UNDERGROUND CABLES 2

INSTALLATION
of
66kV to 330kV XLPE INSULATED CABLES
DMS #7374971
Ref: DMS # 879976 and 1148541
 TOPICS

• Main Components
• Rating of cable circuits
• Function of cable sheath
• Sheath standing voltage (SSV)
• Sheath bonding systems
• Earth continuity conductor (ECC)
• Link and sheath voltage limiter boxes
• Sheath voltage limiters (SVL)
• Cable installation
• Cable trench backfill
• Cable installation in air
• Distributed temperature sensing cable (DTS)
• Cable testing
• Work on cables - safety
• Environmental considerations
• Future trends
 MAIN COMPONENTS OF CABLES

 Conductor
 Load Current Rated
 Losses in Conductor
 Fault Currents Rated

 Insulation
 Stresses
 Semi-conducting Layers
 Manufacturing

 Sheath
 Moisture and Mechanical
Barrier
 Fault Current Rated
 Sheath Standing Voltages
(SSV)
 Earth Bonding Methods
 RATING OF CABLE CIRCUITS

The rating of a cable circuit is primarily influenced by envirnonmental

factors and cable losses:

 Conductor cross section area

 Construction of conductor (Milliken construction for large areas above 800
to 1000mm2)
 Type of insulation (PE or XLPE. Determines max. cable temperature)
 Thermal resistivity of cable components
 Cable surrounding medium
 Thermal resistivity of backfill and native soil
 Depth of burial of the cable and soil temperature
 Other heat sources (Other cable(s))
 Type of cable sheath bonding
 Cable laying configuration (flat and trefoil)
 FUNCTION OF THE METALLIC CABLE SHEATH

 Acts as an impervious sheath to prevent ingress of moisture and

for mechanical strength
 Return path for system fault currents
 Sheath is insulated from earth by the oversheath
 Voltages are induced along the sheath by conductor currents
 Sheath bonding systems need to be disconnected so that the
integrity of the oversheath can be tested
 SHEATH STANDING VOLTAGES

S1
1 S1 p .S 3 p 3 S3 p
S E = 2πfI (2.10 −7 )( log e + j log e )
I S2 1 2 S 22 p 2 S1 p
R
3 S
S
1
2
I
Y
2

I S
B 1
P
1

Sheath standing voltages (SSV) are proportional to:

•Load current
•Length of cable section
•Phase spacing
•Cable diameter
•Cable laying formation
 SHEATH STANDING VOLTAGES (2)

Trefoil Formation
Phase Distances S12=S23=S13 and cable diameter d

1 3 2S
E1 = 2πfI ( 2.10 −7 )(− + j ) log e
2 2 d
2S
E2 = 2πfI (2.10 −7 ) log e
d
1 3 2S
E3 = 2πfI (2.10 −7 )(− − j log e
2 2 d
Flat Formation
Phase spacing S and cable diameter d
1 S 3 4S
E1 = 2πfI (2.10 −7 )(− log e + j log e )
2 d 2 d
2S
E2 = 2πfI (2.10 −7 ) log e
d
1 S 3 4S
E3 = 2πfI (2.10 −7 )(− log e − j log e )
2 d 2 d
Note: All voltages in V/m
 SHEATH STANDING VOLTAGES (3)
Trefoil Formation

V2

V1 V3

Flat Formation V2
S
= 1.1
d
V1 V3
V2
S
=4
d
V1 V3
V2

S
= 10
S = Cable Spacing d
d = Cable Diameter
V1 V3
 SHEATH BONDING SYSTEMS
a) Solid Bonding
Cable sheath ends are bonded directly to earth

Circulating currents flow in the sheath

Solid bonding is usually acceptable for load currents below 500A for short
sections
 SHEATH BONDING SYSTEMS (Continued)
b) Single Point Bonding
Only one end of the cable sheath is bonded directly to earth
 SHEATH BONDING SYSTEMS – Single point bonding

Main Features

 Acceptable maximum induced voltage (SSV) is generally in the order of

65 to 120V
 No international or national agreed maximum voltage standard
 Length of cable between sheath ends can be limited by the SSV.
(Typically 500 to 600m for load currents of >1000A and a SSV of
100V)
 Sheath voltage limiters (SVL) are required at the non-earthed end of
the sheath to limit voltages induced by system fault currents
 Earth continuity conductor (ECC) is required for earth fault return
currents
 ECC to be transposed at the mid-point of the cable route. Note the
location for flat and trefoil formation
 Two single point bonding systems can be joined back-to back. Earth
point can be either at cable ends or at the mid-point
 SHEATH BONDING SYSTEMS (Continued)
c) Cross Bonding
 SHEATH BONDING SYSTEMS – Cross Bonding
ELECTRICAL STRESS DISTRIBUTION
Main Features

Cable route to be divisible by 3 or multiples of three

Minor cable lengths to be all equal in length within a major section
Sheaths bonded directly to earth at the ends of the Major section
(or at the end of the cable route)
Sheaths cross connected at the minor section joint locations and
bonded to earth through SVLs
Major sections can be added indefinitely
No ECC required since sheaths are earthed at the cable ends
Cables laid in flat formation require transposing to equalise SSV
SHEATH BONDING SYSTEMS AND STANDING VOLTAGES
Single Point Bonding

Sheath voltage proportional to length

Cross Bonding

Sheath voltages are completely balanced if minor sections are identical

 EARTH CONTINUITY CABLE (ECC)

Requirements:

 Single point bonding systems require an ECC to carry fault

currents
 Solid and cross bonded systems do not require an ECC since the
sheaths provide a current return path
 ECC has to be adequately rated for the system currents
 Transposed with the phase cables when used with SPB system
 Usually insulated to avoid cathodic erosion between adjacent
services
LINK AND SHEATH VOLTAGE LIMITER BOXES

 Link and SVL boxes are installed at the ends of the cable lengths and
connect the sheath to earth
 Removable links provide a facility to isolate the sheath from earth for
over sheath insulation test to be carried out
 SVLs are installed as required on the earth side of the link
 All earth connection cables have to be rated for the system fault
currents and test voltages
 The boxes have to be water and corrosion proof and rated for the
system fault currents and test voltages
 SHEATH VOLTAGE LIMITERS (SVL)

Function

 Used to protect cable oversheaths, joint sheath gaps, termination base

insulation and bonding leads from being punctured by excessive
voltages.
 Various types of SVL are available. Modern SVL use metal oxide
resisters.
 SVL have to be rated for high current and low voltage
 The SVL should not conduct during system faults but only during
lightning (or switching) surges.
 SVL connections to earth should have minimum impedance and length.
 CALCULATION OF SVL RATING

WP maximum allowable sheath standing voltage is 120V. SVL rating is based

withstanding the maximum induced sheath voltage which occurs during
an external through fault.

1. SVL rating >the induced voltage on the sheath caused by the max system
fault current.
2. Calculate the max impulse withstand voltage (8/20 and 4/10 micro sec)
of the cable oversheath. Obtained from cable data multiplied by 0.75 to
allow for ageing, temperature and mechanical damage of the oversheath
3. From SVL data, check that the SVL selected has a residual voltage
(based on the fault current) is less than the calculated withstand voltage
of the sheath.
4. SVL connection surge impedances should be minimise by using short
(less than 10m) concentric leads.
SVL CHARACTERISTICS
 CABLE INSTALLATION

Three different methods of drawing the cables into the trench:

 Nose pulling – Cables are equipped with a pulling eye for

attaching a winch draw rope. Tension limiting devices and swivels
are required
 Bond pulling uses a parallel winch wire strapped to the cable at
frequent intervals. The ties have to be removed and reapplied at
changes of direction and for ducts
 Hand pulling cables is limited by cable weight and length

Generally, cable rollers are required at frequent intervals (approx

2m intervals) with guide rollers and skid plates at changes of
direction.
 CABLE INSTALLATION
Nose pulling tensions may be calculated as follows

Straight and level

T = T1 + kWL
Where T = Pulling rope tension
T1 = Initial tension
K = Coefficien t of friction (Rollers = 0.1 – 0.2, ducts 0.3 - 0.5)
W = Mass of cable kg/m
L = Length

For inclines (up and downwards) the angle either adds or subtracts to the tension

Sidewall Pressure
P = T/R kg/m

Where T = Exit tension

R = Bending radius
P = Sidewall pressure

Side rollers and skid plates can be used as guides but point loads should be avoided.
Minimum bending radius of the cable should not exceeded.
 CABLE INSTALLATION

DUCTS

 Ducts are pre-installed under road crossings to reduce the disruption to

traffic and under rail facilities
 Internal diameter of the duct shall be adequate for the cable and pulling
eye (D x 1.3)
 Ducts to be clean and without obstructions especially at joints

To maintain the cable rating, the separation between ducts may be

increased. A Bentonite sand slurry may be used to fill the ducts to
improve the transfer of heat from the cable to the surrounding soil
 CABLE TRENCH BACKFILL

The cable trench may be filled with clean native soil or a special
backfill can be used to significantly improve the rating of the
cable circuit in some cases.

 WP uses a 14:1 sand cement mix (by volume) which has a thermal
resistivity of 1.0oC.m/W
 The backfill thermal resistivity has to be maintained when dried out (1%
moisture content)
 The backfill cross sectional area has to be adequate to ensure that the
50oC isotherm is contained within the backfill
 Different mixtures of backfill (clay, sand, gravel) can be developed and
proved for use
 The backfill may be installed wet or dry according to the site . All air
voids have to be eliminated.
 CABLE INSTALLATION IN AIR

When cables are directly buried in soil or backfill, the forces due
to thermal and loading cycling as well as fault current are
restrained.

Cables installed in air are not restrained and provision has to be

made for movement of the cable by one of two methods:

1. Rigid installation fixes the cable in a straight line by clamping

the cable at regular intervals.

2. Flexible installation allows the cable to deflect laterally to

accommodate the expansion and contraction of the cable. Fault
forces are restrained by the use of alternate sliding clamps. The
cable is installed in a horizontal or vertical sinusodial formation.
 DISTRIBUTED TEMPERATURE SENSING (DTS)

Real time cable temperature measurement using optical fibre

technology

 Optical fibres either inserted under the cable sheath or laid on top of the
phase cable(s)
 DTS cable is usually jointed at the same location as the HV cable
 Temperature measurements are taken using optical time domain
reflectrometry (OTDR)
 Cable ‘hot spots’ can be detected and preventative action taken to
prevent permanent cable damage
 Computer software may be used to predict short term and emergency
ratings
 CABLE TESTING
Factory Tests

 Cable and accessory tests include type, routine and sample tests according to
various standards
 Type tests are most important as is a service history of an identical or similar
installation
 Cables above about 300kV should have completed prequalification tests for
one year
 HV AC test voltages applied to the cable and accessories (eg 2.5U0 for 30 m)
 Mechanical tests such as bending and sheath hardness should be carried
out
 Special tests (eg water penetration, fibre optical etc)
 CABLE TESTING
Site Tests

 To prove cable system is fit for service

 Cable and accessories have been tested in the factory. The assembly
on site depends the skill of the workmen
 HV DC tests are not recommended for XLPE insulated cable systems
 AC tests are carried out in place of high voltage tests. These can include
system voltage (U0) being applied for 24 hours
 Sheath tests (eg 10kV for 1 min) Recommended that sheath tests are
carried out at 6 monthly intervals or as required by the manufacturer
 Sheath bonding tests. The continuity and correct connection of the
sheaths has to be checked, especially for cross bonded systems
 WORK ON CABLES - SAFETY
When working on the metallic components of a cable and the cable
sheath bonding equipment, the safety of personnel has to be
considered.

 Induced Voltages
Cables being installed parallel with overhead or underground electrical
systems carrying high currents are exposed to induced voltages,
especially during system faults.

 Transferred Voltages
During earth fault conditions, large currents can flow into the earthing
systems causing a local rise in voltage (EPR). These voltages are
transferred to the cable metallic components if they are connected to
the earthing system.

Safety procedures, such as earthing all the cable metallic components

to earthing mats at the work site, will reduce the effect of the induced
and transferred voltages.
 ENVIRONMENTAL CONSIDERATIONS
Extruded polymeric insulated cables have been gradually extended to higher
voltages. Generally 90kV in 1968, 225kV in 1969 and 400kV in 1985.

Service life of underground cables are designed to exceed 4o years and

manufacturing and generation industries are expected to anticipate the
expectations and trends of the industrial world.

Current measures to improve the technical and environmental performances are:

 Elimination of lead
The use of lead is recognised as being detrimental to the environment both during the refining
and the disposal of the metal. Other metallic sheaths are being investigated as possible
alternatives.

 Reduction of conductor losses especially in large cross sectional areas

The use of conductors with insulated wires decreases conductor losses and increases the rating
of the cable by up to 10%.

 Real time temperature monitoring

Distributed temperature sensors enable dynamic control critical temperatures of the cable
circuit. This allows optimisation of the circuit as it takes into account actual soil temperatures
and the thermal inertia of the cable.

 Synthetic and composite terminations

Generally simplifies construction and improves quality control of terminations and joints. Safety
of the public and electrical personnel is also improved.
ENVIRONMENTAL CONSIDERATIONS (2)
 FUTURE TRENDS
The future trends for cables are:

 Longer routes and higher voltage installations as industry

loads and confidence increases
 Utilities require easier and cheaper installations
 Higher operating stresses to reduce insulation
thicknesses
 Longer cable life to reduce life costs
 Higher system reliability
 More cable circuit installed due to public pressure
 Under grounding of most future LV and MV systems
 Greater use of XLPE insulated cables in DC transmission
systems
 HIGH TEMPERATURE
SUPERCONDUCTIVITY (HTS)

The present status of HTS systems are:

 HTS limited to short lengths (< 100m), high current (kA) and
special applications
 Some systems are now in commercial applications
 Progress to discover new conductors for use at higher (warmer)
temperatures
 HTS systems still require special low temperature cooling
 Compact designs with three phases arranged concentrically
around a centre cooling duct
 GAS INSULATED LINES (GIL)

Characteristics of GIL are:

 Similar to gas insulated substation (GIS) technology

 Wider application in industry than HTS
 Capable of large power transfers as conductor size and shape
are limitless.
 Development of insulating gases based on SF6 mixed with N2