of the extensive use of the SD design since the 80's in Germany and the CD
design since the 90's in France, no corrosion problem has been reported up to now.
In Germany, Sweden, Austria, Denmark, the corrosion, if any, of the aluminium foil is not
considered to be an issue as it does not alter the electrical functionalities of the cable.
A good bonding, as checked in 2.1.1.4 and 2.3.1, guarantees a corrosion free operation.
4.1.3.4 Design SD and SscD:

Q: Sliding at the overlap
A: When the cable has successfully passed the "Long term ageing of the adhesive bonds of
the components of the laminated covering" ref to paragraph 2.1.1.4, this phenomenon does
not occur.
Q: Fatigue performance
A: this is not reported as an issue and is addressed at paragraph 2.6.1.1 of this document
Q: Proving continuity of foil in installed cable.

A: This cannot be measured after installation in a proper way. During the manufacturing
process, if there is a metal foil break, the production is immediately stopped. The cable
length has to be re-covered. When the design has been properly checked, there is no break
during the installation phase, as reported by the world survey.
43
Q: Mechanical robustness
A: This is addressed by the bending, impact, abrasion and sidewall pressure test see 2.2.1.1,
2.1.1.1, 2.1.1.2, 2.1.1.3.
Q: Interruption of metal barrier at the transition from cable to joint.

A: A similar design as the one of the overlap of the metal foil along the cable is used to
provide the continuity of the moisture barrier properties at the joint and cable interface.
Q: Interruption of metal barrier at the transition from cable to termination.

A: Terminations are not in submersed areas. A moisture continuity of the properties is not
compulsory, but the sealing against moisture at the end of the metal foil has to be included in
the termination design.
Q: Necessity to get adaptation joint between traditional cables with extruded screen and
cables with a laminated covering
A: Adaptation joints are proposed by manufacturers. The way to qualify them is out of the
scope of the WG B1.25.
4.1.3.5 All types (CD + SD + SscD):

Q: Repairing of the laminate: Twice, during installation, a heavy tool fell on the cable and
damaged the outer sheath and then the Al screen. After survey, RTE changed parts of the
cable.
A: Repairing of the laminate has been addressed in 3.6
The abrasion test of 2.1.1.2 and impact test of 2.1.1.1 make the cable robust enough for a
normal installation practice.
The repairing of the metal laminate has been addressed in the guide to use section 3.6
Q: Are large bending radii necessary?

A: The bending radii as prescribed in 2.2.1.1 are equal or less than the one prescribed for
extruded metal screen designs.
44
A.1. Functional analysis
Functional analysis of the screen and outer protection of accessories to cables with
laminated coverings:
A detailed functional analysis can be found in TB 303 [29], ANNEX 5.4 pp 72 & 73 for the
joint and 78 & 79 for the termination
45
Key properties of the metal covering:
Function Specification / threat Comment
1 -a. Transfers currents circulating in a. Currents in the screen may
Electrical function cable screen, transfers short be important and the ability of
circuit current. the screen connection not to
overheat during cycling should
be checked (not in cycling
tests in IEC)
-b. Current sharing between double
screens if present
2 -a. No hot spot at connection
Mechanical properties -b. No harmful deformation of cable
or joint insulation
-c. No cracking near the connection Cracking may need more than
Metal
180 cycles to appear (180

cycles: long term test
following IEC 62067 ed1).
Severity depends largely on
the installation environment
and conditions.
3 -a. Compatibility with cable and
Chemical properties joint materials
4 -a. Withstands dielectric transients

Screen disconnection (for
cross-bonding)
5 -a. Avoid water ingress to the
Water tightness insulation
1 -a. Isolation of joint from earth

Electrical function
-b. No degradation of dielectric
function with ageing and during
short circuit
2 -a. Mechanical protection of joint

Thermal-Mechanical function
Outer protection
3 -a. Avoid water ingress into the

Water tightness cable
4 -a. Compatibility with inside

Chemical properties material, resistance against soil
aggression (if cable installed in
ground) or other surroundings
5 -a. Possible shrinkage of cable This effect may be not visible

Interface with cable over- over-sheath and/or shrinkage of during a short period
sheath joint outer protection to be taken
into consideration when designing
the outer protection
1 -a. No degradation because of
system
Cable
Overall properties interactions between all

components and of components
themselves
-b. No water penetration before and

after heat cycling into the cable
system
46
Table 4.1.3.1 Functional Analysis of a High Voltage Cable and cable components
Abbreviations: Routine… R, Sample test… S, Type test….T, Development…. D, Pre-Qualification…. PQ
Here after the part related to screen functions and the parts below and above. It is an update of the TB 303 [29] table.
IEC 60840 and IEC 62067 are under revision and will be published in a near future.The paragraph numbers will be harmonised between the two
specifications. In this brochure the paragraphs are taken from the draft documents of IEC 60840 and 62067
Cable’s Function or Specification/Threat Test to check the functionality Comments

component Property (Relevant paragraphs of draft IEC 60840
/62067 in brackets) In blue relevant
paragraphs of this brochure: TB+§
Layer over 1 -a. Low resistivity to avoid PD at -a. PD measurement (R: §9.2, and T: §12.4.4)
Semicon Electrical interface with screen
properties
2 -a. Resistance to mechanical -a. Bending test before type test (T: §12.4.3)
Thermal- bending during manufacturing Examination after completion of the type tests (T:
mechanical and installation §12.4.8)
properties
- b. Prevent deformation of the -b. 20 cycles (T: § 12.4.6) + PD test (T: § 12.4.4)
semicon and the insulation… +examination (T : §12.4.8)
-c. Water-blocking tapes possibly -c. Water penetration test (T: §12.5.14)
avoid the longitudinal water
penetration (if required)
3 -a. Compatibility with semi-con -a. Compatibility test. Ageing on complete cable
Chemical and screen (T: §12.5.4)
properties
-b. Stability of electrical resistivity -b. 20 cycles (T: § 12.4.6) + measurement of
after heat cycles resistivity after ageing (T: 12.4.9)
47
4 -a. Compatibility test (see above) -a. Ageing on complete cable (T) but no
Interface with measurement on tape (see above)
semi-con and
metal screen -b. Avoid deformation of -b. 20 cycles (T: §12.4.6+ examination (T:
insulation (see above) §12.4.8)
Metal Screen/ 1 -a. Satisfy the short-circuit -a. Calculation of cross section needed
Sheath Electrical conditions (following IEC 60949 and 61443) and (D: TB §
properties 2.1.2.1)
-b. Resistance measurement as for conductor
(S, T: §10.5) and dimensions of the screen (S:
§10.7)
-b. Collects capacitive current -b. Calculation of losses in screen (depending on

and induced currents installation conditions – see IEC 60287)
-c. Electrical connection when -c. T: Heat cycling and temperature

more than one metal screen is measurements
applied (D: TB § 2.1.2.1)
-d. Current sharing in two metal -d. Current sharing following conductivities. d. Missing in IEC. CIGRE
layer constructions WGB1-03 has made a report
TB 272 on this subject in 2005
-e. Good contact between metal - e. PD test + cycles +PD (T: 12.4)
screen/sheath and semicon layer
below
-f. Electrical continuity of the -f.: Resistance measurement (S: §10.5)

screen in case of welding
between two adjacent foils in one
cable length
48
2 -a. Supports mechanical bending -a. Bending test before type test (T: §12.4.3
Mechanical TB § 2.2.1.1)
properties -Examination after completion of the type tests
(T: §12.4.8)
-b. Limited deformation of -b. Thermal short-circuit test on screen (D: TB § b. No official thermal short-
insulation and outer semicon in 2.2.1.1) circuit test in IEC specifications
case of short circuit temperature concerning HV cables
rise
-c. Supports radial pressure -c. Thermo-mechanical test with heat cycles and c. needed in special cases see
during heating ageing test (D: TB § 2.1.1.4) 2.1.1.3.
-d. Radial water tightness in case -d. No need to check, see TB § 2.6.1.2
of composite metal foil screen
-f. Fatigue in case of composite -f. No need to check, see TB § 2.6.1.1 f. The operation feed back
metal foil screen when installed shows that no special test is
in non buried conditions needed when the design
complies with the requirements
-g. Side wall pressure in case of -g. See TB § 2.1.1.3 of this brochure
composite metal foil screen
-h. Correct welding between -h. mechanical tests (TB § 2.1.1.5)

adjacent foils in the cable length
49
3 -a. No corrosion of the metal Ageing test (D: TB § 2.1.1.4)
Chemical
properties
-b. Compatibility with layers or -b. Compatibility test

semi-con
5 -a. Compatibility (see above) -a. Compatibility test: -Ageing of complete cable a. See electric contact
Interface with (T: §12.5.4 with visual examination) properties after compatibility
semi-con or layer test
over semi-con
and over-sheath -b. Correct connection with -b. Heat cycles: -20 cycles (T: §12.4.6) or 180 b. Long term PQ test not in
accessories screens cycles IEC 60840 ed3
and interface (PQ: §13.2.4)
with accessories And thermal short-circuit test, this brochure (D:
TB § 2.1.2.1)
-c. Radial water tightness in case -c. Ageing test following this brochure (D: TB §
of metal laminated covering 2.1.1.4)
50
Over sheath 1 -a. Electrical insulation of screen -a. AC/DC test on sheath (R: §9.4) or a spark
Electrical from earth if required test during manufacturing
properties
-b. Insulate for AC and impulse -b. Test combined with test on outer protection of
voltages in case of cross joints
bonding or single point bonding
-c. No degradation of this

property -c. 20 cycles (T: §12.4.6) + AC and impulse test
on sheath
-d. Correct behaviour in case of -d. Short circuit test on screen, this brochure (D:
short-circuit on outer screen TB § 2.1.2.1 )
2 -a. Supports mechanical bending -a. Bending test this brochure (D: TB § 2.2.1.1)
Thermal- during installation
mechanical
properties -b. Resistance to mechanical -b. Mechanical impact: this brochure (D: TB §
impact during and after 2.1.1.1)
installation
-c. Resistance to abrasion during -c. Tests according this brochure (D: TB §
installation 2.1.1.2)
-d. Good mechanical qualities

before and after ageing e.g. no -d. See the different tests on the different types of
cracking of the outer sheath materials in IEC
(T: §12.5)
-e. Resistance to fire if required
-e. Tests under fire following the relevant tests in
IEC (T: §12.5.13)
51
3 -a. Compatibility with screen -a. Compatibility test: -Ageing on complete cable
Chemical (T: §12.5.4)
properties
-b. Resistance to UV -b. Carbon black content in PE oversheaths: (T:
§12.5.12)
-UV stabilizer in other materials: accelerated
weathering test
-c. Resistance to the chemicals -c. Choice of material depending on the

in ground application
-d. Resistance to termites and -d. Special tests depending on type of termites
rodents where needed (special and rodents: D
additives or design)
4 -a. See above -

Interface with
screen, -b. Shrinkage of over-sheath -b. Long term cycling in presence of accessories: b. Included in long-term pre-
accessories or may give problems with (PQ: §13.2.4) or D qualification test of IEC 62067
external accessories (T: §12.5.16 of IEC 60840) (§ 13.2.3) but not in IEC60840
aggression ed3. Shrinkage, if any, is not
necessarily finished after 20
cycles.
Complete 1 -a. No degradation because of -a. Examination after completion of the type tests
cable Different interactions between all (T: §12.4.8)
electrical and components and of components -b. Short circuit test as D depending on the
mechanical themselves network conditions (to be decided with the
needs network engineers); this brochure (D: TB§
2.1.2.1)
-b. No ingress of water to avoid

insulation degradation and -b. Water penetration test (T: §12.5.14)
dielectric problems with
accessories
52
53
Table.4..1.3.2 Functional analysis of High Voltage cable joint and joint components
Here after the parts related to joints and screen connection. It is an update of the TB 303 [29] table.
IEC 60840 and IEC 62067 are under revision and will be published in a near future.The paragraph numbers will be harmonised between the two
Joints Function or Specification/Threat Test to check the functionality Comments

components Property (Relevant paragraphs of draft IEC 60840
Metal 1 -a. Transfers currents -a. Thermal cycles with current circulating in the a. Currents in the screen may
screening, Electrical circulating in cable screen, screen: D. This brochure (TB § 3.5.2.2) be important and the ability of
connection to function transfers short circuit current. the screen connection not to
cable screen overheat during cycling should
Thermal short circuit test following this brochure be checked, or a design
(D: TB § 2.1.2.1) according to this brochure §
3.5.2.2
.No such short circuit test in
IEC 62067 ed1 nor IEC 60840
ed3
-b. Current sharing between -b. Development test D: Thermal cycling with
double screens if present current circulating in the screen and temperature
measurement in the screen area + examination
2 -a. No hot spot at connection -a. 20 Thermal cycles (T: §12.4.6). a. No short circuit test in IEC
Mechanical Thermal short circuit test following the needs of 62067 ed1 nor in IEC 60840
properties the network would be useful as a development ed3
test D
-b. No harmful deformation of -b. 20 Thermal cycles (T: §12.4.6). and

cable or joint insulation examination (T: §12.4.8)
54
3 -a. Compatibility with cable and -a. Thermal cycles (T: §12.4.6)
Chemical joint materials
properties
-b. Avoid corrosion at the -b. this brochure ( TB § 2.1.2.2)
connections
4 -a. Withstands dielectric -a. AC and impulse tests on outer protection of
Screen transients joints (Annex G)
disconnection
(for cross-
bonding)
5 -a. Avoid water ingress to the -a. Water tightness test
Water tightness insulation Long term heat cycles with joint immersed or in
ground followed by a sheath voltage test
This brochure (D: TB § 2.1.2.2)
Eventual 1 -a. Avoid high thermal a. Design aspect
filling Filling of housing resistance
2 -a. Compatibility with -a. Development test to check the good

Chemical surrounding material behaviour of materials in contact with additives:
properties check of mechanical properties of cable materials
and joint materials after ageing in air oven
3 -a. Avoid water ingress to the -a. This brochure (D: TB § 2.1.2.2)
Water tightness insulation
4 -a. Eventually rigidifies the joint a. Design aspect

Thermal-
Mechanical
properties
55
Outer 1 -a. Isolation of joint from earth -a. Test on outer protection (T: Annex H /Annex
protection Electrical D)
function
-b. No degradation of dielectric -b. Long term test (PQ: §13.2.3 + §13.2.4)
function with ageing and Short circuit test on metal screen this brochure
during short circuit (D: TB § 2.1.2.1)
2 -a. Mechanical protection of a.. Design aspect of system

Thermal- joint
Mechanical
function
3 -a. Avoid water ingress into the -a. Test in water on outer protection (T: Annex
Water tightness cable G)
4 -a. Compatibility with inside -a. Long term test (PQ: §13.2.4) + voltage
Chemical material, resistance against withstand test on outer protection after long term
properties soil aggression (if cable test
installed in ground) or other
surroundings
5 - a. Possible shrinkage of -a. Check the shrinkage of the cable sheath and a. May be 20 cycles are not
Interface with cable over-sheath and/or joint protection after heat cycling of 20 cycles (T: enough to see the long term
cable over- shrinkage of joint outer §12.4.6) or 180 cycles (PQ: §13.2.4) behaviour of the shrinkage
sheath protection to be taken into effect
consideration when designing
the outer protection
56
Complete 1 -a. No degradation because of -a. Examination after completion of the type tests
joint Overall interactions between all (T: §12.4.8)
properties components and of
components themselves -b. Test in water on outer protection (T: Annex
G) or better: Long term test (PQ: §13.2.4) +
-b. No water penetration insulation resistance test on outer protection after
before and after heat cycling long term test
into the cable system
57
Table.4..1.3.3 Functional analysis of High Voltage terminations and components of terminations
Here after the parts related to screen connection with cable. It is an update of the TB 303 [29] table.
IEC 60840 and IEC 62067 are under revision and will be published in a near future. The paragraph numbers will be harmonised between the two
component Function or Specification/Threat Test to check the functionality Comments

of Property (Relevant paragraphs of draft IEC 60840
termination /62067 in brackets) In blue relevant
Screen/Earth 1 -a. Fixation of earth potential a. Engineering problem, to be
connection Electrical considered when installing the
functions system. Bimetal connections to
be considered with special
care
-b. Evacuates short circuit -b. Short circuit test following this brochure (D: b. No short circuit test in IEC
current and circulating currents TB § 2.1.2.1) 60840 ed3 nor in IEC 62067
with both ends earthed ed1
Thermal cycles with current in the screen (D) or Currents in the screen may be
design according to (D: TB § 3.5.2.2) important and the ability of the
screen connection not to
overheat during cycling should
be checked (not in cycling
tests in IEC)
-c. In case of disconnection -c. Impulse and DC/AC test between earth and
from earth, electrical withstand screen as a type test
between earth and screen
d. Engineering problem:
-d. Suppression of screen -Single end earthing
currents with single end High frequency waves at GIS
earthing or special bonding ends to be solved by coaxial
connections to earth
58
2 -a. No degradation of -a. Thermal short circuit test of the earth
Thermal- connection and surrounding connection following the needs of the network
mechanical with thermal short circuit would be useful as a development test D with
properties visual examination
This brochure: (D: TB § 2.1.2.1)
3 -a. No entry of humidity -a. a. Visual inspection on

Interface underneath the outer installed system
protection of the cable
-b. Possible shrinkage of cable -b. Check the shrinkage of the cable sheath and b. May be 20 cycles are not
over-sheath and/or shrinkage joint protection after heat cycling of 20 cycles (T: enough to see the long term
of joint outer protection to be §12.4.6) or 180 cycles (PQ: §13.2.4) behaviour of the shrinkage
taken into consideration when effect. Long term PQ tests
designing the outer protection missing in IEC 60840 ed3
4 -a. No corrosion of contact a. Design: choice of metals

Chemical points and protection
Base plate 1 -a. Supports the weight of a. Design aspect

Mechanical termination and cantilever
properties forces on termination
2 -a. No corrosion of the base -a. Examination when making climatic tests a. Design aspect
Chemical plate
properties
3 -a. Withstand AC/DC/Impulse -a. AC/DC and impulse test on screen connection a. Design aspect
Base plate in specially bonded systems versus base plate
insulators
59
Complete 1 -a. No degradation because of -a. Examination of deterioration after completion a. Leakage may come up with
termination Overall interactions between all of the type tests (T: §12.4.8) and short circuit test time in service and, may be,
properties components and of This brochure (D: TB § 2.1.2.1) will not be detected during
components themselves long-term development tests. It
-b. Correct sealing and no fluid needs regular inspection or
leakage special protection if no
inspection is possible
60
A.2. Bibliography
Specifications/ Recommendations:
[1] Electra No 141 April 1992, CIGRE Working Group 21-14, “Guidelines for tests on high
voltage cables with extruded insulation and laminated protective coverings”
[2] IEC 60183, Ed.2 1984 + Amendment 1, Nov 1990, “Guide to the selection of high voltage
cables”
[3a] IEC 60840, Ed.3 April 2004, “Power cables with extruded insulation and their
accessories for rated voltages above 30 kV (Um = 36 kV) up to 150 kV (Um = 170 kV) –Test
methods and requirements”
[3b] IEC 60840, Draft 2009, “Power cables with extruded insulation and their accessories
for rated voltages above 30 kV (Um = 36 kV) up to 150 kV (Um = 170 kV) –Test methods
and requirements
[4] IEC 60949, Ed.1 1988, “Calculation of thermally permissible short - circuit currents, taking
into account the non adiabatic heating effects”
[5] IEC 61443, Ed. July 1999, “Sort circuit temperature limits of electric cables with rated
voltages above 30 kV (Um = 36 kV)”
[6] IEC TR 61901 Ed.1 2005-07, “Development tests recommended on cables with a
longitudinally applied metal foil for rated voltages above 30 kV (Um = 36 kV)”
[7a] IEC 62067, Ed.1 October 2001 + Amendment 1 January 2006, “Power cables with
extruded insulation and their accessories for rated voltages above 150 kV (Um = 170 kV) up
to 500 kV (Um = 550 kV) – Test methods and requirements”
[7b] IEC 62067 draft 2009 “Power cables with extruded insulation and their accessories for
rated voltages above 150 kV (Um = 170 kV) up to 500 kV (Um = 550 kV) – Test methods and
requirements”
[8] French Standard NF C33-252 (2002), “Câbles isolés ou protégés pour réseaux d'énergie
Câbles unipolaires à isolation synthétique de tensions assignées supérieures à 30 kV
(Um = 36 kV) et jusqu'à 150 kV (Um = 170 kV)” [“Insulated or protected cables for power
systems. Single-core cables with polymeric insulation for rated voltages above 150 kV
(Um = 170 kV) up to 500 kV (Um = 525 kV)”]
[9] French Standard NF C33-253 (2006), “Câbles isolés pour réseaux d'énergie Câbles
unipolaires à isolation synthétique de tensions assignées supérieures à 150 kV
(Um = 170 kV) et jusqu'à 500 kV (Um = 550 kV)” [“Insulated cables for power systems Single-
core cables with polymeric insulation for rated voltages above 150 kV (Um = 170 kV) up to
500 kV (Um = 525 kV)”]
[10] French Standard NF C33-254 (Draft 2008), « Câbles isolés et leurs accessoires
pour réseaux d'énergie exigences particulières relatives à l’utilisation sur les réseaux
électriques français des câbles à isolation synthétique extrudée et de leurs
accessoires de tension supérieure à 30 kV (U m = 36 kV) » [“Insulated cables and their
accessories for the use on French power systems of cables with extruded insulation
and their accessories for rated voltages above 30 kV (Um = 36 kV”]
61
[11] French Customer Specification April 2006, “Spécification RTE - Câbles et
matériels de raccordement pour les liaisons souterraines du 63 kV au 400 kV“
[12] British Standard BS 7970: 2005, “Electric Cables-Metallic wire and foil sheath
constructions of power cables having XLPE insulation for rated voltages from 66kV (Um =
72.5 kV) to 132kV (Um = 145 kV)”
[13] AEIC CS9-06 1st Edition (Draft G, June 4, 2006), “Specification for extruded insulation
power cables and their accessories rated above 46 kV through 345 kVac”
[14] THE IEEE P1142/D1J3 March 2009, “Draft Guide for Selection, Testing Application and
Installation of Cables Having Radial Moisture Barriers and/or Longitudinal Water Blocking”
Other Specifications / Recommendations: WG members to complete
CIGRE Papers
[15] “Consideration of ageing factors in extruded cables and accessories”,

Electra 140 February 1992: CIGRE Working Group 21-09,
[16] “AC overhead and underground HV lines – Comparison and new aspects”, CIGRE paper
21/22-07, Paris 1996
K.G. FRICKE, P.PASCEN, R.D.STECKEL
[17] “Development and qualification of a new 400 kV cable system wit integrated sensors for
diagnostics”, CIGRE paper 21-103, Paris 1998
G.P.VAN DER WIJK, E. PULTRUM, .H.T.F. GEENE
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bulk power transmission”, CIGRE paper 21-105, Paris 1998
E. DORISON, X. BOURGEAT, Y. MAUGAIN, P. ARGAUT, P. DEJEAN, P. MIREBEAU
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supply of Berlin”, CIGRE paper 21-109, Paris 1998
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cross-linked polyethylene insulated cables”, CIGRE paper 21-105, Paris 2000
E. DORISON, Y. MAUGAIN, P. ARGAUT, P. DEJEAN, P. MIREBEAU
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N. U. RAHMAN, K. BARBER
[22] “Reliable HV&EHV XLPE cables”, CIGRE paper 21-105, Paris 2002
J.O. BOSTRÖM, A. CAMPUS, R.N. HAMPTON, E. MARSDEN
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J. KARLSTRAND, P. SUNNEGÄRDH, W. ZENGER; REZA GHAFURIAN, R. BOGGIA
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62
S. SADLER, S. SUTTON, H. MEMMER, J. KAUMANNS
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M. LE STUM, L. BENARD, L. LANDUCCI, P. LESUR, M.H. LUTON, L. MOREAU
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B1-07.
[31] “Short circuit tests and the results on metal sheaths, screens and hybrid sheaths”,
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J.C.M. VAN ROSSUM, C.G.A. KOREMAN, J. SMIT, R. BODEGA, H.T.F GEENE, M.J.M.
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1995
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A. FORD, B. GREGORY, S.M. KING, R. SVOMA,
63
[38] “Thermo mechanical behaviour of 400 kV synthetic cables”, Jicable 1999, Versailles,
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T. BRINCOURT, E. DORISON
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J. BERDALA, P.M. DEJEAN, J. MANSOUR, A. MAXAN
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P. LAVANTUREUX, P. DEGUINES, F. GAHUNGU
[41] “Moisture penetration in XLPE and PILC cables”, Jicable 1999, Versailles, France, paper
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W.S.M. GEURTS, R.ROSS, M.G.M.MEGENS, E.F.STEENNIS,
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[48] “New 400 kV underground cable system project in Jutland (Denmark)”, Jicable 2003,
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[64] Contribution B1 PS1 Q6 from CIGRE 2004 “1081” On the subject of maintenance…
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66

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Advanced Design of Metal Laminated Coverings:

1.1 Metal laminated covering:....................................................................................................................... 7

1.2 Design types: ............................................................................................................................................. 7

Conclusion on laminated covering designs: ...................................................................................................... 11

2 RECOMMENDATION FOR TESTS: .................................................................. 11

2.1 Development tests................................................................................................................................... 12

2.2 Type tests ................................................................................................................................................ 24

2.3 Sample test .............................................................................................................................................. 25

2.4 Routine tests ........................................................................................................................................... 27

2.5 After installation tests ............................................................................................................................ 27

2.6 Tests from earlier recommendation no more considered ................................................................... 28

2.7 Conclusion: ............................................................................................................................................. 30

3.1 Purchasing: ............................................................................................................................................. 32

3.2 Storage: ................................................................................................................................................... 32

3.3 Laying conditions: .................................................................................................................................. 32

3.4 Electrical design vs. Circulation current: ............................................................................................ 33

3.6 Repairing: ............................................................................................................................................... 34

3.7 Maintenance: .......................................................................................................................................... 34

4 THE EXPERIENCE WITH CABLES WITH LAMINATED COVERINGS: .......... 36

4.1 World survey: ......................................................................................................................................... 36

A.1. FUNCTIONAL ANALYSIS .......................................................................... 45

A.2. BIBLIOGRAPHY ......................................................................................... 61

The present brochure replaces Electra 141.

The Terms of Reference are the following:

Three successful designs are today covering the market:

Combined Design - combined mechanical and electrical properties:

The metal foil is mainly aluminium; copper can be used as well.

Separate Design - separated mechanical and electrical properties:

Separate semi-conductive Design – separated electrical and water tightness properties

The Second part is a guide to use.

The Third part is the operational feed back.

A functional analysis of the laminated covering is given in the Appendix.

1.2 Design types:

Copper and other metal-plastic laminate are also used.

Combined Design (CD) - combined mechanical and electrical properties:

A CD cable picture is shown in figure 1.

Figure 1: Combined Design 500kV cable

Separate Design (SD) - separated mechanical and electrical properties:

A SD cable picture is shown in figure 2.

Figure 2: Separate Design 400kV cable

Separate semi-conductive Design (SscD) – separated electrical and water tightness

A SscD cable picture is shown in figure 3.

Figure 3: Separate semi conductive Design 275kV cable

2 Recommendation for tests:

Development Tests: Tests made during the development of a cable design.

2.1.1 Tests on cable

2.1.1.1 Impact test

Table 1: impact test requirements

Impact test Design CD Design SD Design SscD

Height (m) 0,27 1 n/a

Figure 4: Test apparatus for the impact test

The cable should be installed on a rigid metal base.

The requirements for the impact test are presented in Table 1.

≥ 250 150 Dim in mm

Figure 5: Positions of the points of impact

Result: Visual inspection and measurement of impact depth.

Figure 6: Deformation at the impact points to be examined

Result - visual inspection:

c) Test on SscD design