Entry Level Programme 2015

High Voltage Cables

 Contents

Organization Chart
Cable Types & Principles of Operation
Cable Accessories
Design Interfaces
Cable Rating & Sheath Bonding Arrangements
Maintenance & Asset Management for HV Cables
HV Cable Services offered by ESBI

2 esbi.ie
Organisation Chart
 Networks Engineering
Networks Eng. AMS
John Gartland Mick Sherlock

Performance Manager Resources AMS

Mark Lyons Kieran English

HV Projects HV Cables Power System Studies Substation Design OHL Design PACT
Kieran Lynch Robert Donaghy Danijela Klopotan Colm Twomey Ciaran Hughes Greg Hanna

HV PROJECTS PSS Team Primary Plant Standards Protection Technology

Ken Atkinson Dermot Dorgan Peter Ennis Simon Hussey

PSS Team Design Standards Design Systems PAC Team 1

Laura Martinez Hugh Cunningham Oisin Armstrong Brian Cafferty (Bah)

Team CB PSS Team Control & Prot. Planning

Bernard Dee PAC Team 2
Mark Byrne Liam Breathnach Jan Bednarik

Team CD PSS Team Physical Stds. Materials & PreCA

Patrick O’Rourke Stephen Hunt Jeffrey Dunney Tim Kavanagh
 HV Cables
Robert Donaghy

Team CB Team CD
HVC Projects HVC Design
Mark Byrne Patrick O’Rourke

Emma Butler Jack Herring

John Dillon

Oliver Canty Ronan McGuirk

Alan Hoey

Christina Caldwell Gillian Mooney

Gerry Rathborne

Colin Choyce John Martin

Mark Curtis Graham Tobin

Robert Doyle Sinisa Sestanovic

Philip Fay
Cable Types & Principles of Operation
 AC Cable Charging Current

7 esbi.ie
 AC Transferable Power – U/G Cable

No distance limit for AC OHL.

Source: CIGRE
 AC Cable Types

Fluid Filled

Gas Compression

High Pressure Oil Filled

Cross Linked Polyethylene (XLPE)

9 esbi.ie
 Fluid Filled Cables
 Most extensively installed cable globally
 Excellent reliability up to EHV
 Extremely strong dielectric
 Very high safety margins for A.C. stress
 Requires constant monitoring
10
 Difficult to locate leaks (especially if >1 leak)
 Complex circuit design – ancillary equipment
 High maintenance costs
 Environmental risk
 Future spares availability & technical capability?
esbi.ie
 Fluid Filled Cables

• Oil expansion & contraction during heating

and cooling
• When the cable cools, the oil flows back
into the cable, maintaining full impregnation.
• Driving force for the return of the oil comes
from gas cells in the reservoirs, which are
compressed during the expansion phase.

11 esbi.ie
220kV Cable - Oil System Profile
 Gas Compression Cables

 Used up to 110kV in Ireland (275kV internationally) – being phased out

 Cable cores impregnated with high viscosity oil
 Pipeline pressurised with nitrogen gas up to 14 bar
 Simple pressurizing system - no oil tanks required, but requires pressure monitoring
 Resistant to 3rd party damage
 Corrosion risks for pipe
 Limited manufacturer support
 Pipe can be retrofitted with new 3-core XLPE cable without need for pressurization

13 esbi.ie
 High Pressure Oil Filled Cables

 Used up to 220kV in Ireland; widely used in USA

 Cable cores impregnated with high viscosity oil
 Pipeline pressurised with low viscosity oil up to 14 bar
 Oil reservoir required, requires pressure monitoring
 Resistant to 3rd party damage
 Pipe can be retrofitted with new 3-core XLPE cable without need for pressurization
 Corrosion risks for pipe
 Limited manufacturer support

14 esbi.ie
 XLPE Cables

 Used in Ireland up to 400 kV

 Standard for new installations
 Low density polyethylene is cross linked to
allow operation at 90°C
 Introduced to MV in 1960s
 Fully established up to 400kV+ AC
 Simple, quicker and cheaper installation
 Lower maintenance costs
 No pressure monitoring requirements

15 esbi.ie
Manufacturing Process - XLPE
Insulation (VCV Line)

Flow Chart
 Manufacturing Process – Submarine Cable

Manufacturing Video (4 minutes)

Viscas 132kV Submarine Cable Manufacture for Tanzania.wmv

17 esbi.ie
Technology Options for HV Connections

Implementation

Overhead Underground
Lines Cables
(OHL) (UGC)
Current (AC)
Alternating
Electrical Concept

AC OHL AC UGC
Direct Current

DC OHL DC UGC
(DC)
Power Transmission Cable System Selection

Update: now up to
525 kV DC

Source: CIGRE
Cable Accessories
 Cable Accessories

Joints

Terminations
●Outdoor
●GIS
●Oil Immersed

Ancillary Equipment

21 esbi.ie
XLPE Regular Joint
 Transition Joint: To Connect Different Cable Types

23 esbi.ie
Design Interfaces
 Outdoor Sealing End

25 esbi.ie
 Line Cable Interface

220 kV Sealing End Compound

110 kV Sealing End

Tower

26 esbi.ie
GIS Termination
Cables in GIS Stations
 Cables – GIS Interfaces

IEC 60859, IEC 62271-209

29 Design coordination between Cable & GIS supplier essential! esbi.ie
Cables – GIS Interfaces
 Transformer Termination

Some transformers are terminated using outdoor sealing ends

to a bushing

31 esbi.ie
 Link Box

32 esbi.ie
Cable Rating & Sheath Bonding Arrangements
 Factors That Affect Cable Rating

• Ambient / Ground Temperature

• The Cable Materials
• Cable Dimensions
• Sheath Bonding
• Cable Environment Thermal Resistivity
• Depth In Ground
• Proximity Of Other Cables/Heat Sources

34 esbi.ie
 Standard Irish Conditions

• Ground Temperature
– Summer 20°C
– Winter 10°C

• Soil Resistivity
– Summer 1.2 K.m/W
– Winter 1.05 K.m/W

• Burial Depth
– 1.0m

35 esbi.ie
Cable Rating Equation

I = Current flowing in one conductor (A)

∆Ө = Conductor temperature rise above ambient (°C)

R = AC resistance per unit length of the conductor at maximum operating temp (W/m)

Wd = Dielectric loss per unit length for the insulation surrounding the conductor (W/m)

T1 = Thermal resistance per unit length between conductor and sheath (°C-m/W)

T2 = Thermal resistance per unit length of bedding between sheath & armour (°C-m/W)

T3 = Thermal resistance per unit length of the external serving of the cable (°C-m/W)

T4 = Thermal resistance per unit length between the cable surface & surround (°C-m/W)

n = Number of cable cores

1‫ = ג‬Ratio of losses in the metal sheath to total losses in all conductors in that cable

2‫ = ג‬Ratio of losses in the armor to total losses in all conductors in that cable

Source: IEC 60287

Footer
 Sheath Bonding

• Circulating sheath currents can reduce ampacities by 30-40%

• If current path is interrupted, voltages will appear on the sheath

Types of bonding:
● Solid Bonding (Both Ends Earthed)
● End-Point or Mid-Point Bonding (Single Point Bonding)
● Cross-Bonding

37 esbi.ie
 Single Point Bonding

38 esbi.ie
 Cross Bonding

39 esbi.ie
Bonding & Earthing Diagram
Standard Cable Sizes in Ireland (XLPE)
Maintenance & Asset Management
The Irish Transmission System
 HV Cables on ESB System

                                   

Voltage Cable Type Cable Length Total No. of

(km) Circuits
Low-Pressure Oil Filled (LPOF) 23
110kV Gas Compression (GC) 17 310
Cross-Linked Polyethylene (XLPE) 240
Low-Pressure Oil Filled (LPOF) 45
220kV High-Pressure Oil Filled (HPOF) 19 44
Cross-Linked Polyethylene (XLPE) 70
400kV Low Pressure Oil Filled (LPOF) 2 4
Cross-Linked Polyethylene (XLPE) 0.3

44 esbi.ie
 Age Profile of ESB HV Cables

60

50

40
Length (km)

110kV
30 220kV

20 400kV

10

0
1951-60 1961-70 1971-80 1981-90 1991-00 2000-
Year of Installation

45 esbi.ie
 Causes of Cable System Failure

46 esbi.ie
 Cable Maintenance

Preventive maintenance
– Inspection, route patrols
– Routine servicing
– Condition based monitoring of circuits
– Appropriate to cable type

Corrective maintenance

Arises due to:

– Type Fault
– Design flaw
– Material deficiency

Fault maintenance
– Unplanned
– Arises due to a failure in service

47 esbi.ie
 Oil Filled and Gas Compression Cables

1.   Continuous measurement of oil / gas pressure

2.   Pressure and alarm system checks

3.   Annual checks
– sheath voltage test (5kV / 1min)
– inspection of terminations
– functional checks of gauges and alarms
– checks of link boxes
– inspections of oil / gas feeding system for leaks/ corrosion.

4.   Condition assessment for wall bushings and cable

terminations

48 esbi.ie
 XLPE Cables

1. Annual sheath voltage test (5kV / 1min)

2. Annual inspection of terminations

3. Annual checks of link boxes

4. Condition assessment for wall bushings and cable

terminations

49 esbi.ie
 Third Party Damage

The most common cause of failures!

50 esbi.ie
 Outdoor
Sealing End
Failure
The Moyle Interconnector

CABLE REPAIR PROJECT

 Elements of the Moyle Interconnector

53 esbi.ie
 Project Goals

• Project Goals
• Locate the fault on the cable
• Confirm that only one fault exists on the cable
• Safely complete repair on the out of service Moyle Interconnector Cable
• Restore 250MW back onto the grid
• Cable repair joint to last for 3 years until new cable is laid in 2017

• Moyle Repair Video (9 minutes)

 https://vimeo.com/138223215
 

54 esbi.ie
HV Cable Services Offered by ESBI
 Services Offered by HV Cables

Design & Engineering

• Full range of design services for HV cable projects, covering new projects,
extensions, modifications, upratings and diversions of all cable types:
- XLPE Cables
- Low Pressure Oil Filled Cables
- Gas Compression Cables
- High Pressure Oil Filled Cables
- Submarine Cables
- AC & DC

• In depth knowledge and contacts in the leading HV cable manufacturers

• Cable route selection including preparation of cable route drawings

• Feasibility studies for HV Cable projects

• Civil design and engineering of HV cable circuits

• Stakeholder engagement

56 esbi.ie
 Services Offered by HV Cables

Design & Engineering

• Geographical, geological and resistivity surveys for cable routes

• Cable rating calculations

• Scope of work, material requirements and work programmes

• Cost estimates, cash flow projections

• Safety documentation throughout the project

 Preliminary Health & Safety Plans

 Design Risk Assessments
 Safety File

• Detailed cable system design including interface design, sheath bonding,

earthing arrangements and phasing.

• Co-ordination of interfaces with contractors, IPP’s etc.

57 esbi.ie
 Services Offered by HV Cables

Procurement Support

• Technical specifications and enquiry documentation preparation

• Tender assessment

• Witness factory acceptance tests of cables & accessories.

• Assess suppliers in regard to financial status, design/manufacturing/test

capability and facilities and quality control procedures.

Project Management and Construction Supervision

• Work programming, manpower and materials planning and budgeting

• Procedures for project control and reporting

• On site supervision during construction & installation – land & submarine

• Monitor and report on project implementation, compliance with quality

standards, programme, budgets, safe work methods etc.

58 esbi.ie
Thank you

www.esbi.ie