TYPES OF CABLE INSULATIONS

TYPE CHARACTERSTICS/APPLICATION

PAPER PHASED OUT / OBSOLETE

INSULATED
PVC FILLED COMPOUND. SUITABLE FOR LOW EXCELLENT
THERMOPLASTIC VOLTAGE WEATHERABILITY .
INSULATION APPLICATION USEFUL FOR WIRES &
IN NATURE.
MOSTLY UP TO 1100 APPLIANCE CORDS.
HEAVIER IN WEIGHT VOLTS.
Density 1.35 to 1.60 Max. Operating Temp. 70
Deg. C
Short Ckt. Temp. 160 Deg.
C

XLPE PURE SUITABLE FOR EXCELLENT

CABLE ELECTRICAL, THERMAL
INSULATION THERMOSET INSULATIONS UP TO & MECHANICAL
LIGHTER IN 220 KV. PROPERTIES.
(XLPE)
Used in all heavy duty Max. Operating Temp. 90
WEIGHT.
cables from 1100 volts Deg. C
Density 0.93 onwards. Short Ckt. Temp. 250 Deg.
C
 XLPE INSULATED CABLES UP
TO 33 kV
• 1.9/3.3 Kv Screened & Unscreened Cable.
• 3.3/3.3 Kv Screened & Unscreened Cable.
• 3.8/6.6 Kv Screened & Unscreened Cable.
• 6.6/6.6 Kv Screened Cable.
• 6.35/11 Kv Screened Cable.
• 11/11 Kv Screened Cable.
• 12.8/22 Kv Screened Cable.
• 19/33 Kv Screened Cable.
 HISTORY OF XLPE

silane/sioplas ,

Steam peroxide, irradiation, L.V. monosil, MV monosil, Copolymer

1940 1950 1960 1970 1980 1990

MANUFACTURING OF XLPE
CABLES
 COMPARISION OF CROSSLINKING METHODS.
METHOD RADIATION PEROXIDE METHOD CHEMICAL METHOD
METHOD (SILANE CROSSLINKING)

Steam Cured Dry/ Co-polymer Siloxane

Nitrogen
Characterstics gas cured

Compound LDPE LDPE+ LDPE + Vinyl Silance Co-Polymer

Peroxide Peroxide
Source of energy for Radiation Peroxide Peroxide Moisture
cross linking with high with high
pressure temp. gas.
steam
Temperature reqd. Ambient More than More than Ambient to 90oC
for crosslinking 200 oC 200 oC 23oC  90 o C

Pressure reqd. for Ambient /Normal 18 to 20 Bar 5 to 10 Bar Ambient / Normal

crosslinking atmospheric atmospheric

Equipment for cross Accelecator & High High Simple Enclosure rigid or
linking Screening Pressure temperatu flexible .
Steam re gas
generation circulation
Equipment High UnitHigh Unit
High Low
construction Cost
Processability Easy Complex Easy Easy

Output Low Low Medium Medium

 WATER TREEING
RESISTANCE COMPARISION
• Y Axis % Retention 90

of Electric Strength 80
Silane
70 Cured
60 XLPE
Cable
Silane Cured XLPE 50
40
Vs 30 Std. Dry
Cure
Std. Gas Cured / Dry 20
Cable.
Cured Cable 10
0
 AC Breakdown strength of various Types of XLPE
99
90 Steam cured XLPE
Dry Cured XLPE &
Silane cured XLPE
Probabilty of AC Breakdown

50
Percentage
10 5
2

10 20 30 40 50
Average Breakdown Stress kV/mm
**Statistical AC Breakdown Voltage
 Contents of water & micro voids
in XLPE Cable
Production Highest Water Content No. of Voids per Maximum Size
Process during Process in ppm mm-3 of Void
(Vacuoles) pm

Steam Curing 1000-2000 106 30

Gas Cured 200 6 - 104 15

Water Cooled

Gas Cured 50 – 100 10 4 15

Silane Cured 80 10 4 15
 Relation Between water solubility level in
polyethylene temperature &
pressure.
10bar
Water Solubility

5 bar

1 bar
Level

Transition
Temperature.

Temperature
 Reduction in AC Breakdown Strength of XLPE in
Water at working Voltage in relation to time.
kV/mm

100

Chemically cure/Silane
cure/Gas cured XLPE
75
AC Breakdown stress

50
25

Normal Working Stress

2.5

Test Duration in Years.

 CRITICAL TESTS ON HIGH
VOLTAGE CABLES

GOVERNING SPECIFICATIONS:-
a.IS 7098 PART 2/1985 : Indian Standard
b.IEC 60502/Part 2 : Switzerland
c.BS 6622 : British Standard.
1.Partial Discharge Test. 2. Impulse Withstand Test.
3.Heating Cycle Test. 4. Dielectric Power Factor Test.
5.High Voltage Test.