De ning extrusion

[ ]
Rubber cable insulation and
sheathing line EPL 20

M
a
i
l
l
e
f
e
r

-

A
p
r
i
l

2
0
0
9
Maillefers rubber cable insulation and sheathing line features
the latest technology and equipment. Versatile and efcient, it is
specially designed for manufacturing rubber cables for demand-
ing applications like ship wiring, welding, mining, wind mills, etc.
EPL 20
Rubber cable insulation and sheathing line
Combining good electrical and mechanical characteristics, rubber cables offer superior performance in ap-
plications where resistance to abrasion, oil, ozone, and extreme temperatures is essential. Rubber cable
production is subject to strict scheduling of deliveries, short runs, numerous tailor-made products and
processing of wide section of rubber compounds. It requires exible production planning, process control
and versatile process equipment. Maillefers cable manufacturing technology includes a wide range of
vulcanizing lines adapted to local conditions and optimized to meet cable manufacturers requirements. The
SSCV (Super Steam Cable Vulcanizing) line is specially designed for the insulation and sheathing of rubber
cables.
Maillefers Super Steam CV line is an intelligent com-
bination of the conventional steam curing process and
direct electrical heating of the curing tube zones, well
known from Maillefers world leading XLPE CV lines.
The Super Steam line offers the best possible exibility
on the market today for manufacturing different kinds
of cables with crosslinkable insulations and jackets.
The amazing versatility of the line becomes apparent
with the wide range of materials and large variety of
cable types covered. The processes include insulating,
sheathing, lling and coloring of Low Voltage and Me-
dium Voltage rubber cables. With Nitrogen supply and
Maillefer multi purpose extruders, it is even capable of
producing dry cured XLPE Medium Voltage cables.
Typical production speeds
Cable Normal CCV
at 20 bar steam
pressure
Maillefer SSCV
at 20 bar steam
pressure
Normal CCV
at 10 bar steam
pressure
Maillefer SSCV
at 10 bar steam
pressure
3 x 95 mm 1 kV EPDM
Insulation 19.0 m/min 21.0 m/min 8.3 m/min 16.1 m/min
Sheathing 6.4 m/min 7.8 m/min 4.6 m/min 6.5 m/min
35 mm 20 kV EPDM
Insulation 10.0 m/min 14.1 m/min 5.1 m/min 11.6 m/min
120 mm EPDM
Insulation 10.0 m/min 12.1 m/min 4.7 m/min 9.5 m/min
Line speci cation example
Accurate data on cable/conductor size, weight, insulation/sheathing materials and the available insulation
area in the plant are essential in determining the conguration of the product line.
An application for rubber insulated and sheathed cables
Cables 10 400 mm insulation up to 70 kV
4 x 4 mm - 4 x 185 mm
1 x 400 mm, rubber-sheathed round cables
e.g. 8 x 2.5 mm, rubber-sheathed, flat cable, Cu, fine wire
Line execution Catenary, inclined, curing with electrical heating, and/or
steam, water cooling
Catenary factor 130 m
Curing length 60 100 m (max. 42 m electrical heating)
Cooling length 24 60 m stepless regulation
Tube length 120 m
Pay-off 20,000 kg max. 4000 mm
Take-up reel 20,000 kg max. 4000 mm
Rated power approximately 700 kVA
Power consumption in operation total 200 kVA, for curing and cooling 60 kVA
Tube pressure 3 25 bar
Tube temperature max. 450 C
Steam consumption in operation 60 150 kg/h
Water consumption in operation 6 m at +20 C
Compressed air 6 bar 3m/h ATP
Extruders NMR 6014 D, NMR 8014 D or NMR 10014 D for
semi-conductive material
NMR 15014 D for insulation and sheathing
KPP 4510D for colour stripe extrusion
Line design speed up to 100 m/min
Water cooling section
cooling length is variably adjustable
C
A
va
Robust construction, high quality materials
and long experience in extrusion guarantee
excellent performance and long trouble-free
life time for Maillefer extruders.
Rubber extruders are equipped with hydraulic
rubber stripe feeding for stable output. Hop-
per feeding of rubber and XLPE pellets is also
available.
S
Th
In
te
te
El
cie
m
pr
op

Water-cooled extruders
Maillefer supplies extruders for a wide range
of materials. The L:D ratio is 14:1; if XLPE is
also extruded, an L:D ratio of 20:1 is recom-
mended.
Steam curing section
Electrically heated curing section
with steam atmosphere
Crossheads
A wide range of crossheads is available for
various rubber cable applications.
Super Steam process
The Super Steam line has three sections:
Electrically heated curing section with steam atmosphere
Steam curing section
Water cooling section
In a Super Steam line, the heating section consists of several electrically heated zones. The tube
temperature in the electrically heated parts is independent of the steam pressure, whereas the
temperature in the steam part of the tube corresponds to the pressure of the saturated steam.
Electrical heating together with pressurized steam gives a major improvement in heating ef-
ciency. Even under low pressure, the speed is more than doubled (see the line speed table). The
maximum line speed is achieved by controlling the temperature prole of section one, the steam
pressure in sections one and two, and by adjusting the cooling length accordingly. The speed is
optimized so that the temperature of the cable surface is kept under its maximum limit.

Water section Steam section Electrical section

Length (m)
Temperature difference
of cable surface
between Supersteam
and steam
T
e
m
p
e
r
a
t
u
r
e

(

C
)
AUTOCURE 4
Maillefers new Autocure 4 line control for CV-lines provides a modern tool for the operator to
inuence and control the process. The NSS cure calculation program optimizes process param-
eters for each cable type. Saved process parameters are retrieved from the recipe library.
Automatic sequences like start, production, slow and end minimize the scrap. Quality ramping
and synchronization of both line speed and curing temperature are ensured.
During the production, all measured values are shown in gures and historical trend curves. All
abnormal situations are monitored and singnaled via visual and audible alarms. It is also possible
to be alerted with a mobile phone. The number of operators is minimized using extra displays and
control panels near the crosshead, at the reel stations and at the end of the line.
Features
Simulation of continuous vulcanizing cable
making process
Recipe generation and library
Historical data logging of all measured process
parameters
Easy integration of instruments or extra ma-
chines, also retrot
Minimized operator need with help of the multi-
panel system
Easy integration to a factory network
Start and end scrap is minimized
The PSU process computer saves and monitors
all parameters. Placed in a quiet and comforta-
ble room, the operator monitors the process and
adjusts the process parameters when needed.
The PSU can also be connected to factory net-
work for remote recipe loading, process moni-
toring and reporting.
A connection to the Internet is also possible.
A remote PSU display can be placed at the reel
stations.
A simpler, low cost Autocure 4 Slimline version
includes a large touch panel (MP377 12)

Versatile Multipurpose Line

Maillefer Super Steam offers four types of processes for different kinds of
cable applications in one single line:
1. Conventional Steam Curing
The line can be used as traditional steam curing line with up to 24 bar op-
erating pressure, equivalent to 220 C temperature, for Low and Medium
Voltage rubber cable insulating and sheathing.
2. High Pressure Super Steam Curing
The curing process is boosted by direct electrical heating of vulcanizing
tube zones to max. 450 C and thus higher production speed is achieved.
This method is used for manufacturing of almost any kinds of vulcanized
rubber cables. Zone temperatures are computed and controlled in such
way that the highest allowed temperature of cable surface is not exceed-
ed.
3. Low Pressure Super Steam Curing
This special application of the Super Steam process is extremely use-
ful and can shorten the pay-back time of the line remarkably: the steam
pressure can be regulated down without dramatic loss in production
speed. Thus the production speed is several times higher than solely with
the low pressure steam, which means dramatic jump in line productivity.
The process has major importance in jacketing of multi core cables, as
their sensitive structure easily suffers through too high steam pressure.
Another clear advantage is better exibility and bending performance of
the completed cable, which belong to the most valuable characteristics of
rubber cables.
4. Nitrogen Dry Curing
Nitrogen supply makes the line a dry cure vulcanizing process, and it can
be used for manufacturing of Medium Voltage XLPE and rubber cables.
This feature, thanks to the tube electrical heating, makes the line ex-
tremely exible by including XLPE cables in the production program, and
allowing dry curing also for Medium Voltage rubber insulating.
e
d
rs
-
nd
-
el
As worldwide leader of extrusion and winding
solutions to the wire & cable and pipe industries,
our mission is to maximize the productivity of our
customers through superior technology, know-how
and service.
Energy cable solutions
Energy cable insulation and jacketing lines
LV insulation and jacketing lines
Insulation lines
Multisil insulation lines
Automotive insulation lines
CV lines for energy cable
MV, HV and EHV cable production
Rubber cable production

M
a
i
l
l
e
f
e
r

-

A
p
r
i
l

2
0
0
9
Product centers
Maillefer SA
Route du Bois 37 Phone +41 21 694 41 11
P.O. Box 259 Fax +41 21 691 21 43
CH1024 Ecublens info@maillefer.net
Switzerland www.mailleferextrusion.com
Maillefer Extrusion Oy
Ensimminen savu Phone +358 9 886 65 600
FIN01510 Vantaa Fax +358 9 886 65 771
Finland info@maillefer.net
www.mailleferextrusion.com
Visit our website for a complete listing of worldwide locations.