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XLPE Cable Systems
Users guide
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2 ABB
C O N T E N T
XLPE Cable Systems Page
Introduction...........................................................................3
XLPE cable systems - design, installation and testing....... 4
XLPE cables .........................................................................
Cable accessories.................................................................
Installation of XLPE cable systems ......................................5
Testing of XLPE cable systems..............................................
XLPE cable and cable system standards............................6
IEC .....................................................................................
CENELEC.............................................................................
ICEA .....................................................................................
ISO Standards ......................................................................
XLPE cable system congurations......................................7
Trefoil and at formation ........................................................
Bonding of metallic screens ..................................................
Current rating for XLPE cable systems ...............................8
Current rating for three-core cables, ampres ......................
Current rating for single-core cables, ampres ................... 9
Rating factors ...................................................................11
Rating factor for cross section area of metal screen ..........
Rating factors for cables in the ground..............................
Rating factor for cables in pipes in the ground............... 12
Rating factor for cables installed in air ...............................
Example of the use of rating factors ..................................
Overload...............................................................................
Short-circuit currents ............................................................
Maximum short-circuit currents due to thermal restrictions.. 13
Dynamic forces at short circuits ............................................
Page
Cable drums .......................................................................14
Selection of cable drum .................................................... 15
Sizes and weights of wooden drums.....................................
Large and special drums.......................................................
Testing of XLPE cables...........................................................
Cable handling........................................................................
Minimum bending radius.......................................................
Maximum pulling forces ........................................................
XLPE cable design...............................................................16
Conductors ............................................................................
Standards - IEC and ICEA.....................................................
Conductor water sealing .......................................................
Insulation.................................................................................
Conductor screen.................................................................
XLPE insulation .................................................................17
Insulation screen...................................................................
Metallic screen........................................................................
Copper wire screen, standard design....................................
Copper wire screen, water tight design .................................
Lead sheath..........................................................................
Copper tape screen..............................................................
Non-metallic outer sheath ................................................. 18
Conductive outer layer ..........................................................
Flame retardant outer layer....................................................
Fire behavior...........................................................................
Technical data for cables in the ABB XLPE cable system .....19
Formulae ............................................................................. 26
Support ................................................................................. 27
To make sure you have the latest version of this
brochure, have a look atwww.abb.com/cables
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ABB 3
Introduction
Interfaces you can trust
ABB manufactures underground and submarine powercables up to the highest voltages available.
Furthermore, we produce associated joints, terminationsand other accessories for all types of cables. The productsare designed to work perfectly together. Thus, we know
what we connect.
Experience you can rely on
We have extensive experience of cable projects all over the
world, encompassing every aspect from planning to com-missioning, including engineering, route surveys, cable-lay-ing, installation and final testing. Very few manufacturerscan point to such a long tradition in the high voltage fieldas ABB. We delivered our first electrical cable in 1883 andintroduced triple-extruded XLPE cables around 1970. Inthe early 1970s we started to supply cables for over 100kV and our first 245 kV XLPE cable was put into service in1978. ABB has since then supplied more than 6,000 km of
XLPE cables above 100 kV. Experience you can rely on.
Research and development
ABB has always been a pioneer in the high voltage fieldand we have many worlds first and world records amongour references. But there are no shortcuts to success.Maintaining our position calls for innovative research anddevelopment, backed up by the wealth of know-how wehave accumulated over the years. One of the driving forcesfor our R&D is to meet the new and constantly increasing
requirements from the power industry and a deregulatedmarket. Today we aim to develop the solutions our custo-mers will need tomorrow.
State-of-the-art manufacturing lines
Experience and state-of-the-art expertise go hand in handfor us. We have been manufacturing cables for over 120
years and have since the beginning been one of theleading producers. Our factories are among the mostmodern in the world and our advanced quality systemleaves nothing to chance. Every cubic millimeter of the
cable has to be perfect. We design and produce cables inaccordance with internationally approved standards or/andaccording to our customers specifications.
This guide presents XLPE cables and systems for under-ground applications mainly.
I N T R O D U C T I O N
XLPE Cable Systems
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XLPE cable systems design, installation and testing
XLPE cables
Single- or three-core XLPE cables consist of the following
components:
Conductor
- Cu or Al stranded compacted conductor or
- Cu segmental conductor or
- Cu or Al conductor with key-stone shaped profiles
- Longitudinal water sealing of conductor
Triple extruded and dry cured XLPE insulation system
Metallic screen
Copper wire screen
Copper tape screen
Radial water sealing
- Al - PE laminate
- Cu - PE laminate - Lead sheath
Longitudinal water sealing of metallic screen
Non-metallic outer sheath
- PE
- PVC
- Halogen free flame retardant
- Co-extruded conductive layer over the sheath for
special sheath testing
Armour
- Single wire armour
- Double wire armour
Cable accessories
The set-up of cable accessories for ABB XLPE cable systems
covers:
Straight joints and joints with integrated screen
separation for cross bonding
Transition joints for connection of XLPE to uid-
lled cables
Outdoor terminations with porcelain or composite
insulators
Screened separable connectors for switchgears and
transformers
Terminations connecting to transformers and
Gas Insulated Switchgears (GIS)
Link boxes for earthing and cross-bonding
Distributed Temperature Sensing (DTS) Systems
More information about our accessories is available on
www.abb.com
X L P E C A B L E S Y S T E M S - D E S I G N , I N S T A L L A T I O N A N D T E S T I N G
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ABB 5
Testing of XLPE cable systems
The standard routine tests, sample tests, type tests and afterlaying tests are normally performed according to IEC-stan-dards. Other international or national standards may be fol-
lowed upon agreement between contractor and purchaser.
Routine tests of XLPE cables and accessories
PD-measurement test. High-voltage test of main insulation Electrical Test of oversheath, if required Visual inspection
Sample tests
Sample tests are carried out with a frequency according toapplicable IEC standards. Conductor examination Electrical resistance of conductor Check of dimensions Capacitance test Hot set test Electrical Tests
After laying tests
DC voltage test of oversheath An AC voltage test of main insulation
Installation of XLPE cable systems
The installation of cable systems consists mainly oftrenching, cable pulling, clamping of cable as well asmounting of accessories. ABBs certified installers perform
the high quality work necessary to achive a reliable opera-tion of the cable system.ABB has long and good experience from different
installation technologies like direct burial, duct, shaft, trough,tunnel and submarine installations, but also trenchlesstechnologies like directional drilling, pipe jacking and others.
X L P E C A B L E S Y S T E M S S T A N D A R D D E S I G N A N D O P T I O N S
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ABBs XLPE cable systems are designed to meet require-ments set in international or national standards. Some ofthese are listed below.
IEC
XLPE cable systems specified according to IEC(International Electrotechnical Commission) are amongmany other standards accepted. IEC standards are conside-red to express an international consensus of opinion.
Some frequently used standards are:IEC 60228
Conductors of insulated cables.
IEC 60287
Electric cables - Calculation of the current rating.
IEC 60332
Tests on electric cables under fire conditions.
IEC 60502
Power cables with extruded insulation and their accesso-ries for rated voltage from 1 kV (U
m=1,2 kV) up to 30 kV
(Um=36 kV).
IEC 60840
Power cables with extruded insulation and their accessoriesfor rated voltage above 30 kV (U
m=36 kV) up to 150 kV
(Um=170 kV). Test methods and requirements.
IEC 60853Calculation of the cyclic and emergency current rating ofcables.
IEC 61443
Short-circuit temperature limits of electric cables with ratedvoltages above 30 kV (U
m=36 kV)
IEC 62067
Power cables with extruded insulation and their accessoriesfor rated voltage above 150 kV (U
m=170 kV) up to 500 kV
(Um=550 kV). Test methods and requirements.
CENELECIn Europe, cable standards are issued by CENELEC.(European Committee for Electrotechnical Standardization.)They are as a rule implementations of the IEC specifica-tions. Special features in design may occur depending onnational conditions.
HD 620
Distribution cables with extruded insulation for rated volta-ges from 3.6/6 (7.2) kV up to and including 20.8/36 (42) kV.
HD 632
Power cables with extruded insulation and their acces-sories for rated voltage above 36 kV (U
m
=42 kV) up to 150kV (U
m=170 kV). Part 1- General test requirements.
Part 1 is based on IEC 60840, and follows that standardclosely.HD 632 is completed with a number of parts and sub-sections for different cables intended to be used underspecial conditions which can vary nationally in Europe.
ICEA
For North America cables are often specified according toICEA (Insulated Cable Engineers Association, Inc.)
S-97-682
Standard for utility shielded power cables rated 5-46 kV.
ISO Standards
ABB has well-developed systems for quality and environ-mental management which put the needs and wishes ofthe customer first. Our systems comply with the requi-rements of ISO 9001 and ISO 14001 and are certified byBureau Veritas Quality International.
XLPE cable and cable system standards
ISO 14001 Certicate of Approval ISO 9001 Certicate of Approval
X L P E C A B L E A N D C A B L E S Y S T E M S T A N D A R D S
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ABB 7
Trefoil and flat formation
One group of XLPE cables may be placed in trefoil (tri-angular) or flat formation according to figure. The choicedepends on several factors like screen bonding method,conductor area and available space for installation.
Bonding of the metallic screens
Different methods of bonding the metallic sheaths may bechosen when designing a cable system. The usual bondingmethods are described below:
Both-ends bonding
A system is both ends bonded if the arrangements are suchthat the cable sheaths provide path for circulating currentsat normal conditions. This will cause losses in the screen,
which reduces the cable current carrying capacity. Theselosses are smaller for cables in trefoil formation than in flatformation with separation.
Trefoil or at formation
XLPE cable system configurations
Single-point bonding
A system is single point bonded if the arrangements aresuch that the cable sheaths provide no path for the flow ofcirculating currents or external fault currents. In such case,a voltage will be induced between screens of adjacent
phases of the cable circuit and between screen and earth,but no current will flow. This induced voltage is propor-tional to the cable length and current. Single-point bondingcan only be used for limited route lengths, but in generalthe accepted screen voltage potential limits the length.
X L P E C A B L E S Y S T E M C O N F I G U R A T I O N S
Cross-bonding
A system is cross-bonded if the arrangements are suchthat the circuit provides electrically continuous sheath runsfrom earthed termination to earthed termination but withthe sheaths so sectionalised and cross-connected in orderto eliminate the sheath circulating currents. In such case, a
voltage will be induced in between screen and earth, butno significant current will flow. The maximum induced
voltage will appear at the link boxes for cross-bonding.This method permits a cable current-carrying capacity ashigh as with single-point bonding but longer route lengthsthan the latter. It requires screen separation and additionallink boxes.
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The XLPE cable should at least have a conductor crosssection adequate to meet the system requirements forpower transmission capacity. The cost for energy lossescan be reduced by using larger conductor.
On-load losses are basically the ohmic losses in theconductor and the metallic screen. The XLPE cables can beloaded continuously to a conductor temperature of 90C.However, in order to keep a load margin, or to keep thelosses lower, or to avoid possible thermal instability due todrying out the surrounding soil, it may be advantageous tolimit the operating temperature to, approximately, 65C.
The dielectric losses of XLPE insulation are present alsoat no load. Those losses depend on the operation voltage
applied and shall be considered above 100 kV.
The dielectric losses are lower for XLPE insulated cablesthan for EPR insulated cables.
The continuous current ratings for three-core cables aregiven in Table 1 and for single-core cables in Tables 2-5.The continuous current ratings are calculated accordingto IEC 60287 series of standards and with the followingconditions:- One multi-core cable or one three-phase group of
single-core cables
- Ground temperature 20C- Ambient air temperature 35C- Laying depth L 1.0 m- Distance s between cable
axes laid in flat formation 70 mm + De
- Ground thermal resistivity 1.0 Km/W
Rating factors for single-core cables are given in Tables 6to 14.
Table 1
Rated voltage up to 220 kV
Cross
section
mm2
Aluminium conductor Copper conductor
In ground In air In ground In air
65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC
16 74 89 60 82 96 115 78 105
25 95 115 80 110 120 145 105 140
35 115 135 97 130 145 175 125 170
50 135 160 120 165 175 210 155 210
70 165 195 145 195 210 250 185 250
95 195 230 170 230 250 300 220 290
120 220 265 200 270 285 340 255 345150 245 295 225 300 315 380 285 390
185 280 335 255 345 355 430 325 440
240 320 385 300 400 410 495 380 515
300 365 435 335 455 460 555 430 580
400 410 490 385 525 515 625 490 680
500 465 560 445 610 580 700 560 780
630 525 635 510 705 640 785 635 890
800 585 715 585 810 705 865 715 1000
1000 645 785 655 915 755 935 785 1100
Current rating for XLPE cable systems
C U R R E N T R A T I N G F O R X L P E C A B L E S Y S T E M S
Current rating for three-core cables, ampres
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ABB 9
Table 2
Rated voltage 10-70 kV, aluminium conductor 25 or 35 mm2screen
Cross
section
conductor
Cables in Ground Cables in Air
Flat formation Trefoil formation Flat formation Trefoil formation
Crossbonded Both ends Cross bonded Both ends Crossbonded Both ends Cross bonded Both ends
mm2 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC
95 220 265 215 260 205 250 210 250 230 310 225 305 200 270 200 270
120 250 300 245 295 235 285 240 285 265 360 260 350 225 310 230 310
150 280 340 270 325 265 320 265 320 305 410 290 395 260 355 260 355
185 320 385 304 365 300 360 300 360 350 470 330 450 295 405 295 405
240 370 445 345 420 350 420 345 420 415 560 380 520 350 480 350 480
300 420 505 385 465 395 475 390 470 475 645 430 590 400 550 400 545
400 480 575 430 520 450 540 445 535 555 750 490 675 470 640 465 635
500 550 660 475 580 515 620 505 610 645 875 555 770 545 745 535 735
630 625 755 525 645 585 705 570 690 755 1025 625 870 630 865 615 850
800 710 855 575 710 660 795 635 775 875 1190 700 980 725 995 705 975
1000 790 955 625 770 730 885 700 855 995 1355 770 1080 820 1130 790 1100
1200 850 1035 655 815 785 950 745 910 1095 1490 820 1160 890 1235 855 1190
1400 910 1105 685 850 830 1010 785 960 1185 1620 865 1230 960 1330 915 1275
1600 960 1165 705 880 870 1060 815 1005 1265 1735 905 1285 1015 1410 960 1345
2000 1045 1270 740 930 935 1145 870 1075 1405 1930 965 1380 1115 1555 1045 1470
Table 3
Rated voltage 10-70 kV, copper conductor 25 or 35 mm2screen Segmental conductor for 1200 mm2or more.
Crosssection
conductor
Cables in Ground Cables in Air Flat formation Trefoil formation Flat formation Trefoil formation
Crossbonded Both ends Cross bonded Both ends Crossbonded Both ends Cross bonded Both ends
mm2 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC
95 285 340 275 330 270 320 270 325 300 400 285 390 255 350 255 350
120 325 390 310 375 305 365 305 365 345 465 325 445 295 400 295 400
150 365 435 340 410 340 410 340 410 390 530 360 495 335 455 335 455
185 410 495 375 455 385 465 385 460 450 610 405 560 380 520 380 520
240 475 570 425 515 445 535 440 535 530 720 465 645 445 615 445 610
300 540 645 465 570 505 605 495 600 610 830 520 725 510 705 505 695
400 610 735 515 630 570 690 555 675 710 960 585 815 595 815 580 800
500 695 835 560 690 645 780 625 755 820 1115 650 915 680 940 660 915
630 785 950 610 755 725 875 690 845 950 1295 720 1020 780 1080 750 1045
800 880 1065 655 815 800 975 760 930 1085 1485 790 1125 880 1220 840 1175
1000 965 1170 695 870 870 1065 815 1005 1215 1665 855 1220 980 1360 925 1300
1200 1115 1350 745 935 1035 1255 915 1125 1440 1965 950 1355 1190 1645 1070 1505
1400 1200 1450 775 970 1105 1345 960 1185 1575 2145 1000 1430 1290 1785 1145 1610
1600 1270 1540 795 1000 1165 1420 995 1235 1685 2305 1035 1490 1370 1905 1205 1695
2000 1395 1695 830 1045 1265 1545 1055 1315 1890 2590 1100 1585 1520 2115 1300 1845
C U R R E N T R A T I N G F O R X L P E C A B L E S Y S T E M S
Current rating for single-core cables, ampres
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Table 4
Rated voltage 110-500 kV, aluminium conductor 95 mm2screen
Cross
section
conductor
Cables in Ground Cables in Air
Flat formation Trefoil formation Flat formation Trefoil formation
Crossbonded Both ends Cross bonded Both ends
Crossbonded Both ends Cross bonded Both ends
mm2 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC
300 405 490 365 445 390 465 380 460 455 610 415 565 405 550 400 540
400 465 560 405 495 445 535 430 525 535 715 470 640 470 635 460 625
500 535 640 450 550 505 610 485 590 620 835 530 725 545 740 525 720
630 610 735 495 605 575 695 545 665 725 975 595 820 625 855 605 830
800 690 830 535 660 650 785 605 740 835 1130 655 910 720 985 680 940
1000 770 935 575 710 720 875 660 815 955 1295 715 990 810 1115 760 1055
1200 825 1005 605 750 770 940 700 865 1045 1415 765 1070 880 1215 820 1140
1400 880 1075 630 780 820 1000 740 910 1125 1520 800 1125 945 1305 875 1220
1600 930 1130 649 805 855 1050 765 950 1200 1635 835 1175 1000 1385 920 1285
2000 1005 1230 680 845 920 1135 810 1010 1330 1820 885 1250 1095 1525 995 1395
Table 5
Rated voltage 110-500 kV, copper conductor 95 mm2screen Segmental conductor for 1200 mm2or more.
Cross
section
conductor
Cables in Ground Cables in Air
Flat formation Trefoil formation Flat formation Trefoil formation
Crossbonded Both ends Cross bonded Both ends
Crossbonded Both ends Cross bonded Both ends
mm2 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC 65oC 90oC
300 520 625 440 540 495 600 475 580 585 785 505 690 515 700 505 685
400 595 715 480 590 560 680 535 650 680 915 560 775 595 810 575 785
500 675 815 525 645 635 770 595 725 785 1060 620 860 680 930 650 890
630 760 925 565 700 710 865 655 805 910 1230 680 950 780 1070 730 1010
800 850 1035 600 745 790 960 715 880 1035 1410 740 1040 875 1210 810 1130
1000 935 1140 635 790 855 1050 765 945 1160 1590 790 1115 970 1345 885 1240
1200 1070 1295 675 840 995 1215 820 1015 1365 1850 875 1235 1155 1590 990 1390
1400 1145 1390 695 870 1060 1300 855 1065 1480 2010 915 1295 1245 1720 1050 1480
1600 1210 1475 715 900 1120 1375 885 1110 1605 2185 950 1350 1340 1850 1110 1570
2000 1310 1610 740 930 1210 1490 930 1165 1780 2435 995 1425 1465 2040 1185 1685
2500 1415 1745 770 970 1300 1605 970 1225 2010 2760 1055 1515 1625 2270 1275 1825
3000 1490 1840 790 995 1365 1695 1000 1265 2175 2995 1095 1575 1735 2435 1340 1925
C U R R E N T R A T I N G F O R X L P E C A B L E S Y S T E M S
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ABB 11
Rating factors
Rating factor for cross section area of metal screen
Applicable to single-core cables in trefoil formation. Screensbonded at both ends.
For single-point bonding or cross-bonding no rating factorapplies for the cross section area of metal screen.
Table 6 10-70 kV 35 mm2screen
Rating factor for tables 2 and 3
Conductor
mm2Copper screen mm2
Al Cu 25 35 50 95 150 240 300
300 1.00 1 0.99 0.98 0.97 0.96 0.95
500 300 1.00 1 0.99 0.97 0.95 0.93 0.93
800 500 1.01 1 0.99 0.96 0.93 0.90 0.90
1200 630 1.01 1 0.99 0.95 0.92 0.89 0.882000 800 1.01 1 0.98 0.94 0.91 0.87 0.86
1200 1.02 1 0.97 0.91 0.85 0.81 0.80
2000 1.03 1 0.96 0.88 0.82 0.77 0.76
3000 1.03 1 0.96 0.88 0.82 0.76 0.75
Table 7 110-500 kV 95 mm2screen
Rating factor for tables 4 and 5
Conductor
mm2Copper screen mm2
Al Cu 25 35 50 95 150 240 300
300 1.02 1.02 1.01 1 0.99 0.98 0.97
500 300 1.03 1.03 1.02 1 0.98 0.96 0.96
800 500 1.05 1.04 1.03 1 0.97 0.94 0.94
1200 630 1.06 1.05 1.04 1 0.97 0.93 0.922000 800 1.07 1.06 1.04 1 0.96 0.92 0.91
1200 1.12 1.1 1.07 1 0.94 0.89 0.88
2000 1.16 1.13 1.09 1 0.93 0.87 0.86
3000 1.17 1.14 1.10 1 0.93 0.87 0.85
Rating factor for cables in the ground
Table 9
Rating factor for ground temperature
Conductor
temperature,oC
Ground temperature, oC
10 15 20 25 30 35 40 45
90 1.07 1.04 1 0.96 0.93 0.89 0.84 0.80
65 1.11 1.05 1 0.94 0.88 0.82 0.74 0.66
Table 10
Rating factor for ground thermal resistivity
Thermal resistivity,
Km/W
0.7 1.0 1.2 1.5 2.0 2.5 3.0
Rating factor 1.14 1.00 0.93 0.84 0.74 0.67 0.61
Table 11
Rating factor for phase spacing
One group in at formation with cross-bonded or single-bonded
screens
Spacing s, mm De
De+70 200 250 300 350 400
Rating factor 0.93 1 1.03 1.05 1.07 1.08 1.10
C U R R E N T R A T I N G F O R X L P E C A B L E S Y S T E M S
Table 8
Rating factor for laying depth
Laying depth, m Rating factor
0.50 1.10
0.70 1.05
0.90 1.01
1.00 1.00
1.20 0.98
1.50 0.95
1 mm2copper screen is equivalent to: 1.66 mm2aluminium sheath
12.40 mm2lead sheath
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Table 12
Rating factor for groups of cables in the ground
One three-core cable is equivalent to one group of single-core cables
Distance cc
between groups,
mm
Number of groups
1 2 3 4 5 6 7 8 9
100 1 0.76 0.67 0.59 0.55 0.51 0.49 0.47 0.46
200 1 0.81 0.71 0.65 0.61 0.49 0.56 0.53 0.52
400 1 0.85 0.77 0.72 0.69 0.66 0.64 0.63 0.62
600 1 0.88 0.81 0.77 0.74 0.72 0.71 0.70 0.69
800 1 0.90 0.84 0.81 0.79 0.77 0.76 0.75 0.75
2000 1 0.96 0.93 0.92 0.91 0.91 0.91 0.90 0,90
Rating factor for cables installed in pipes in the ground
The rating factor given for single-core cables partiallyinstalled in separate pipes, applies only when a cable sec-tion between screen earthing points must be partially laidin pipes, under the following conditions:- the cables are laid in trefoil formation over the major
portion of the section- the pipes are laid in flat formation- the piped length is less than 10% of the section
between earthing points- one cable per pipe- the pipe diameter is two times the cable diameter.
Rating factor for cables installed in air
Table 13
Rating factor for cables in pipes in ground
Single-core
cables
partially
installed in
separate
pipes
Single-core
cables in
separate
pipes
Single-core
cables in
a common
pipe
Three-core
cable
in a pipe
0.94 0.90 0.90 0.90
Example of the use of rating factors
2 groups of 60 kV XLPE cables with aluminium conductors1 x 500/150 mm2in the ground in trefoil formation. Metalscreens bonded at both ends, 90C conductor temperature.Table 2 gives current rating 610 A, unadjusted value.
Table Rating factor
Current rating 610 A 2 -
Screen area 150 mm2 6 0.95
Laying depth 1.5 m 8 0.95
Ground temperature 30C 9 0.93
Ground thermal resistivity 1.5 Km/W 10 0.84
Distance between groups 400 mm 12 0.85 (2 groups)
Overload
As infrequently as possible, an XLPE-cable may be over-loaded above 90C and the conductor temperature mayreach up to 105C. Singular emergency overloads are notexpected to produce any significant damage to the cable.However both occurrence and duration of these overloadsshould be kept at a minimum. Cyclic and emergency ratings
can be calculated according to IEC publication 60853.
Short-circuit currents
During short circuit conditions the maximum allowabletemperature in conductor or screen/metallic sheath isdetermined by the adjoining insulation and sheath materi-als. This is specified in IEC 61443 Short circuit temperaturelimits of electric cables with rated voltage above 30 kV(U
m=36 kV). The dynamic forces between the conductors
must be taken into account for cable installations.
C U R R E N T R A T I N G F O R X L P E C A B L E S Y S T E M S
Table 14
Rating factor for ambient air temperature
Air temperature, oC 5 10 15 20 25 30 35 40 45 50 55
Rating factor 1.28 1.24 1.19 1.15 1.10 1.05 1.0 0.95 0.89 0.83 0.77
Adjusted current rating per group;
610 x 0.95 x 0.95 x 0.93 x 0.84 x 0.85 = 365 A
Please note that use of rating factors gives good generalindication during planning future circuits.Once a circuit layout is defined, an accurate calculationshould be performed to confirm the assumptions.
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ABB 13
Copper screens may reach a temperature of 250oC withoutdamaging adjacent insulating material. With an initial tem-perature of 50oC this corresponds to a current density of150 A/mm2during 1s. (Both higher and lower current den-sities may be allowed if other conditions apply.)Lead sheaths are limited to 210oC at short circuit. With aninitial temperature of 50oC this corresponds to a currentdensity of 28 A/mm2during 1 s.
Maximum short circuit currents due to thermal restrictions
The thermal energy developed during a short-circuit isdetermined by the short-circuit magnitude and duration.For design purposes, an equivalent short-circuit current
with a duration of 1 sec is used according to formulabelow. This formula is valid for a short-circuit duration of0.2 to 5.0 sec.
Ish=short-circuit current during time t
sh
I1=short-circuit current rating during 1 second. See the 1
s-
value in tables 15 for the conductor and in Table 16 forthe metal screen.tsh=short-circuit duration
For XLPE insulated conductors the maximum allowableshort circuit temperature is 250oC.
C U R R E N T R A T I N G F O R X L P E C A B L E S Y S T E M S
Table 15
Max. short-circuit current on the conductor during 1 s, kA
Conductor temperature before the short-circuit
Cross
section
Aluminium
conductor
Copper
conductor
mm2 65oC 90oC 65oC 90oC
25 2.6 2.4 3.9 3.6
35 3.6 3.3 5.5 5.0
50 5.2 4.7 7.8 7.2
70 7.2 6.6 11.0 10.0
95 9.8 9.0 14.9 13.6
120 12.4 11.3 18.8 17.2
150 15.5 14.2 23.5 21.5
185 19.2 17.5 29.0 26.5
240 24.8 22.7 37.6 34.5
300 31.1 28.3 47.0 42.9
400 41.4 37.8 62.7 57.2
500 51.8 47.2 78.4 71.5
630 65.2 59.5 98.7 90.1
800 82.8 75.6 125 114
1000 104 94.5 157 143
1200 124 113 188 172
1400 145 132 219 200
1600 166 151 251 229
2000 207 189 313 286
per mm2 0.104 0.0945 0.157 0.143
Table 16
Max. short-circuit current on the screen during 1 s, kA
Metallic screen
cross section, mm2
Metallic screen
temperature
before the short-circuit
Copper
screen Lead sheath 50oC 70oC
16 94 2.6 2.4
25 147 4.1 3.8
35 206 5.8 5.4
50 295 8.3 7.7
95 560 16 15
150 884 25 23
300 1768 50 46
per mm2Cu 0.165 0.153
per mm2Pb 0.028 0.026
Dynamic forces at short circuits
Apart from the thermal stress in case of short-circuit, thedynamic stresses in cables and accessories must be takeninto consideration.
The dynamic effect of parallel conductors carrying cur-rent is responsible for the dynamic stress.The dynamic forces between two conductors, can be cal-culated as:
Where; Ipeak
= 2.5 Ish[kA]
Ish= Short current [kA] RMS
S = Centre to centre spacing between
conductors [m]F = maximum force [N/m]
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14 ABB
Table 17
Selection of cable drum
Cable
diameter
Cable lengths in metres on standard drum
Drum type
mm K14 K16 K18 K20 K22 K24 K26 K28 K30
36 570 760 850 1155 1560 2090 2860 4000 5800
38 470 630 820 1075 1290 1780 2490 3600 4900
40 450 610 690 900 1100 1560 2220 3200 4400
42 430 500 660 870 1070 1510 2160 3100 3950
44 340 480 530 720 1030 1310 1830 2800 3900
46 330 450 510 690 860 1260 1780 2430 3460
48 310 360 480 660 820 1070 1540 2360 3130
50 360 400 550 670 1020 1490 2090 2820
52 340 385 530 670 910 1280 1830 2750
54 320 360 505 640 870 1280 1775 2450
56 260 360 475 610 825 1090 1715 2380
58 240 275 385 510 720 1040 1550 2090
60 275 365 480 680 990 1490 2030
62 250 365 480 680 460 1270 1770
64 250 345 450 545 825 1270 1730
66 240 345 370 545 825 1230 1535
68 240 320 345 515 785 1025 1475
70 250 345 515 670 1030 1475
72 250 345 480 635 985 1260
74 250 320 400 635 985 1260
76 230 320 400 625 810 1210
78 230 320 400 600 810 1210
80 230 325 500 810 1015
82 230 325 470 775 1015
84 210 300 470 660 1015
86 210 300 470 615 965
88 210 275 440 615 840
90 210 275 440 615 840
92 355 585 800
94 325 585 800
96 325 485 755
98 325 485 640
100 325 455 640
>100 Cable drums with bigger barrel diameter are needed for big diameter cables
(normally steel drums)
The drums are made of high-quality wood.
Cable drums
C A B L E D R U M S
Wooden drums/reels are standardised . For certain purposes steeldrums/reels are applicable. Both wooden and steel-drums can beobtained for special purposes with other measures than stated below.
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ABB 15
Table 18
Sizes and weights of wooden drums
Drum type
K14 K16 K18 K20 K22 K24 K26 K28 K30
Shipping volume m3 2.14 2.86 3.58 5.12 6.15 7.36 10.56 13.88 17.15
Drum weight incl. battens kg 185 275 320 485 565 625 1145 1460 1820
a Diameter incl battens mm 1475 1675 1875 2075 2275 2475 2700 2900 3100
b Flange diameter mm 1400 1600 1800 2000 2200 2400 2600 2800 3000
c Barrel diameter mm 800 950 1100 1300 1400 1400 1500 1500 1500
d Total width mm 982 1018 1075 1188 1188 1200 1448 1650 1800
e Spindle hole diameter mm 106 106 131 131 131 131 132 132 132
Large and special drums.
Steel drums with larger outer diameters are available, buttransport restrictions have to be considered. Special low-loading trailers and permits from traffic authorities can be
needed depending on local regulations and conditions. Special wooden drums with larger barrel diameter orlarger width are also available.
Table 19
Rated voltage and corresponding test voltages
according to IEC
Type test Routine tests
Nominal
voltage
Impulse
voltage
AC voltage
test
Partial discharge
test at
kV kV kV
Duration
minutes kV
10 75 21 5 10
20 125 42 5 21
30 170 63 5 31
45 250 65 30 39
66 325 90 30 54
110 550 160 30 96
132 650 190 30 114
150 750 218 30 131
220 1050 318 30 190
275 1050 400 30 240
330 1175 420 60 285
400 1425 440 60 330
500 1550 580 60 435
Tests according to other standards can be carried out upon
agreement.
Table 20
Minimum bending radius for standard designs
Single-core
cable
Three-core
cable
At laying 15 De
12 De
When installed 10 De
8 De
Deis the external diameter of the cable
Other designs may apply other bending radii.
Cable handlingTesting of XLPE cables
C A B L E D R U M S | T E S T I N G | C A B L E H A N D L I N G
Maximum pulling forces
The following pulling forces should not be exceeded:Aluminium conductors 40 N/mm2(4 kg/mm2)Copper conductors 70 N/mm2(7 kg/mm2)
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16 ABB
Table 21
IEC
Cross section
Diameter
approx.
Maximum d.c. resistance
at 20oC, ohm/km
mm2 kcmil mm aluminium copper
25 49 5.8 1.20 0.727
35 69 7.0 0.868 0.524
50 99 8.0 0.641 0.387
70 138 9.6 0.443 0.268
95 187 11.2 0.320 0.193
120 237 12.8 0.253 0.153
150 296 14.2 0.206 0.124
185 365 15.9 0.164 0.0991
240 474 18.0 0.125 0.0754
300 592 20.5 0.100 0.0601
400 789 23.1 0.0778 0.0470
500 987 26.4 0.0605 0.0366
630 1243 30.2 0.0469 0.0283
800 1579 33.9 0.0367 0.0221
1000 1973 37.9 0.0291 0.0176
1200 2368 41.4 0.0247 0.0151
1600 3158 47.4 0.0186 0.0113
2000 3947 53.5 0.0149 0.0090
2500 4934 66 0.0120 0.0072
3000 5920 72 0.0100 0.0060
Conductors
XLPE Cable Design
Insulation
Conductor screen
The conductor screen consists of an extruded layer firmly
bonded to the XLPE insulation. A very smooth material isused to obtain a high quality of the electrical performance.
Table 22
ICEA
Cross section
Diameter
approx.
Nominal d.c. resistance
at 20oC, ohm/km
AWG kcmil mm2 mm aluminium copper
4 21.2 5.4 1.36 0.830
2 32.6 6.8 0.857 0.521
1 42.4 7.6 0.680 0.413
1/0 53.5 8.5 0.539 0.328
2/0 67.4 9.6 0.428 0.261
3/0 85 10.7 0.383 0.206
4/0 107 12.1 0.269 0.164
250 127 13.2 0.228 0.139
300 152 14.5 0.190 0.116
350 177 15.6 0.162 0.0990
500 253 18.7 0.114 0.0695
750 380 23.0 0.0759 0.0462
1000 507 26.9 0.0563 0.0347
1250 633 30.2 0.0454 0.0278
1500 760 33.5 0.0380 0.0231
1750 887 36.2 0.0325 0.0198
2000 1013 38.0 0.0285 0.0173
2500 1267 42.5 0.0230 0.0140
3000 1520 46.2 0.0192 0.0117
1 ohm/100 ft = 3.28 ohm/km
C O N D U C T O R S | I N S U L A T I O N
Standards IEC and ICEA
Conductors are manufactured according to the followingstandards:
IEC (International Electrotechnical Commission) StandardPublication 60228, Class 2: Stranded circular or shaped
conductors of copper or aluminium.ICEA, Standard Publication No. S-97-682, further specified inASTM B 400-18 for aluminium, ASTM B 496-81 for copper.
Conductor water sealing
If required, the conductor can be water sealed by:- Swelling material between the conductor strands.
This material turns into jelly when in contact with water.- Filling compound between the conductor strands.
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ABB 17
Copper wire screen, standard design
A polymeric sheath covers the copper wire screen.
Metallic screen
Copper wire screen, water tight design
Radial water sealing is achieved by using a metal-PElaminate. The metal is normally aluminium. Copper mayalso be used. The laminate is bonded to the polyethylene,
which gives excellent mechanical properties. Longitudinalwater sealing is achieved by using a water swelling mate-rial at the copper wires or swelling powder between thescreen wires.
Lead sheathRadial water sealing achieved by a corrosion resistant leadsheath. Longitudinal water sealing is achieved by using a
water swelling material applied under the lead sheath.
Copper tape screen
Cross section defined by the geometrical cross section ofthe copper tapes.
I N S U L A T I O N | M E T A L L I C S C R E E N
XLPE insulation
The XLPE insulation is extruded simultaneously with theconductor screen and the insulation screen, e.g. tripleextrusion. The interface surfaces between insulation andconductive screens are not exposed at any stage of themanufacturing. High quality material-handling systems,triple extrusion, dry curing and super-clean XLPE materialsguarantee high quality products. The insulation thicknessis determined by the design electrical stresses for AC orimpulse. The actual thickness for different voltage levelsand conductor sizes is given in Tables 23 to 39.
Insulation screen
This screen consists of an extruded layer firmly bonded tothe XLPE insulation. The material is a high quality conductivecompound. The interface between the screen and the insula-tion is smooth.
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18 ABB
Non-metallic outer sheath
PE or PVC are normally used for the non-metallic outersheath. IEC 60502 recommends a thickness of t = 0.035 xD + 1.0 mm, where D is the diameter under the sheath.
For heavy installations a larger thickness is recommended.PE is the first choice for most applications. PVC is usedwhen there are high requirements on fire retardation beha-viour.
Conductive outer layer
A conductive outer layer facilitates testing of the non-metallic outer sheath. This testing is important to ensurethe physical integrity of the cable from time to time, eitherin factory, after transportation, directly after laying, upon
completion of the installation, or periodically thereafter.A conductive outer layer obtained by simultaneous extrusi-on with the non-conductive outer sheath presents superiorelectrical and structural properties.
Flame retardant outer layer
For PE-sheathed cables a halogen free and flame retardantlayer can be applied in order to limit the fire spread inbuildings and tunnel installations.
Fire behavior
This relates to cables in buildings and tunnels.
Several serious fire accidents have focused attention onthe fire behaviour of cables. Experience shows that cablesseldom initiate fires. However, in some cases cable instal-lations have influenced the extent of a fire, as a propagatorof flames and or as a source of intense aggressive smoke.
Cables having a PVC sheath are considered as flame retar-dant. However, once PVC is on fire, it generates hydro-chloric acid fumes (HCl) acid. This gas is highly corrosiveand irritating to inhale. Cables with a standard PE outersheath do not generate any corrosive HCl but are notflame retardant. Special polyolefines with flame retardantproperties but without chlorine or any other halogenes areoptional for the outer sheath.
N O N - M E T A L L I C O U T E R S H E A T H | C O N D U C T I V E O U T E R L A Y E R | F L A M E R E T A R D E N T O U T E R L A Y E R | F I R E B E H A V I O R
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ABB 19
Cross-
section
of con-
ductor
Diameter
of con-
ductor
Insulation
thickness
Diameter
over
insulation
Cross-
section
of
screen
Outer
diameter
of cable
Cable
weight
(Al-con-
ductor)
Cable
weight
(Cu-con-
ductor)
Capaci-
tance
Charging
current
per
phase
at 50 Hz
Inductance Surge
impe-
dance
mm2 mm mm mm mm2 mm kg/m kg/m F/km A/km mH/km mH/km
Table 23
Single-core cables, nominal voltage 10 kV (Um= 12 kV)
50 8 3.4 16.4 16 24.0 0.7 1.0 0.24 0.4 0.42 0.73 24.5
70 9.6 3.4 18.0 16 26.0 0.7 1.2 0.27 0.5 0.40 0.70 21.6
95 11.2 3.4 19.6 25 28.0 0.9 1.5 0.30 0.5 0.38 0.67 19.3
120 12.8 3.4 21.0 25 29.0 1.0 1.8 0.33 0.6 0.37 0.64 17.3
150 14.2 3.4 22.6 35 31.0 1.3 2.2 0.36 0.6 0.35 0.63 16.1
185 15.9 3.4 24.2 35 32.0 1.4 2.5 0.39 0.7 0.34 0.61 14.7
240 18 3.4 26.9 35 35.0 1.6 3.1 0.44 0.8 0.33 0.59 13.5
300 20.5 3.4 29.2 35 38.0 1.9 3.7 0.48 0.9 0.32 0.57 12.1
400 23.1 3.4 32.0 35 41.0 2.2 4.7 0.53 1.0 0.31 0.55 11.1
500 26.4 3.4 35.4 35 44.0 2.6 5.7 0.60 1.1 0.30 0.53 9.9
630 30.2 3.4 39.0 35 48.0 3.1 7.0 0.67 1.2 0.29 0.51 8.7
800 33.9 3.4 42.9 35 53.0 3.7 8.6 0.74 1.3 0.28 0.49 8.0
1000 37.9 3.4 47.1 35 58.0 4.4 10.6 0.82 1.5 0.28 0.48 7.3
1200 44 3.4 52.8 35 64.0 5.1 12.5 0.93 1.7 0.27 0.46 6.3
1400 49 3.4 59.8 35 71.0 6.0 14.7 1.06 1.9 0.27 0.45 6.1
1600 52 3.4 62.8 35 74.0 6.7 16.6 1.11 2.0 0.26 0.44 5.8
2000 56 3.4 66.8 35 79.0 7.9 20.3 1.19 2.2 0.26 0.43 5.4
Table 24
Single-core cables, nominal voltage 20 kV (Um= 24 kV)
50 8 5.5 20.6 16 29.0 0.8 1.1 0.17 0.6 0.46 0.74 33.4
70 9.6 5.5 22.2 16 30.0 0.9 1.4 0.19 0.7 0.43 0.70 29.7
95 11.2 5.5 23.8 25 32.0 1.1 1.7 0.21 0.7 0.41 0.68 26.8
120 12.8 5.5 25.2 25 34.0 1.2 2.0 0.22 0.8 0.39 0.65 23.7
150 14.2 5.5 26.8 35 35.0 1.5 2.4 0.24 0.9 0.38 0.63 21.9
185 15.9 5.5 28.4 35 37.0 1.6 2.8 0.26 0.9 0.37 0.62 20.0
240 18 5.5 31.1 35 40.0 1.9 3.4 0.29 1.1 0.35 0.60 17.7
300 20.5 5.5 33.4 35 42.0 2.1 4.0 0.32 1.2 0.34 0.57 16.1
400 23.1 5.5 36.2 35 45.0 2.5 5.0 0.35 1.3 0.33 0.56 14.5
500 26.4 5.5 39.6 35 49.0 2.9 6.0 0.39 1.4 0.32 0.54 12.7
630 30.2 5.5 43.2 35 53.0 3.4 7.3 0.43 1.6 0.31 0.52 11.2
800 33.9 5.5 47.1 35 58.0 4.0 9.0 0.48 1.7 0.30 0.50 10.1
1000 37.9 5.5 51.3 35 62.0 4.8 11.0 0.53 1.9 0.29 0.48 9.1
1200 44 5.5 57.0 35 68.0 5.5 13.0 0.60 2.2 0.28 0.46 7.2
1400 49 5.5 64.0 35 76.0 6.5 15.2 0.68 2.5 0.28 0.45 6.7
1600 52 5.5 67.0 35 79.0 7.2 17.1 0.71 2.6 0.27 0.45 7.6
2000 56 5.5 71.0 35 83.0 8.4 20.8 0.76 2.8 0.27 0.44 6.9
Technical data for cables in the ABB XLPE cable system
T E C H N I C A L D A T A F O R C A B L E S I N T H E A B B X L P E C A B L E S Y S T E M
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20 ABB
Cross-
section
of con-
ductor
Diameter
of con-
ductor
Insulation
thickness
Diameter
over
insulation
Cross-
section
of
screen
Outer
diameter
of cable
Cable
weight
(Al-con-
ductor)
Cable
weight
(Cu-con-
ductor)
Capaci-
tance
Charging
current
per
phase
at 50 Hz
Inductance Surge
impe-
dance
mm2 mm mm mm mm2 mm kg/m kg/m F/km A/km mH/km mH/km
Table 25
Single-core cables, nominal voltage 30 kV (Um= 36 kV)
95 11.2 8.0 28.6 25 37 1.4 2.0 0.16 0.9 0.44 0.67 34.2
120 12.8 8.0 30.2 25 39 1.6 2.4 0.17 0.9 0.42 0.65 30.8
150 14.2 8.0 31.7 35 41 1.9 2.8 0.19 1.0 0.41 0.63 28.2
185 15.9 8.0 33.4 35 42 2.1 3.2 0.20 1.1 0.39 0.61 26.3
240 18 8.0 35.7 35 45 2.3 3.8 0.22 1.2 0.38 0.59 23.7
300 20.5 8.0 37.9 35 48 2.6 4.5 0.24 1.3 0.37 0.57 21.5
400 23.1 8.0 41.3 35 51 3.0 5.5 0.26 1.4 0.35 0.55 19.5
500 26.4 8.0 44.4 35 54 3.5 6.6 0.29 1.6 0.34 0.53 17.6
630 30.2 8.0 48.2 35 58 4.0 8.0 0.32 1.8 0.33 0.51 15.5
800 33.9 8.0 52.9 35 63 4.9 10.0 0.36 1.9 0.32 0.49 14.0
1000 37.9 8.0 56.9 35 67 5.7 12.1 0.40 2.2 0.31 0.48 12.9
1200 44 8.0 60.4 35 74 6.6 14.2 0.43 2.3 0.29 0.45 10.9
1400 49 8.0 63.4 35 81 7.4 16.2 0.45 2.5 0.29 0.44 9.6
1600 52 8.0 67.0 35 84 8.1 18.2 0.48 2.6 0.29 0.43 9.1
2000 56 8.0 73.1 35 88 9.6 22.3 0.53 2.9 0.28 0.42 8.2
Table 26
Single-core cables, nominal voltage 45 kV (Um= 52 kV)
95 11.2 7.5 27.8 25 37 1.4 2.0 0.16 0.9 0.43 0.67 34.2
120 12.8 7.5 29.2 25 39 1.6 2.4 0.17 0.9 0.42 0.65 30.8
150 14.2 7.5 30.8 35 41 1.9 2.8 0.19 1.0 0.40 0.63 28.2
185 15.9 7.5 32.4 35 42 2.1 3.2 0.20 1.1 0.39 0.61 26.3
240 18 7.5 35.1 35 45 2.3 3.8 0.22 1.2 0.37 0.59 23.7
300 20.5 7.5 37.4 35 48 2.6 4.5 0.24 1.3 0.36 0.57 21.5
400 23.1 7.5 40.2 35 51 3.0 5.5 0.26 1.4 0.35 0.55 19.5
500 26.4 7.5 43.6 35 54 3.5 6.6 0.29 1.6 0.34 0.53 17.6
630 30.2 7.5 47.2 35 58 4.0 8.0 0.32 1.8 0.32 0.51 15.5
800 33.9 7.5 51.1 35 63 4.9 10.0 0.36 1.9 0.31 0.49 14.0
1000 37.9 7.5 55.3 35 67 5.7 12.1 0.40 2.2 0.30 0.48 12.9
1200 44 7.5 61.0 35 74 6.6 14.2 0.43 2.3 0.29 0.45 10.9
1400 49 7.5 68.0 35 81 7.4 16.2 0.45 2.5 0.29 0.44 9.6
1600 52 7.5 71.0 35 84 8.1 18.2 0.48 2.6 0.29 0.43 9.1
2000 56 7.5 75.0 35 88 9.6 22.3 0.53 2.9 0.28 0.42 8.2
T E C H N I C A L D A T A F O R C A B L E S I N T H E A B B X L P E C A B L E S Y S T E M
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ABB 21
Cross-
section
of con-
ductor
Diameter
of con-
ductor
Insulation
thickness
Diameter
over
insulation
Cross-
section
of
screen
Outer
diameter
of cable
Cable
weight
(Al-con-
ductor)
Cable
weight
(Cu-con-
ductor)
Capaci-
tance
Charging
current
per
phase
at 50 Hz
Inductance Surge
impe-
dance
mm2 mm mm mm mm2 mm kg/m kg/m F/km A/km mH/km mH/km
Table 27
Single-core cables, nominal voltage 60 kV (Um= 72.5 kV)
95 11.2 9.0 30.8 25 39.0 1.5 2.1 0.14 1.7 0.45 0.69 38.0
120 12.8 9.0 32.2 25 41.0 1.6 2.4 0.15 1.8 0.43 0.67 35.1
150 14.2 9.0 33.8 35 43.0 1.9 2.8 0.17 2.0 0.42 0.65 31.9
185 15.9 9.0 35.4 35 44.0 2.1 3.2 0.18 2.1 0.40 0.63 29.8
240 18 9.0 38.1 35 47.0 2.3 3.8 0.20 2.4 0.39 0.61 27.4
300 20.5 9.0 40.4 35 50.0 2.6 4.5 0.22 2.6 0.37 0.59 24.8
400 23.1 9.0 43.2 35 53.0 3.0 5.5 0.24 2.8 0.36 0.57 22.8
500 26.4 9.0 46.6 35 56.0 3.5 6.6 0.26 3.1 0.35 0.55 20.9
630 30.2 9.0 50.2 35 60.0 4.0 7.9 0.29 3.4 0.34 0.53 18.7
800 33.9 9.0 54.1 35 65.0 4.7 9.7 0.31 3.8 0.32 0.51 17.4
1000 37.9 9.0 58.3 35 70.0 5.5 11.7 0.35 4.1 0.31 0.50 15.7
1200 44 9.0 64.0 35 76.0 6.3 13.7 0.40 4.8 0.30 0.47 13.7
1400 49 9.0 71.0 35 83.0 7.4 16.0 0.44 5.2 0.30 0.46 13.0
1600 52 9.0 74.0 35 86.0 8.1 18.0 0.46 5.5 0.29 0.45 12.4
2000 56 9.0 78.0 35 91.0 9.4 21.8 0.49 5.8 0.29 0.45 11.6
Table 28
Single-core cables, nominal voltage 70 kV (Um=84 kV)
185 15.9 10.0 37.4 35 47.0 2.2 3.3 0.17 2.1 0.41 0.63 31.7
240 18 10.0 40.1 35 49.0 2.5 4.0 0.18 2.3 0.40 0.61 29.8
300 20.5 10.0 42.4 35 52.0 2.8 4.6 0.20 2.5 0.38 0.59 27.0
400 23.1 10.0 45.2 35 55.0 3.2 5.7 0.22 2.8 0.37 0.57 24.7
500 26.4 10.0 48.6 35 59.0 3.6 6.7 0.24 3.0 0.36 0.55 22.6
630 30.2 10.0 52.2 35 62.0 4.2 8.1 0.26 3.3 0.34 0.53 20.5
800 33.9 10.0 56.1 35 67.0 4.9 9.9 0.29 3.7 0.33 0.51 18.6
1000 37.9 10.0 60.3 35 72.0 5.7 11.9 0.32 4.0 0.32 0.50 17.0
1200 44 10.0 66.0 35 78.0 6.5 14.0 0.37 4.7 0.31 0.48 14.8
1400 49 10.0 73.0 35 85.0 7.6 16.3 0.40 5.1 0.30 0.47 14.1
1600 52 10.0 76.0 35 88.0 8.3 18.3 0.42 5.3 0.30 0.46 13.4
2000 56 10.0 80.0 35 93.0 9.7 22.1 0.44 5.6 0.29 0.45 12.7
T E C H N I C A L D A T A F O R C A B L E S I N T H E A B B X L P E C A B L E S Y S T E M
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22 ABB
Cross-
section
of con-
ductor
Diameter
of con-
ductor
Insulation
thickness
Diameter
over
insulation
Cross-
section
of
screen
Outer
diameter
of cable
Cable
weight
(Al-con-
ductor)
Cable
weight
(Cu-con-
ductor)
Capaci-
tance
Charging
current
per
phase
at 50 Hz
Inductance Surge
impe-
dance
mm2 mm mm mm mm2 mm kg/m kg/m F/km A/km mH/km mH/km
Table 29
Single-core cables, nominal voltage 110 kV (Um= 123 kV)
150 14.2 14.5 44.8 95 55.0 3.3 4.2 0.12 2.4 0.46 0.65 41.6
185 15.9 14.0 45.4 95 56.0 3.4 4.6 0.13 2.6 0.44 0.65 40.2
240 18 14.0 48.1 95 59.0 3.7 5.2 0.15 2.9 0.43 0.63 36.2
300 20.5 13.0 48.4 95 59.0 3.9 5.7 0.16 3.3 0.40 0.60 32.8
400 23.1 13.0 51.2 95 62.0 4.3 6.8 0.18 3.6 0.39 0.58 29.7
500 26.4 13.0 54.6 95 66.0 4.8 7.9 0.20 3.9 0.38 0.56 27.0
630 30.2 13.0 58.2 95 69.0 5.4 9.3 0.21 4.3 0.36 0.54 25.0
800 33.9 13.0 62.1 95 74.0 6.2 11.1 0.23 4.7 0.35 0.52 22.9
1000 37.9 13.0 66.3 95 79.0 7.0 13.2 0.26 5.1 0.34 0.51 20.7
1200 44 13.0 72.0 95 85.0 7.9 15.3 0.30 5.9 0.32 0.49 18.1
1400 49 13.0 79.0 95 93.0 9.1 17.8 0.32 6.4 0.32 0.48 17.3
1600 52 13.0 82.0 95 96.0 9.9 19.8 0.34 6.7 0.31 0.47 16.4
2000 56 13.0 86.0 95 100.0 11.2 23.6 0.35 7.1 0.31 0.46 15.7
2500 66 13.0 96.0 95 111.0 13.3 28.8 0.40 8.1 0.29 0.41 13.7
3000 72 13.0 102.0 95 117.0 15.2 33.8 0.43 8.7 0.29 0.39 12.7
Table 30
Single-core cables, nominal voltage 132 kV (Um= 145 kV)
150 14.2 18.5 52.8 95 63.0 4.0 5.0 0.11 2.5 0.49 0.66 46.7
185 15.9 17.5 52.4 95 63.0 4.1 5.2 0.12 2.8 0.47 0.66 44.6
240 18 16.5 53.1 95 64.0 4.2 5.7 0.13 3.1 0.44 0.64 40.8
300 20.5 15.5 53.4 95 64.0 4.3 6.2 0.15 3.5 0.42 0.61 35.7
400 23.1 15.0 55.2 95 66.0 4.7 7.2 0.16 3.9 0.40 0.59 33.0
500 26.4 15.0 58.6 95 70.0 5.2 8.3 0.18 4.2 0.39 0.57 29.8
630 30.2 15.0 62.2 95 74.0 5.8 9.7 0.19 4.6 0.37 0.55 27.6
800 33.9 15.0 66.1 95 79.0 6.6 11.6 0.21 5.0 0.36 0.53 25.2
1000 37.9 15.0 70.3 95 83.0 7.5 13.7 0.23 5.5 0.35 0.51 23.2
1200 44 15.0 76.0 95 89.0 8.4 15.9 0.26 6.3 0.33 0.49 20.5
1400 49 15.0 83.0 95 97.0 9.7 18.4 0.28 6.8 0.33 0.48 19.4
1600 52 15.0 86.0 95 100.0 10.5 20.4 0.30 7.1 0.32 0.47 18.3
2000 56 15.0 90.0 95 105.0 11.9 24.3 0.32 7.5 0.31 0.46 17.2
2500 66 15.0 100.0 95 115.0 14.0 29.5 0.36 8.6 0.30 0.41 15.2
3000 72 15.0 106.0 95 122.0 15.9 34.5 0.38 9.2 0.29 0.39 14.3
T E C H N I C A L D A T A F O R C A B L E S I N T H E A B B X L P E C A B L E S Y S T E M
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ABB 23
Cross-
section
of con-
ductor
Diameter
of con-
ductor
Insulation
thickness
Diameter
over
insulation
Cross-
section
of
screen
Outer
diameter
of cable
Cable
weight
(Al-con-
ductor)
Cable
weight
(Cu-con-
ductor)
Capaci-
tance
Charging
current
per
phase
at 50 Hz
Inductance Surge
impe-
dance
mm2 mm mm mm mm2 mm kg/m kg/m F/km A/km mH/km mH/km
Table 31
Single-core cables, nominal voltage 150 kV (Um= 170 kV)
185 15.9 22.0 62.4 95 73.0 5.0 6.1 0.10 2.8 0.50 0.67 52.3
240 18 20.5 61.1 95 73.0 5.1 6.5 0.11 3.1 0.47 0.65 47.1
300 20.5 19.5 61.4 95 73.0 5.2 7.1 0.13 3.4 0.45 0.62 41.1
400 23.1 18.5 62.2 95 74.0 5.5 7.9 0.14 3.8 0.42 0.60 37.6
500 26.4 17.5 63.6 95 75.0 5.8 8.9 0.16 4.3 0.40 0.58 33.2
630 30.2 17.0 66.2 95 78.0 6.3 10.2 0.18 4.8 0.38 0.55 29.5
800 33.9 17.0 70.1 95 83.0 7.1 12.1 0.19 5.2 0.37 0.54 27.7
1000 37.9 17.0 74.3 95 87.0 8.0 14.2 0.21 5.7 0.36 0.52 25.3
1200 44 17.0 80.0 95 94.0 9.0 16.5 0.24 6.5 0.34 0.50 22.3
1400 49 17.0 87.0 95 101.0 10.3 19.0 0.26 7.0 0.33 0.48 21.0
1600 52 17.0 90.0 95 105.0 11.1 21.0 0.27 7.3 0.33 0.48 20.2
2000 56 17.0 94.0 95 109.0 12.5 24.9 0.28 7.7 0.32 0.47 19.2
2500 66 17.0 104.0 95 120.0 14.8 30.3 0.32 8.8 0.31 0.41 16.9
3000 72 17.0 110.0 95 126.0 16.7 35.3 0.35 9.4 0.30 0.39 15.6
Table 32
Single-core cables, nominal voltage 220 kV (Um= 245 kV)
400 23.1 22.5 70.2 185 84.0 7.4 9.9 0.12 5.0 0.44 0.61 43.0
500 26.4 21.5 71.6 185 85.0 7.7 10.8 0.14 5.5 0.42 0.59 37.8
630 30.2 20.5 73.2 185 88 8.3 12.2 0.15 6.1 0.40 0.56 34.4
800 33.9 20.5 77.1 185 93 9.2 14.1 0.16 6.6 0.39 0.55 32.0
1000 37.9 20.5 81.3 185 98 10.2 16.4 0.18 7.1 0.37 0.53 29.1
1200 44 20.5 87.0 185 104 11.6 19.0 0.20 8.1 0.36 0.51 26.1
1400 49 20.5 94.0 185 111 12.6 21.3 0.22 8.7 0.35 0.50 24.3
1600 52 20.5 97.0 185 114 13.5 23.4 0.23 9.1 0.34 0.49 23.3
2000 56 20.5 101.0 185 119 15.0 27.4 0.24 9.6 0.33 0.48 22.2
2500 66 20.5 111.0 185 129 17.4 32.9 0.27 10.8 0.32 0.41 19.6
3000 72 20.5 117.0 185 136 19.3 37.9 0.29 11.6 0.31 0.39 18.3
Table 33
Single-core cables, nominal voltage 275 kV (Um= 300 kV)
500 26.4 25.5 79.6 185 91.0 8.9 12.0 0.12 6.4 0.44 0.60 42.9
630 30.2 24.0 80.2 185 93.0 9.2 13.1 0.13 7.1 0.42 0.57 38.8
800 33.9 23.0 82.1 185 97.0 9.9 14.8 0.16 7.8 0.40 0.55 33.3
1000 37.9 22.5 85.3 185 101.0 10.7 16.9 0.17 8.5 0.38 0.54 30.9
1200 44 22.5 91.0 185 107.0 11.8 19.2 0.19 9.6 0.36 0.51 27.7
1400 49 22.5 98.0 185 115.0 13.2 21.8 0.21 10.4 0.36 0.50 25.7
1600 52 22.5 101.0 185 118.0 14.0 23.9 0.22 10.8 0.35 0.49 24.6
2000 56 22.5 105.0 185 122.0 15.5 27.9 0.23 11.4 0.34 0.48 23.4
2500 66 22.5 115.0 185 133.0 18.0 33.5 0.26 12.8 0.33 0.41 20.7
3000 72 22.5 121.0 185 139.0 20.0 38.6 0.27 13.7 0.32 0.39 19.6
T E C H N I C A L D A T A F O R C A B L E S I N T H E A B B X L P E C A B L E S Y S T E M
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24 ABB
Table 34
Single-core cables, nominal voltage 330 kV (Um= 362 kV)
630 21.8 26.0 84.2 185 99.5 9.8 13.7 0.13 8.3 0.43 0.57 38.2
800 33.7 24.5 85.1 185 100.9 10.3 15.2 0.15 9.3 0.40 0.54 34.1
1000 37.9 23.5 87.3 185 103.5 11.0 17.2 0.17 10.3 0.39 0.52 30.6
1200 44 23.0 92.0 185 110.6 12.3 19.7 0.19 11.9 0.37 0.49 26.6
1400 49 23.5 100.0 185 117.1 13.5 22.2 0.20 12.6 0.36 0.47 25.1
1600 52 24.0 104.0 185 121.3 14.6 24.5 0.21 12.9 0.36 0.46 24.5
2000 56 24.5 109.0 185 126.7 16.3 28.7 0.21 13.4 0.35 0.44 23.6
2500 66 25.0 120.0 185 138.5 19.0 34.5 0.24 14.8 0.33 0.41 21.3
3000 72 25.0 126.0 185 144.9 21.1 39.7 0.25 15.8 0.33 0.39 20.0
Table 35
Single-core cables, nominal voltage 400 kV (Um= 420 kV)
630 29.8 31.0 94.2 185 110.2 11.4 15.3 0.12 8.2 0.45 0.57 42.6
800 33.7 30.0 96.1 185 112.7 12.1 17.1 0.13 9.0 0.43 0.54 38.9
1000 37.9 28.5 97.3 185 114.2 12.7 18.9 0.14 10.0 0.41 0.52 34.9
1200 44 27.5 101.0 185 120.3 13.9 21.3 0.17 11.5 0.38 0.49 30.2
1400 49 26.5 106.0 185 123.5 14.6 23.3 0.18 12.7 0.37 0.47 27.4
1600 52 26.5 109.0 185 126.7 15.5 25.5 0.19 13.2 0.36 0.46 26.3
2000 56 27.0 114.0 185 132.0 17.3 29.7 0.20 13.7 0.36 0.44 25.4
2500 66 27.0 124.0 185 142.7 19.9 35.4 0.22 15.4 0.34 0.41 22.6
3000 72 27.5 131.0 185 150.2 22.2 40.8 0.23 16.2 0.33 0.39 21.5
Table 36
Single-core cables, nominal voltage 500 kV (Um= 550 kV)
800 33.7 35.0 106.1 185 123.4 14.0 18.9 0.12 10.7 0.45 0.54 42.8
1000 37.9 33.0 106.3 185 123.8 14.3 20.5 0.13 11.9 0.42 0.52 38.4
1200 44 31.0 108.0 185 127.8 14.8 22.3 0.15 14.0 0.40 0.49 32.8
1400 49 31.0 115.0 185 133.1 16.4 25.1 0.16 15.0 0.39 0.47 30.6
1600 52 31.0 118.0 185 136.3 17.4 27.3 0.17 15.5 0.38 0.46 29.5
2000 56 32.0 124.0 185 142.7 19.4 31.8 0.18 16.0 0.37 0.44 28.7
2500 66 32.5 135.0 185 154.5 22.4 37.9 0.19 17.6 0.36 0.41 26.0
3000 72 33.0 142.0 185 162.0 24.9 43.5 0.20 18.5 0.35 0.39 24.7
Cross-
section
of con-
ductor
Diameter
of con-
ductor
Insulation
thickness
Diameter
over
insulation
Cross-
section
of
screen
Outer
diameter
of cable
Cable
weight
(Al-con-
ductor)
Cable
weight
(Cu-con-
ductor)
Capaci-
tance
Charging
current
per
phase
at 50 Hz
Inductance Surge
impe-
dance
mm2 mm mm mm mm2 mm kg/m kg/m F/km A/km mH/km mH/km
T E C H N I C A L D A T A F O R C A B L E S I N T H E A B B X L P E C A B L E S Y S T E M
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ABB 25
Cross-
section
of con-
ductor
Diameter
of con-
ductor
Insulation
thickness
Diameter
over
insulation
Cross-
section
of
screen
Outer
diameter
of cable
Cable
weight
(Al-con-
ductor)
Cable
weight
(Cu-con-
ductor)
Capaci-
tance
Charging
current
per phase
at 50 Hz
Inductance
mm2 mm mm mm mm2 mm kg/m kg/m F/km A/km mH/km
Table 37
Three-core cables nominal voltage 10 kV (Um= 12 kV)
25 5.8 3.4 14.2 10 41.0 1.2 1.7 0.20 0.3 0.38
35 7.0 3.4 15.4 16 44.0 1.5 2.1 0.22 0.4 0.36
50 8.0 3.4 16.4 16 46.0 1.7 2.6 0.24 0.4 0.34
70 9.6 3.4 18.0 16 50.0 2.0 3.3 0.27 0.5 0.33
95 11.2 3.4 19.6 25 54.0 2.5 4.3 0.30 0.5 0.31
120 12.8 3.4 21.0 25 57.0 2.9 5.1 0.33 0.6 0.30
150 14.2 3.4 22.6 35 61.0 3.4 6.2 0.36 0.6 0.29
185 15.9 3.4 24.2 35 64.0 3.9 7.4 0.39 0.7 0.28
240 18.0 3.4 26.9 35 70.0 4.8 9.3 0.44 0.8 0.28
Table 38
Three-core cables nominal voltage 20 kV (Um= 24 kV)
25 5.8 5.5 18.4 10 51.0 1.7 2.2 0.14 0.5 0.43
35 7.0 5.5 19.6 16 54.0 2.0 2.6 0.16 0.6 0.40
50 8.0 5.5 20.6 16 56.0 2.2 3.2 0.17 0.6 0.39
70 9.6 5.5 22.2 16 60.0 2.6 3.9 0.19 0.7 0.37
95 11.2 5.5 23.8 25 63.0 3.1 4.9 0.21 0.7 0.35
120 12.8 5.5 25.2 25 67.0 3.5 5.8 0.22 0.8 0.33
150 14.2 5.5 26.8 35 70.0 4.1 6.9 0.24 0.9 0.32
185 15.9 5.5 28.4 35 74.0 4.7 8.1 0.26 0.9 0.31
240 18.0 5.5 31.1 35 80.0 5.6 10.1 0.29 1.1 0.30
Table 39
Three core cables nominal voltage 30 kV (Um= 36 kV)
25 5.8 7.5 22.4 10 62 2.4 2.9 0.11 0.6 0.48
35 7 7.5 23.6 16 65 2.7 3.4 0.12 0.7 0.45
50 8 7.5 24.6 16 67 3.0 3.9 0.13 0.7 0.43
70 9.6 7.5 26.2 16 71 3.4 4.7 0.14 0.8 0.41
95 11.2 7.5 27.8 25 75 4.0 5.8 0.16 0.9 0.39
120 12.8 7.5 29.2 25 78 4.5 6.7 0.17 0.9 0.37150 14.2 7.5 30.8 35 82 5.1 7.9 0.18 1.0 0.35
185 15.9 7.5 32.4 35 85 5.7 9.1 0.20 1.1 0.35
240 18 7.5 35.1 35 92 6.7 11.2 0.22 1.2 0.33
300 20.5 7.5 37.5 35 97 9.2 14.8 0.24 1.3 0.31
T E C H N I C A L D A T A F O R C A B L E S I N T H E A B B X L P E C A B L E S Y S T E M
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26 ABB
F O R M U L A E
Formulae
Where
= relative permittivity of the insulation d
0= external diameter of the insulation (mm)
di
= diameter of condutor, including screen (mm) XLPE
= 2.3
PAPER= 3.3
Where U
= rated voltage (kV) f
= frequency (Hz)
C = capacitance (F/km)tan = loss angle
Where trefoil formation: K = 1 flat formation: K = 1.26 s = distance between conductor axes (mm) r = conductor radius (mm)
Formula for capacitance Formula for dielectric losses
Formula for inductance
Formula for inductive reactance
Where f = frequency (Hz) L = inductance (mH/km)
Conductor screen:
Formula for electric stress
di
= radius of conductor screend
0= radius of XLPE insulation
U = voltage across insultaion
Insulation screen:
d0XLPE
di
Formula for maximum short circuit currents
Ish=short-circuit current during time t
sh
I1=short-circuit current rating during 1 second. See the 1
s-
value in tables 15 for the conductor and in Table 16 forthe metal screen.tsh=short-circuit duration
For XLPE insulated conductors the maximum allowableshort circuit temperature is 250oC.
Formula for calculation of dynamic forces between
two conductors
Where; Ipeak
= 2.5 Ish[kA]
Ish= Short current [kA] RMS
S = Centre to centre spacing betweenconductors [m]
F = maximum force [N/m]
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ABB 27
SupportThe transmission network in most countries is very largeand complex. It may incorporate different systems e.g. dif-ferent types of over-head lines systems, fluid-filled cable
systems and extruded cable systems. Sometimes both ACand DC-systems are present as well as both land andsubmarine cable systems.
ABB experienced project managers, technical specialistsand other staff will give their professional support in thisevaluation of suitable solutions. We aim to offer the mostoptimal solution and we can supply the complete under-ground or submarine cable system which can include:
Power cables for underground or submarineapplications
Cable accessories Control- and telecommunication cables System design for network optimisation Project management Civil works Installation and supervision Testing and start-up operations Disassembly and recovery of old cables Fault location and repair Maintenance of fluid-filled systems Leasing of installation equipment Training
NOTE: All figures given in this brochure are non-bindingand indicative only
S U P P O R T
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2GM
5007GB
.pdf
Elan
ders
Novum,
Vs
ters
0306
For additional information please contact
your local ABB Sales Office or visit us under
www.abb.com/cables