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PRINCIPLES

of

M.V. CABLE JOINTING AND TERMINATING


CONSTRUCTION OF XLPE

CABLES
Construction of XLPE cables

Conductor
Conductor Screen
XLPE insulation
Insulation Screen
Copper Screen
Filler

Binder tape

Lead Sheath
Bedding

Armour

Over sheath
Construction of XLPE cables

Conductor
Conductor Screen
XLPE insulation
Insulation Screen
Copper Screen
Filler

Binder tape

Bedding
Armour

Outer sheath
Construction of XLPE cables

Conductor
•Carries the load current.

Conductor screen
•Ensures smooth and void free interface with insulation

Insulation
•Prevents the flow of electricity from the energized conductors to
the ground or an adjacent conductor
•Withstands the electrical stresses produced by the alternating
voltage
•Withstands superimposed transient voltage stress on the
conductor
Construction of XLPE cables

Insulation screen
•Ensures that the electrical field is confined within the
polymeric insulation
•Strippable type and bonded type.

Copper Screen
•Keeps the insulation screen at Earth potential.
•Carries the charging current.
•Serves as a path for earth fault currents.

Filler
•Fills gaps between cores
•Rounds up the cable
Construction of XLPE cables

Binder Tape
•Binds the cores & filler together and separates the cores
from the next layer

Bedding
•Serves as a cushion for the armour
•Extruded bedding protects ingress of water
Construction of XLPE cables

Armour
•Protects against mechanical stresses
•Serves as a path for earth fault currents.

Types of armour:

•Steel Tape Armour (STA)


•Galvanized Steel Wire (GSW) or (SWA)
•Galvanized Steel Strip
•Aluminum wire armour (single core cables).
Construction of XLPE cables

Oversheath
•Protects against external impact or pressure
•Protects against corrosion
•Protects from water ingress

Types of outer sheath

•PVC •PE •LSF(LSZH)

Conducting Coating on the outer sheath


• Enables to check sheath integrity

•Graphite coating
•Extruded semi-conducting layer (For HV
cables)
Construction of XLPE cables
Construction of XLPE cables

Special Constructions

Interstice conductor

Graphite coating
BASIC CONCEPTS
Basic Concepts

What is Electrical Stress?


Basic Concepts

V
Max stress
11kV ---- 2.2kV/mm
33 kV---- 3.5kV/mm
Uo
132kV--- 8 kV/mm

Potential Distribution within XLPE insulation


Basic Concepts

Break Down Voltage (BDV)

Voltage Insulation

• Air – 3 kV/mm
• PVC – 20-30 kV/mm
• XLPE - 40-50 kV/mm
Basic Concepts

Air void in solid insulation

Voltage

δt

V δV

Stress across air void = δV/ δt

t
Basic Concepts

Eliminating air voids in cables


•Triple extrusion

•Super clean XLPE

•Dust proof extrusion area


•Smooth interface between conductor screen and XLPE
insulation
Basic Concepts

Nick on XLPE insulation

Insulation screen

XLPE Insulation Conductor


Screen

Conductor U0
Basic Concepts

Deep Cut on XLPE insulation

Insulation screen

XLPE Insulation Conductor


Screen

Conductor U0
Basic Concepts

Lifting of semi-conducting
screen

Insulation screen

XLPE Insulation Conductor


Screen

Conductor U0
Basic Concepts

95%
75%

55%

35%

15%
Insulation screen

XLPE Insulation Conductor


Screen

Conductor U0

Flux lines Equipotential lines

Stress concentration at the screen termination


Basic Concepts
35% 55%

95% 75%
15% 75%
95%

55%

35%

15%
Insulation screen Stress Control Layer

Conductor
Screen

U0

Flux lines Equipotential lines without control

Equipotential lines with control

Stress control layer at the screen termination


STRESS GRADING BY GEOMETRICAL PROFILE
STRESS GRADING IN ‘M-SEAL PUSH-ON’
QS-1000 Field Plot

E1 : 1.45 kV / mm Max. Electrical Stress in Connector Area


E2 : 1.66 kV / mm Max. Electrical Stress in the Insulation
E3 : 2.07 kV / mm Max. Electrical Stress at Semi-con Edge
E4 : 2.32 kV / mm Max. Electrical Stress in the Original Cable
Basic Concepts

IMPORTANT
While preparing the cable:

• Take care to avoid any damage on insulation

•The end of semi-conducting screen is the most stressed area


of a joint or termination. Take care to avoid any damage or nick
on the insulation in this area.

•While removing strippable type semi-conducting screen, take


care not to lift up the edge of the screen termination.

•After removing the semi-conducting layer,polish the insulation


surface with Al. oxide cloth and cleaned with cleaning fluid.
CONDUCTOR CONNECTION
Conductor connections

Methods of conductor connections:

•Soldering
•Compression
•Mechanical Connector
Conductor Connection

Crimping
•Correct connectors
•Good crimping tool
•Correct dies
•Required no. of crimps
•Always smoothen any sharp edges by filing.
•Use corrosion inhibiting paste for Aluminium conductors
Important
Connector is the heart of a joint. Wrong selection of
connector and/or crimping tool/die can lead to
overheating of ferrule and premature failure of
joint/termination.
REQUIREMENTS OF JOINTS AND

TERMINATIONS
Requirements of Joints & Terminations

Requirements of Joints

• Conductor connection
• Stress grading
• Insulation
• Screen continuity
• Interface
pressure(Elasticity)
• Earth continuity
• Sealing
• Mechanical strength
Requirements of Joints & Terminations

Requirements of Terminations

• Conductor connection
• Stress grading
• Interface pressure (Elasticity)
• Creepage Insulation
• Earth continuity
• Sealing
• Resistance against UV light (for Outdoor)
JOINTING & TERMINATION

SYSTEMS
Jointing & Termination Systems

• Cast Resin system


• Taped system
• Heat shrinkable system
• Premoulded system
• Cold shrinkable system

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