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EHV Cable Installation Technology for Tunnels and Ducts in Japan

S. TSUCHIYA T. IIDA Y. MORISHITA

Tokyo Electric Power Kansai Electric Power Chubu Electric Power
Company Company Company
T. NAKAJIMA Y. AKIYA T. KURATA
VISCAS EXSYM J-Power Systems
Corporation Corporation Corporation
JAPAN

SUMMARY

Long-length cables have been installed in tunnels for purposes of total project cost reduction,
construction period shortening and joint quantity reduction in a view point of a cable circuit reliability
advancement in Japan. Recently, the long-length cable installation technology are also developed and
applied for successive installation in multiple duct sections.
Meanwhile, for cases in which older Oil-Filled cables are replaced with new XLPE cables, the
effective use of existing narrow utility tunnels through the use of triplex type large conductor XLPE
cables is being applied, and for duct applications, narrow manhole installation technology for
installing XLPE cables in existing manholes is also being applied.
This report introduces the technological issues involved in long-length cable installations in tunnels,
ducts and means of addressing those issues, also introduces the effective use of existing infrastructure
through the use of triplex type large conductor cables, new joint installation technology for existing
narrow manholes, and installation technology for deep vertical shafts.

KEYWORDS
Long length cable installation - Tunnels - Ducts - Triplex type large conductor size cable -
Narrow manholes - Deep vertical shafts

kurata.tatsuo@jpowers.co.jp
Foreword

Long length cable installation projects for tunnels and ducts application have been completed
successfully in Japan since 1990’s. Max. continuous cable length 2500 m and 1050 m were installed in
a tunnel and duct respectively. The long length cable installation technology has developed for
purposes of total project cost reduction, construction period shortening and joint quantity reduction in
a view point of a cable circuit reliability advancement. Long-length cable installation has mostly been
used for tunnels, in which the limitations at the time of installation are few—as long as various
technical issues concerning matters such as the cable manufacturing equipment, the transport method,
and the installation base have been adequately addressed. However, practical needs and improved
installation technology have led to the increasing application of long-length cable installation to duct
installation. It is said that we are now at a point where long-length cable installation is no longer
limited by manufacturing and installation technology but by transport limitations. Various cable
installation achievements in Japan are shown in Table 1-1.
Opportunities for using utility tunnels and ducts are increasing even in countries that have mostly used
direct buried cable application, and the long-length cable installation technologies have the potential to
be applied widely.
In addition to introducing action assignments and their counter approaches for long length cable
installation, this report also introduces Japanese trends in unique power cable installation technology,
such as a retrofit jointing technology for existing narrow manhole, installation technology in vertical
shaft.

Table 1-1 Achievements in Long-Length Cables Installation in Tunnels and Ducts, Narrow Manhole Cable installation,
and Vertical Shaft cable Installation
Cable Cable Commission
Length Year
500 kV XLPE 1/C 800 mm2 1150 m 1994
275 kV XLPE 1/C 2500 mm2 1800 m 1998
500 kV XLPE 1/C 1000 mm2 1200 m 1999
500 kV XLPE 1/C 1000 mm2 1100 m 1999
500 kV XLPE 1/C 2500 mm2 1800 m 2000
Tunnel

DC500 kV Oil-Filled 3000 mm2 2200 m 2000

275 kV XLPE 1/C 2500 mm2 2500 m 2002
275 kV XLPE 1/C 1500 mm2 1770 m 2005
500 kV XLPE 1/C 1000 mm2 1700 m 2005
275 kV XLPE 1/C 2500 mm2 2250 m 2006
154 kV XLPE 3/C 1000 mm2 (Triplex) 711 m 2008
275 kV XLPE 1/C 2500 mm2 2350 m Under Construction
77 kV XLPE 3/C 150 mm2 (Triplex) 1050 m 1995
500 kV XLPE 1/C 2500 mm2 956 m 2000
Duct

275 kV XLPE 1/C 2000 mm2 860 m 2003

275 kV XLPE 1/C 2500 mm2 840 m 2003
Narrow

275 kV XLPE 1/C 1500 mm2 - 1999

h-ole
Man

154 kV XLPE 1/C 2000 mm2 - 2008

275 kV XLPE 1/C 1500 mm2

Sha

200 m 2005
-ft

(Vertical Shaft)

1
1. Installation Technology for Long-Length Cable
1-1 Long-Length Cable Installation in Tunnel
A number of factors have to be taken into consideration when long-length cables are installed in
tunnels. These include the length to which cable length can be installed, the installation method, the
time allotted for installation, the installation cost, the power supply capacity required for cable
installation, cable installation base type, workability, cable drum sizes, cable drum transport methods,
transport vehicle selection, and necessity to apply for permission to transport ultra-heavy vehicle.
For the 2500 m long 275 kV 2500 mm2 XLPE cable whose installation was completed in 2002,
because the overall drum weight was approximately 140 tons, a variety of factors needed to be taken
into detailed consideration when the drum was transported from the factory to the port and then by
land from the port to the installation base. These factors included traffic permissions and other legal
regulations, subgrade durability, and load restrictions for bridges crossed. Also, even for shipping the
drum by sea, taking the ease of operation of the approximately 300-ton floating crane used to lift the
drum into consideration, an appropriate time, when the waves would be calm, had to be carefully
determined.
The typical methods for installing long-length cables in tunnels are (1) the hauling machine method,
(2) the motor driven roller method, (3) the magnetic belt method, and (4) the twin pulley method. The
hauling machine method or the motor driven roller method is used typically, but the magnetic belt
method, which makes high-speed cable installation possible, and the twin pulley method are used
when multiple cables must be installed from the same base over a long conveyance distance in tunnel.
A recent achievement of long-length cable installation is a 2250 m long 275 kV 1 x 2500 mm2 XLPE
cable (transport drum width 11.8 m, Flange diameter 3.7 m) using both a motor roller and a hauling
[1]
machine, which was completed in 2006.

1-2 Long-Length Cables Installation in Duct

Long-length cable installation has been also required in duct application in which existing manhole is
used as intermediate manhole to pull multiple spans, even in 275kV class cable.
However, there are cases to apply long-length cable installation in which with conventional cable
specification and method due to excess allowable values of pulling tension and/or side wall pressure
due to too large diameter and heavy weight of cable, especially in higher voltage class. Through
improvements in the cable specifications that correspond to smaller cable dimensions and lighter
weight, it has even been possible to install longer length 275kV XLPE cables in duct.
Cable outer diameter was decreased by applying a laminated foil water blocking layer with
considering installation length, in lieu of an extruded and corrugated aluminum sheath or a stainless
steel sheath. Then, this has made it possible to transport longer cables under conventional restrictions.
At the same time, long-length cable installation in duct is accomplished by effective use of existing
manhole. For duct long-length cable installation, a nose pulling by a winch with synchronized hauling
machines or ball rollers set up at the intermediate manhole is one of effective methods. These
equipments are used to stabilize the long cable behavior and to reduce pulling tension. Especially for
the ball roller as shown in Fig. 1-1, it is popularly used in existing narrow manhole owing to its
[1]
smaller size.
When the pulling tension increases as result of increased cable size and weight, the pulsation
phenomena will be a cause of a problem. The phenomena are originated due to the elongation of
pulling wire. As a countermeasure of the pulsation phenomena, a synchronized hauling machines/ball
rollers is implemented in the intermediate manhole. These installation technologies have been
employed for long-length duct installation, for example 860 m long 275 kV 2500mm2 XLPE cable

2
installation in 2003.

Fig. 1-1 Ball Roller Application in Manhole

2. Replacement Technology in Tunnels and Duct Cable Systems

The replacement of aged oil-filled cables with new XLPE cables in pre-existing tunnels and ducts is
being promoted, but the cable installation space in pre-existing infrastructure is more limited than in
new one.
In tunnels, to maintain the highest transmission capacity in the narrowest possible installation space,
triplex type large conductor XLPE cables are used as a solution in lieu of single-core XLPE cables.
Thermo-mechanical behavior test results of triplex type large conductor XLPE cable are introduced.
In ducts, securing offsets to absorb the thermal expansion and contraction of XLPE cables installed in
pre-existing narrow manholes that were designed for oil-filled cables can be extremely difficult. Also,
the cables itself can be installed inside a narrow manhole, but when the assembly space is narrow,
installation can be difficult because of factors such as the need to be careful not to exceed acceptable
bending radius. Thus, thermo mechanical behavior was evaluated and workability in a narrow manhole
was verified.

2-1. Effective Use Pre-existing Tunnels

Since the triplex type XLPE cables absorb thermal expansion by relaxation of twisting, it is
unnecessary to consider the thermal expansion and snaking. Fig. 2-1 shows a comparison of the space
taken up in a tunnel by triplex type cable and a single-core XLPE cable applying vertical snaking.
Using triplex cables enable to decrease the space taken up by a single-core cable. Then, increasing the
cable conductor size, triplex type XLPE cable enables to ensure the upgrading transmission capacity.
By applying features of “thermal expansion absorption by itself and large transmission capacity of the
large conductor size triplex type”, retro-fitting of pre-existing tunnel was accomplished. Two existing
154 kV oil-filled cable circuits were upgraded to 6 large triplex type cable circuits. Figure 2-2 shows
the upgraded layout in a tunnel. [2]

3
 Space for Triplex
Type Cable
6 ccts
newly
installed
Space for 2 ccts
Single-Core XLPE removed
Cable with Vertical
Snaking

(Newly installed 154 kV

(Existing 154 kV
Triplex XLPE cables)
Oil-Filled cables)

Fig. 2-1 Space comparison between Triplex Type Fig. 2-2 Advantage of Large Size Triplex XLPE Cables
Cable and vertically snaked Single-Core cable in pre-existing tunnel

Although the triplex type XLPE cable thermal expansion and contraction can be ignored comparing
with single-core XLPE cables, mock-up test on triplex type large conductor cable was conducted to
figure out the thermo-mechanical behaviors.
Approx. 90 m of 154 kV 1000 mm2, approx. 60 m of 154 kV 600 mm2 and 66 kV 1000 mm2 triplex
type XLPE cables were used in the tests.
The mock-up test assembly is shown in Fig. 2-3. As test results, even though the triplex type XLPE
cable, it was observed that the cable sag between support structure. The large conductor cross-section
triplex type XLPE cable characteristics are similar to snaking cable with applying long support
distance. Therefore, cable fixing shall be considered at the end portion. Summary of test results are
shown in Table 2-1.
For the actual application of 154 kV 1000 mm2 triplex type XLPE cable, 1.5 m support intervals were
applied. Thus, cable occupation space in a tunnel was minimized. Then, since the joint spacing in the
tunnel was limited, the long-length triplex type XLPE cable was installed with considering the joint
allocation and long distance conveyance in the tunnel. The long distance conveyance of the triplex
type large conductor size XLPE cable was accomplished by using motor driven roller method as
shown in Fig. 2-4. Records of the triplex type large conductor cable installation with long distance
conveyance in tunnels are shown n Table 2-2.

Table 2-1 Test Result Summary of Support Interval

Offset End 66kV Triplex
Support 154kV Triplex XLPE
Fixing End Support Spacing 1.5～3m XLPE
Spacing
600mm2 1000mm2 1000mm2
3.0m － × －
2.4m （○） － （○）
2.0m ○ － ○
1.5m ○ ○ ○
Fig. 2-3 Outline of Mock-up Test Assembly Symbol; ○：Applicable ×：Inapplicable －：Not tested
（○）：Cleat fixing is required at offset portion

4
 Table 2-2 154kV Triplex Type Cable installation Records
Conveyance
Conveyance
Cable Length Distance in
Period
Tunnel
627m 4300m 3 days

Motor Roller Free Roller Control Cable 706m 4800m 3-4 days

Fig. 2-4 Long Distance Cable Conveyance by 711m 5400m 4 days

Motor-Driven Roller in Tunnel

2-2. Cable Installation in Narrow Manholes

To ensure a proper designed performance on XLPE cable joint installed in a manhole, an interface
pressure between “rubber-unit which is a main insulation of joint” and “cable insulation screen
surface” is the most important. It was concerned that cable installation in a narrow manhole would be
a cause of degraded interface pressure that results from cable bending radius reductions under thermo
mechanical movement. Therefore, the interface pressure evaluation in a narrow manhole was carried
out. The mock-up tests for 154 kV XLPE cable installed in a narrow manhole which was designed for
pre-existing 154 kV oil-filled cable were conducted. The thermo mechanical properties were evaluated
as a first step. The electrical performance was evaluated as a second step. Then, the rubber insulation
units of both EPR and Silicon were tested. Test assembly and test conditions are shown in Fig. 2-5 and
Table 2-3 respectively. Also, to simulate the power plant loaded condition, continuous load and
switching off conditions were included in the interface pressure evaluation. As results, the interface
pressure was verified that the allowable minimum pressures (EPR: 0.2 MPa, Silicon: 0.05 MPa) were
ensured under the various severer conditions. Measured interface pressure is shown in Fig. 2-6.
Additionally, workability in a narrow work space (6 m long x 2 m width x 2 m height) was verified.
Joint assembling work and cable treatment work were verified to be performed in a narrow manhole.
Workability verification in a narrow manhole was conducted as shown in Fig. 2-7. Also, long term test
and lightening impulse test were conducted to the assembled sample. Then, the installation technology
was practically applied after confirming that the prescribed characteristics were satisfied.[3][4]

Table.2-3 Conditions for Evaluation Tests

6000
2105 2105 Step/No. Voltage Heat Expansion Fixing Nos. of
ＩＪ側 ＮＪ側
Cycle*1 & Cleat Cycle
可動架台 H H 可動架台 Contraction*2
90oC
オフセット部 オフセット部
1 Not applied Applied 3
2 90oC Both ends Applied 10
Pressure )
(Interface

Dummy Cable 3 Cont. Fixed Applied Cont.

Step 1

ダミー線路
Not
90oC 3
Apply
ＩＪ側 Test本線路
Sample ＮＪ側 4 90oC Both ends Applied 10
W W
5 90oC Both ends N/A 10
6 90oC Single end Applied 10
Movable Movable 7 90oC*3 Both ends Applied 25
Support Support 8 105oC*3 Both ends Applied 5
(Voltage )

AC
Step 2

9 145kV Cont. Fixed Applied Cont.

Fig. 2-5 Test Assembly of RBJ 90oC 3
10 90 oC Single end Applied 5
11 Imp. 1035kV x 3 nos. (Ambient temp.) *3
Re- *1) 8 hrs on & 16 hrs off heat cycle
marks *2) Yearly 205 mm/Daily 30 mm applied by 8 hrs loading
*3)In accordance with JEC3408 std. including PD
measurement at 145 kV / 10 min.

5
 100 1.20
No.1 ：ヒートサ イクルの み No. 3：連続 負荷 一定 No .5： クリート無し
No.1 No.2 No.3 No.4 No.5 No.6

Interface Pressure (MPa)

N o.2： 両端 伸縮 No. 4：片 側伸 縮 No. 6：ガイド 管無 し 1.10
80
1.00

60 0.90
Temp(oC).

0.80
40

面圧[MPa]
温度（℃）

0.70
20
0.60
Interface Pressure
0 Ambient Temp.外気温 Interface Temp.
界面温度 界面面圧 0.50

0.40
-20
0.30
許 容面 圧

-40 0.20
0 5 10 15 20 25 30 35 40 45
試験日数 最低許容面圧
Day Minimum allowable0.2MPa
interface pressure 0.2MPa
Fig. 2-6 Variation of temperature and pressure at interface between
RBJ and cable core (STEP1) EPR Rubber Unit Fig. 2-7 Workability Verifying in Narrow Manhole

3. Installation Technology for Deep Vertical Shafts

Standard installation methods shown in Table 3-1 have been applied for vertical shaft cable
installation. Snaking installation is normally applied for large size cables from a view point of dealing
with thermal expansion and contraction. An example of 275 kV XLPE cable installation in a deep
vertical shaft is introduced below.
Installation methods for a 275 kV 1500 mm2 XLPE cable in a 200 m vertical shaft were carefully
studied. Three installation methods shown in Table 3-2 took the conditions of the shaft into account.
In the nose pulling method, it would be necessary to rig a shooter with a radius of at least 4 m
to ensure an acceptable side wall pressure in the upper area of the shaft, and thus given the
restrictions of the shaft installation space, this method could not be applied. Also, the bond
pulling method could not be applied because of difficulties regarding the necessity of a
specialized bond clamp for the cable and regarding the workability of removing snaking.
In the end, after evaluating the methods in terms of installation technology, safety, and cost,
the hauling machine method was applied. In the middle of the shaft, 14 hauling machines
were equipped with exceptionally responsive servomotors and installed the cable while
supporting its weight (27 kg/m). Before installation of the actual cable, a 250 m long test piece
cable was installed with the intent of verifying and checking the cable transport capability of
the installation system. After the test piece installation test, the actual installation was
conducted and completed successfully in 2005.[5]

Table 3-1 Standard installation methods for vertical shaft areas

Upper area (mid area) Direct installation cleat Snake installation Tension member
cleat support method support method cleat support method method
Cleat

Cleat Tension member

Cleat
Anchoring Device
Cable
Cable Cable with Tension
member

Cable
Guide Pipe

6
 Table 3-2 Installation Methods Considered for the 200 m Deep Vertical Shaft

Nose Pulling Method Hauling Machine Method Bond Pulling Method

Back-up Winch
Winch Winch Winch

Wire Wire

Pulling Pulling
Direction Direction Wire
Guide wall Pulling
Backup wire
Direction
Guide wire
Pulling Eye Pulling Eye Pulling Eye
Outline

Bond Clamp
Guide Guide Hauling
Machine Hauling
Hauling Hauling Machin Back tension
Machine Machine Winch

･Pulling by upper side winch. ･Distribute the pulling tension by ･ Bonding cable with the pulling
Feature

･Upper guide wall radius shall be using hauling machines set in wire by fixing bond clamp. Pulling
larger to minimize the side wall vertical shaft. tension is distributed to the pulling
pressure of cable wire.

4. Conclusions
This report introduced the technological issues involved in long-length cable installations in tunnels
/ducts and means of addressing those issues, also introduced the effective use of existing infrastructure
through the use of triplex type large conductor cables, new joint installation methods for existing
narrow manholes, and installation methods for deep vertical shafts.

BIBLIOGRAPHY
[1] K. Fukuda et al; Recent Installation Technology for XLPE Cables in Japan, CIGRE B1-303,
2006
[2] K. Iwasaki et al; Recent Technologies for Replacement of Underground Cable Systems, CIGRE
SYMPOSIUM, Osaka, Japan Nov. 2007, No.103
[3] T. Shiro et al; Evaluation of 154kV Factory-Expanded Cold Shrinkable Joint in Narrow Manhole,
Proceedings of the eighteenth Annual Conference of Power & Energy Society, IEEJ, No. 126,
2007 [in Japanese]
[4] T. Shiro et al; Evaluation of 154kV Site-Expanded Type Rubber Block Joint in Narrow Manhole,
Proceedings of the eighteenth Annual Conference of Power & Energy Society, IEEJ, No.127,
2007 [in Japanese]
[5] T. Fujichika et al; Installation of High-voltage XLPE cable into 200m deep vertical shaft,
Proceedings of the sixteenth Annual Conference of Power & Energy Society, IEEJ, No.300, 2005
[in Japanese]