Type Testing and Pre-Qualification Testing of a 230 kV EHV Cable System

WesternUnderground September27,2012

TAT and PQT of 230 kV System (Re: IEC, AEIC and ICEA)
Company Introduction and Capabilities Plans for 230 kV System Certification and Reports Range of Approval

Introduction to XIGNUX

Infrastructures
DESIGN CONSTRUCTION TRANFORMERS LOW,MEDIUM&HIGH VOLTAGECABLES PROCESSING INDUSTRIES

VOLTRAK PROSEL SCHRADER IOESA

PROLECGE INDOTECH GEPROLEC

CMEWIRE&CABLE CMSA MAGNEKON ELETEC MULTIPAK CDN SAOMARCO

CARNESFRIAS BOTANAS

HV & EHV Technological Advances in Viakables History

1976. The first 69 kV high voltage cable with EPR insulation in Latin-American. 1986. 115 kV XLPE HV cable. 1998. 138 kV XLPE HV cable. 2005. 138 kV XLPE HV cable IEC 60840 Qualification (CTL Lab). 2011. 230 kV XLPE EHV system IEC 62067 (NEETRAC). 2011-2012. 138 kV XLPE HV Smooth Aluminum Sheath Cable and Copper Wires Shield and Aluminum Foil Laminated Cable, IEC 60840, AEIC CS9 & ICEA S-108720 Qualification (CTL Lab). 2011-2012. 230 kV XLPE EHV system AEIC/ICEA (NEETRAC).

HV Cables Experience
MV Extruded (XLPE / EPR) and PILC cable manufacturer for more than 45 years. HV XLPE Extruded 69 kV manufacturer for over 30 years. HV XLPE Extruded115 /138 kV manufacturer for over 25 years. 69 -138 kV history highlights in recent years: More than 1.1 million meters for HV & EHV Products. Largest order: 190 km Cu 800 mm2 115 kV. Average order: 10 km.

HV & EHV Technical Capabilities

Dry Cured Extrusion. True Triple Extrusion (Vertical state of the art process).
For HV & EHV: 69 kV 138 kV 250 2000 mm2 230 kV 380 2000 mm2 Eccentricity lower than 5%.

Introduction to CME

ENERGY
POWER&CONTROL

DISTRIBUTION
BUILDINGWIRE

MAGNEKONMAGNET
WIRE

CABLES

CABLES

CABLES

EnergyDivision
UtilityT&D Substations,PowerGeneration Industrial OEM&Specialty

DistributionDivision
Constructionwire Residential Commercial Industrial

MagnetWire
MotorRepair TransformerWinding OEM

Introduction to CME

Plans for 230 kV System

Critical Elements MarketStudy Tounderstand demandforcablesystems& decideonconstruction. Accessories Inhouseorworkwith amanufactureof accessories.Identifyaccessories fortesting. Testing Understand requirementsforsystem testing ExternalLaborInhouse? SelectWitnessingEngineer/s Execution Preparation,Testing,Reporting,etc.

230 kV Cable Construction

ABB Kabeldon Exterior Cable Terminations

APECB245kVOutdoorTerminationCeramic PremoldedEPDMStressConeforgeometricstresscontrol FillingwithPolybuteneoil Weight:515KgCreepabledistance:8300mm,Height:2570mm Maximumstressintheaccessory:3.7kV/mm

APECB245kVOutdoorTerminationSilicone PremoldedEPDMStressConeforgeometricstresscontrol FillingwithPolybuteneoil Weight:290KgCreepabledistance:9360mm,Height:3030mm Maximumstressintheaccessory:3.7kV/mm

ABB Kabeldon SF6 Cable Termination and Joints

ABBKabeldon 245kVJXMandJSM PremoldedOnePieceEPDMJoints Crossbondedandstraight Length:2690mm,Diameter:330mm Maximumstressintheaccessory:5kV/mm

APEGA245kVGasInsulatedSwitchgear(GIS)Terminations PremoldedEPDMStressConeforgeometricstresscontrol Weight:270KgLength:1680mm,Diameter:450mm Maximumstressintheaccessory:3.7kV/mm

Testing Requirements for HV & EHV Power Cable Systems 46< kV 345 (Ref: AEIC CS9)

Testing Requirements for HV & EHV Power Cable Systems 150< kV 500 (Ref: IEC 62067)

Testing Requirements for HV & EHV Power Cables 46< kV 345 (Ref: ICEA S-108-720)

Protocols for 230 kV System

IEC 62067 (System) ICEA S-108-720 (Cable) Combined (IEC and ICEA) Test Program (Ref: NEETRAC) Sequential IEC, ICEA Test Program to Satisfy both IEC and AEIC Requirements Compliance with AEIC CS9 through Compliance with:
IEC 62067 (System)+ ICEA S-108-720 (System, not cable only)+ IEC 62067 Annex D (Test for outer protection of buried joint)

Testing Capabilities (EHV)

Witnessing Engineers
CFEComisin Federalde Electrcidad
LaboratoryEquipmentand MaterialsTesting(LAPEM)isan organizationoftheFederal ElectricityCommissionwhich aimstomeettheneedsof nationalandinternationalpower sector,providingspecialized engineeringstudies,laboratory andfieldequipmentand materials,andasquality managementandsupplysystems inareliable,timelyandeffective, basedonahighdegreeof specializationofitsstaff,witha serviceorientedattitude.

NEETRACisaselfsupporting, membershipbasedcenter withintheSchoolofElectrical andComputerEngineeringat GeorgiaTech.Ourgoalisto helptheelectricutility industrysolvetheeveryday problemsassociatedwiththe complextaskoftransmitting anddistributingelectric energyreliabilityand efficiently.

IEC 62067 Type Test set up for 230 kV

SETUPLOOPIEC62067 20DAYS@254kV 20HEATINGCYCLES@95C

IMPULSETEST 10@1050kV ANNEXD

IEC 62067 Type Test Results

AEIC CS9 & ICEA S-180-720 Type Test set up for 230 kV
SETUPLOOP 20DAYS@266kV

20HEATINGCYCLES@105C

IMPULSETEST 10@1050kV

AEIC CS9 & ICEA S-108-720 Type Test Results

IEC 62067 Pre-Qualification set up

JOINT:CROSSBONDED

JOINT:STRAIGHT

TERMINATION:Right Porcelain,Left Composite.Middleterminationis thevoltagefeed(siphon)fromthe laboratory

SF6TERMINATIONS

IEC 62067 Pre-Qualification set up

OUTDOORTERMINATIONS 180HEATINGCYCLES@95C&365DAYS@216kV

SF6TERMINATIONS

IMPULSETEST 10@1050kV

IEC 62067 Pre-Qualification Results

AEIC CS9 Pre-Qualification for 230 kV

Additional90HEATINGCYCLESafterIECPQT@ 105Cand226kV

IMPULSETEST 10@1050kV

AEIC CS9 Pre-Qualification Results

Sequence of Load Cycles Applied to the 230 kV XLPE Qualification Cable System

IEC & AEIC Qualification

ContextofHighVoltageCableSystemTests withinanInversePowerLawModel

Sequence of Load Cycles Applied to the 230 kV XLPE Pre Qualification Cable System

It is particularly noteworthy that the compliance with AEIC CS9-06 was achieved on a cable that had previously completed the requirements of IEC 62067 2006 Section 13 cable system test (reported separately). Thus it had completed a sequence of load cycles as shown in Table 1. Furthermore the 230 kV XLPE Pre Qualification Cable System has completed two sequences of impulse tests at elevated temperatures (10 positive / 10 negative).

Test of Outer Protection for Buried Joint IEC 62067 ANNEX D

Range of Approval for 230 kV System AEIC CS9 06

1. 2. 3. 4. Cable system voltages 230 kV Conductor sizes 2000 mm2 Cable systems with emergency operating temperatures 105 C. Cable systems with the same or similar construction as that tested: a) CablesmanufacturedatConductoresMonterrey Plant,usingaVerticalContinuousVulcanization(VCV)lineand insulatingandsemiconductingmaterialsDowHFDA0801BK/DowHFDB4201SC/DowHFDK0587BKS b) TerminationsprovidedbyABBKabeldonofSweden(APECB245kVOutdoorTerminations(Composite&Porcelain)) c) TerminationsprovidedbyABBKabeldonofSweden(APEGA245kVOutdoorTerminations(GIS)) d) 245kVJSAMPremoldedOnePieceEPDMSlipOnStraightJoint type14,providedbyABBKabeldonofSweden e) 245kVJXBMPremoldedOnePieceEPDMSlipOnCrossBondedJoint type14,providedbyABBKabeldonof Sweden Cable systems with the same or lower electrical stresses as that tested: a) Cableswithvoltagestressesonthecableattheconductorscreen7.58kV/mmandattheinsulationscreen4.37 kV/mm. b) Terminationswithcompositeandporcelainbodiesforvoltages230kVandmaximumelectricalstresseswithinthe insulation3.7kV/mm(detaileddocumentationonfilewithConductoresMonterrey). c) GISTerminationsforvoltages230kVandmaximumelectricalstresseswithintheinsulation3.7kV/mm(detailed documentationonfilewithConductoresMonterrey). d) PremoldedOnePieceEPDMSlipOnStraightJointforvoltages230kVandmaximumelectricalstresseswithinthe jointinsulation5kV/mm(detaileddocumentationonfilewithConductoresMonterrey). e) PremoldedOnePieceEPDMSlipOnCrossBondedJointforvoltages230kVandmaximumelectricalstresses withinthejointinsulation5kV/mm(detaileddocumentationonfilewithConductoresMonterrey).

5.

Thank You!