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MV and HV Cables, GIS Introduction and
Technology




Prof. Dr. Ing. Habil. H. Borsi

Bali 2013
page 2/xx

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1925 1950 1975 2000 1825 1850 1875 1900 Time
Power cable with
paper dielectric
1890 10-kV-Massekabel (fr Wechselstrom)
1913 33-kV-Massekabel (Radialfeldkabel/Hchstdter)
1924 132 kV low-pressure oil-filled cablel
1931 External gas pressure cables
1931 High-pressure oil cable
1936 220 kV low-pressure oil-filled cable
1937 Internal gas pressure cable
1952 400 kV low-pressure oil-filled cable
1974 500 kV low-pressure oil-filled cable
1980 1100-kV low-pressure oil-
filled cable (test cable)
Beginning of cable technology
1847 First communication cable with gutta-percha insulation
1880 First power cable with gutta-percha insulation (dc)
1882 First power cables with impregnated fiber fabric insulation and lead sheath
Historical developement
page 3/xx

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1980 1990 2000 1940 1950 1960 1970 Time
Power cables with plastic dielectric
Historical developement
1960 20 kV cables with PE insulation
1966 138 kV cables with PE insulation
1969 225 kV cables with PE insulation
1979 275 kV cables with XLPE insulation
1986 400 kV cables with VPE insulation
1988 500 kV cables with VPE insulation
1947 20 kV cables with PE insulation
page 4/xx

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The main structural elements of a single core cable and
its functions
Event
page 5/xx

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1994 1978 1998
TB RE MI FRH
MZA
IPH
1998 2000
Reuter Mitte Friedrichshain Marzahn
Vattenfall Europe Transmission
Wolmirstedt
Vattenfall Europe Transmission
Neuenhagen
Oil cabel
7.6 km
Overhead cable
1.1 km

(Berlin territory)
Overhead cable
2.6 km
Oil cabel
8.1 km
XLPE-cabel
6.5 km
XLPE-cabel
5.4 km
Overhead
7.0 km

(Berlin territory)
(1)
(1) Tunnel Teufelsseekanal: 0.32 km
(2) Tunnel Havelquerung: 0.52 km
(3) Tunnel Schlosspark: 1.10 km
(4) Tunnel Spree: 0.27 km
380-kV-overhead line 21.4 System-km
380-kV-oil cable 31.4 System-km
380-kV-XLPE- cable 23.8 System-km
(laying in the tunnel) 27.4 System-km
(2) (3)
6,3 km Tunnel 5,2 km Tunnel
(4)
Overview
The 380 kV diagonal
High and extra high voltage cables for big city supply
page 6/xx

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High voltage transmission technique (380 kV)
Development of high voltage cable technology
Oil cable
- Proven system of over 30 years of use under service
conditions
- Disadvantage through increased demands on
secondary systems by oil-paper insulation and the use of
forced cooling
With the use of appropriate and high quality pure synthetic
plastics as well as the further development of the extrusion
process (since 1960), there was the possibility for the
production of high-voltage cables with solid insulation.
XLPE cable
- Very good operating experience Bewag / Vattenfall
Europe Berlin since 1998
- Maintenance-free and easy-to-install cable with Increased
transmission capacity
page 7/xx

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About medium voltage cables
Despite fission product, free polymerization of highly polar material
due to the presence of permanent dipoles.

High loss factor and permittivity by orientation polarization
page 8/xx

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Countermeasure:
Addition of basic lead compounds
in order to accumulate free
radicals (obstruction of the zipper
effect) and bind the fission
products HCl to electrical
neutralization; coloring in order to
protect the material from the light.

Effects of aging:
Early increase of the loss factor in
the ionic conduction area
embrittlement
Event
Aging of PVC by UV light or heat
Zipper-like separation of the chain molecule with the formation of
double bonds and elimination of hydrochloric acid (schematically)
page 9/xx

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Continuous crosslinking system ("continousvulcanisation" CV) for the
production of plastic cables with EPR insulation; the free slack of the
conductor during the crosslinking and cooling sections are matched,
indirect heat transfer in the crosslink pipe by means of superheated steam
Event
Chain line for the production of EPR cables
page 10/xx

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Properties of EPR as Medium Voltage Insulation
Permittivity at 50Hz
Loss factor at 50 Hz, 20-90 C
Specific direct current conductivity at 20-90 C
Short-term dielectric strength of samples 1 mm thick, 50 Hz
Dielectric strength cable, 5 m long, 3-4 mm thick, 15-20 Hz,
Continuous operation temperature (max.)
Short circuit temperature
Mechanical tensile strength at room temperature
Elongation

2.5-3.0
20-60*10
-4
10
-16
-10
-14
S/cm
100-160 kV/mm
50 kV/mm
90 C
250 C
5-8 N/mm
2
250-350%

page 11/xx

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Clear superiority of EPR in the
high temperature range,
excellent thermal reserves in
case of overload and short-
circuit
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Mechanical tensile strength of EPR compared to cross-
linked polyethylene (XLPE)
page 12/xx

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Structural formula of polyethylene
chain (schematically)
By-theoretically-absolutely
symmetrical molecular structure
and the absence of polar reaction
products exceptionally high
dielectric material with an
extremely small loss factor (10
-4
)
and low DZ (~2.2).
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Polyethylen and XLPE cables

Polyethylene (PE) =polymerization product of ethene or ethylene
C2H4
page 13/xx

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The proportion of the less dense
amorphous zones with an
irregular molecular structure
increases with the number of
tertiary carbon atoms, and with
the temperature. Consequently,
LDPE contains larger amorphous
content than HDPE. Above the
crystalline melting temperature
(110-130 C) the materials are
completely amorphous.
Molecular structure of semi-crystalline materials, as an
example polyethylene (schematic)
page 14/xx

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Material data of polyethylene at room temperature
1) XLPE specification are valid for dry crosslinking
2) AC voltage values are valid for short-term load
Event
Properties LDPE HDPE XLPE
General
Production
Melting behavior
Specific gravity (g/cm
3
)
Crystallite (vol. -%)
Molecular weight
Flammability
Maximum continuous temperature (Cantigrad)

Dielectric properties
Dielectric constant at 50 Hz
Dissipation factor at 50 Hz (.10
-4
)
Resistivity (.m)

Dielectric Strength (kV/mm)
Physical limit (partially failed)
Model samples 1mm (50 Hz)
VDE plates 1 mm (50 Hz)
Cable 5.5 mm (50 Hz)
Cables (power surge)

Polymerization
Thermoplastic
0.918
40-45
70.000-100.000
yes
70


2.2-2.3
1-2
>10
17



800
150
50-100
30-50
about 100

Polymerization
Thermoplastic
>0.95
70-80
150.000
yes
80


2.3-2.4
1-3
>10
17



800
150
50-100
40-60
ca 100

Polymerization
Thermoelastic
0.918
40-45
70.000-100.000
yes
90


2.2-2.3
1-3
>10
17



800
150
50-100
50-70
about 100
page 15/xx

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Weak interface polarization determines the loss factor reduction from 0 to
80 C.
Reducing the DZ as a result of increasing crystallite melting over
temperature results in decreasing the density.

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Loss factor and permittivity (DZ) of LDPE and XLPE at
2 KV/mm
page 16/xx

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Structure plus interface and screen pad to avoid sticking of the shield
wires to the plastic jacket and protect the outer conductive before wire
screen prints
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Standard XLPE cable
page 17/xx

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Longitudinal and radial watertight XLPE cable

For high voltage quasi-standard
Polymer-coated Al-foil overlaps
along a cross-water protection
Swelling tape, rubber or powder
coat for inner longitudinal water
seal
page 18/xx

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Inner and outer "conductive layers" in the form of overlaps wound Al-
coated Hchstdter papers; Paper insulation wound with a gap of several
layer paper tapes
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Cables with impregnated paper insulation
Basic structure of the paper insulation of a cable

page 19/xx

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The need of the gaps between neighboring strips of paper at bending
When it comes to narrow gaps at bending it causes compression of the
paper with cavity formation
Event
page 20/xx

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Advantages Paper Kabel Disadvantages compared to XLPE cables
Low susceptibility of PD by
automatic cavity filling with
impregnating
"self-healing" local damage by
post flow impregnating
high resistance to aging, time-
tested performance up to 400 (500)
kV.
for oil-filled cables possibility of
impregnating process on installed
cables
no risk of water treeing
Easy on-site testing capability
with DC
approximately 10 times higher loss factor
(20/10
-4
) and 50% larger DZ: at the same
voltage 30 times higher loss power
complex production with drying, degassing,
vacuum impregnation
complicated sets (socket terminals + Links),
no prefabricated elements used
Risk of the outflow of impregnating material
in the mountains
not maintenance free (gas pressure or Oil
monitoring)
damage causes environmental hazard
because of leaking impregnating oil
Advantage and disadvantage of high voltage cables with
impregnated paper insulation compared with XLPE cables
page 21/xx

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Nitrogen-filled
membrane body
(same volume)
changes due to
thermal cycles of
impregnating oil
automatically.
Distance between
neighboring expansion
tanks: 0.3 ... 1 km.
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Pressure maintenance in oil cable systems
overcompensation vessels
page 22/xx

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Impregnating oil with low viscosity and hollow channel in the lead to
maintain the impregnating supply.
Event
Cross section of a low-pressure oil-filled cable
Main features:

page 23/xx

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Properties of low-pressure oil-filled cables
Loss factor tan (50 Hz, 20 C)
Permittivity
r
(50 Hz, 20 C)
Impulse withstand voltage(1...5/50 S)
Short-term strength (50 Hz)
Duration withstand voltage (50 Hz)
Operating field strength at the conductor E
0

Max. continuous operating temperature
Operating pressure (Nitrogen N
2
)

20-30*10
-4

3.5
100-130 kV/mm
45-50 kV/mm
40-45 kV/mm
13-16 KV/mm
85 C
~3 bar

page 24/xx

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Max. permissible system
pressure on the valley side for
mechanical reasons about 6.5
bar;
minimum pressure required on
the mountain side for electrical
reasons about 2 bar.
Accordingly all 60-70 m height
differential locking sleeves
must be provided with
expansion tanks.
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Distribution of oil-filled cable systems in mountainous
region into sections with separate pressure maintenance

page 25/xx

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Water as a polar molecule
increases the loss factor by
orientation polarization and
promotes ion conduction (a).

In addition, water may
evaporate at high concentration
under field exposure and form
bubbles: reduction of dielectric
strength (b).

Consequence: effective drying
Event
Influence of water content on the electrical properties of
paper impregnated dielectrics at 50 Hz / 20 C
page 26/xx

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Components of a paper-cable manufacturing line
(without impregnating and coating equipment)
page 27/xx

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Based on the respective transmission
power only <0.1% loss development,
but absolutely considerable energy.

Main sources of loss:
Current heat in conductor and
dielectric losses at 380 kV oil cable?


-1600 mm
2
conductor cross section
respectively
-Conductor losses valid for rated
current 1.1 kA
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Loss sources in high and extra high voltage cables
page 28/xx

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Greatly restricted thermal
dissipation very close to the
cable due to dehydration of
the soil and heating leads to
excessive heating of the
dielectric. In addition,
unfavorable conditions by
mutual influence of several
neighboring conductors in
three-phase system.
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Temperature gradient in the surroundings of a high-
power cable
page 29/xx

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Direct heat dissipation from the cable surface by cooling water enables
improved performance three to four times compared to normal burial.
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Increasing the transmission capacity of cable
systems through forced cooling
The application of
cooling method in the
400 kV cable network
BEWAG, Berlin:
page 30/xx

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Methods of forced cooling for high power cables
Indirect water-
cooling of the
cable surface

Laying of cables and cooling pipes in
lean concrete
-Advantages: Easy to install, protected
route
-Disadvantage: Limited cooling capacity
Direct water-
cooling of the
cable surface
Laying up of all three phases in a
common trench or cooling - channel
-Advantage: Compact route, effective
cooling
-Disadvantage: In case of damage
difficult repair
Laying up in separate cooling tubes
-Benefit: Effective cooling
-Disadvantage: Large line width
Lead-Direct
cooling (water or
oil)

Cooling passage in each conductor
-Advantage: Very effective cooling
directly "at source"
-Disadvantages: Expensive cables and
links
page 31/xx

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Main components are:
Conductor as a hollow tube for enlarging the radius of curving (reduction
of surface field strength consequently)
Housing at earth potential as return conductor
Supporting insulators with special design for the central guiding of the
conductor
SF6 insulating gas under increased pressure as the main dielectric
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Basic structure of gas pipe cables
page 32/xx

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Applications for Gas-Insulated Lines (GIL)
- Very low capacitive and resistive
losses reduce operating costs and
avoid reactive power compensation.
- Very low electromagnetic fields
allow the use in the neighborhood of
residential areas and technically
sensitive areas.
- Connecting load centers with higher power requirements via the
distance of a few kilometers
- With transmission power of 3000 MVA reaches the GIL the
transmission capacity of overhead lines and exceeds the
transmission capability of solid-insulated cables.
page 33/xx

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Advantages and disadvantages of SF6 Gas pipe cables
Advantages Disadvantages
Large conductor cross-sections
and thus high transmission rates
achievable
Extremely low internal losses,
based on the nominal power <0.1%
per system-km
Environmentally friendly, no risk of
soil contamination with liquid
impregnation
Suitable for vertical installation
without any additional measure
Regenerable dielectric, proven
long-term electrical strength
Suitable for voltages>420 kV
Large cable dimensions,
expensive
Only short pieces transportable,
complex piping with welding works
Special spring elements for
compensation of thermally induced
length changes required
Not fully testable in the factory
Non-maintenance free (compared
to XLPE)
Changing the direction of paths
only by using special spherical
segments
page 34/xx

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Countermeasure :
Limiting pressure to <5
bar (absolute) or heating
the most susceptible parts
of the system.
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Falling breakdown voltage through gas condensation
below about -32 C
Condensation decreases the molecular density in remaining gas
chamber and consequently reduces the dielectric strength.
page 35/xx

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Field concentration in the
edge, and tangential stress
on the insulating surface
(danger of creeping
discharges):

Targeted field controlling is
required!
Event
Field and potential lines at the offset edge of the outer
conducting layer or Hchstdter foil of high voltage
cable (schematic)
page 36/xx

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Conclusions from the 380 kV development have also led to the
development of the sets in the 110 kV voltage level!
sleeve body
control electrodes
Conducting layer
XLPE- cabel
Cross-bonding
cable
conductor connection
sleeve housing
One-piece
deferral sleeve
Made of EPDM
One-piece deferral sleeve
Made of Silicon
Epoxy resin with Stress cones made of
silicone rubber
Testing and Quality Assurance
Complete set
page 37/xx

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Application area: in plastic cables up to 400 kV

Advantages: Low dielectric loss, easy assembly on site, complete
prefabrication and testing at the factory
Disadvantage: design, especially for higher voltages
Event
a) Geometric-capacitive

Conductive deflector control,
embedded in elastic insulating
compound, reduces the volume
capacity on the cable end, extends
the field distribution on the
electrical load and shifts electrical
stress in sustainable solid (Silicon
rubber, EPR, EPDM).
page 38/xx

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With unchanged geometry
and frequency, the increase
of the induced voltage is
proportional to current and
conductor length:
It is the reason of the current
displacement in the
neighboring conductors
(proximity effect) and
transient currents in double-
grounded cable sheath
(jacket flow losses)
Event
Voltage induction due to the magnetic field of the
flowing current in conductor
page 39/xx

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Consequence: compensation of the
induced sheath voltage by symmetric out
crossing ("cross bonding") of the cable
sheaths or screens

With absolutely identical path lengths of the
individual sections in the symmetric
crossed system, the induced sheath
voltages add up to zero at the cable end:

No compensation currents - no additional
losses
Event
Shield losses by inducing currents at both earthed sides
of jacket or shield, based on total losses of the 3-phase
system
page 40/xx

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History of the
induced sheath
voltage in out
crossing
(arbitrary units)
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Full-crossing of the cable shealds (cross bonding)
page 41/xx

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Testing and Quality Assurance
Section length
Heating/cooling cycle
max. conductor temp.
Test voltage at 50 Hz

Duration of test
120 m
16 h / 32 h
90C (+ 5 K, - 0 K)
1.7 x U0 = 1.7 x 230 kV = 400 kV *)

1 year
Switching impulse
(250/2500 s)

Lightning impulse
voltage (1.2/50 s)
*)

With continuous partial discharge measurements on all sets

950 kV (5 pos., 5 neg.)


1175 kV (10 pos., 10 neg.)

Experimental setup at CESI in Italy
Test for 400 kV long-term test
page 42/xx

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Summary of routine tests acc. to IEC, VDE
Examination Application to ...
Short-duration power frequency test

cable with paper and plastic
insulation
loss factor measurement cables with paper insulation
Partial discharge measurement cable with plastic insulation
On site test (Power-on)

all cable systems after
installation



page 43/xx

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Decoupling of PD signals via
coupling capacitor connected in
parallel to the cable.

Advantage: With cable
breakdown, no galvanic infeed of
high voltage in quadrupole

Disadvantage: Reduced
sensitivity (PD signals can be
closed to circuit by Z)
Event
a) Parallel connection:
page 44/xx

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Quadrupole coupling in series
with the test object
To increase the sensitivity an
additional "return path capacity
in parallel

Event
b) Coupling series:
Advantage: good sensitivity

Disadvantage: when cable
breaks down, galvanic infeed of
the high voltage securing in four
pole - effective overvoltage
protection required
page 45/xx

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Two coupling quadrupoles form a
bridge with coupling capacitor and
cable.

Advantage: sensitivity as b),
additionally limited noise
suppression by external extinction
pulses in the detector input

Disadvantage: as b), additionally
complicated

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c) Bridge circuit:

basic circuits for partial discharge tests on cables
page 46/xx

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Partial discharge test setup in a shielded measuring
chamber with Filter
page 47/xx

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PD measurement on a 3-phase cable system
Event
Partial discharge measurement
page 48/xx

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The PD pulses, originated from the fault location, propagate with constant speed in
both directions. At the open end, a pulse is reflected and thus meets later the
measuring instrument. The time difference t is proportional to the distance difference
l = 2a. Requirements for the determination of a from t: calibration of the total
running time over 2L by impulse Injection at the cable beginning (duration until the
arrival of the reflected pulse: t = 2L/v).
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Principle of the Location
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