HV Accessories

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Agenda/ Overview
Subject: HV Power Cable Accessories

Intention:
a basic understanding of HV power cable accessories, their
function and application
to understand the accessories as a integral part of high voltage
cable systems
Presentation of current accessory programs of nkt cables

Topics:
introduction
basics of cable accessories
design, function and application of high voltage power cable
accessories
installation, tests, standardisation

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Product portfolio: Accessories for HV cable systems
(voltage range 72 550kV)
reliable connection of cables Joints
reliable connection to other equipment
Terminations
additional equipment
for safe operation
of the cable system

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Basics of Cable Accessories

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 Main Functions of Cable

Safety Insulation of Current Carrying

Protection Function
Different Potentials

Outer
Sheath Insulation Conductor

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 Main Functions of Accessories
Safety Insulation of Current Carrying
Protection Function
Different Potentials

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Stress control sample: water pipe

End of pipe
low pressure

End of pipe
higher pressure

End of pipe
high pressure

End of pipe
with funnel
high pressure

Straight pipe =
constant water flow
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Stress control

Conductor

Insulation

Outer Semi-
conductive Layer

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 Electrical stress calculation

Example: Outdoor Termination with

Porcelain Insulator
(equipotential lines)

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 Stress Calculation
Example: Prefabricated Joint
(equipotential lines)

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 Source: Borealis

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 Electrical interface strength vs.
interface pressure and surface smoothness
p y
x z
material strength

XLPE
E

SIR
electrical interface strength

Rz=const.

electrical
strength of air

transition
zone

(nearly) only (nearly) no

Source: cavities cavities
ICC Fall 2003

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interface pressure, surface smoothness
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Material for Stress Cones

Ethylene Propylene Silicone Rubber

Rubber (SiR)
(EPR, EPDM)
Elasticity hard soft
Range of low wide
elongation
Fire behavior combustible Non-combustible
Temperature range -40 100C -50C 180C
Material costs low high

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Advantages of Silicone Rubber
O2 and UV resistant
Chemical Bond Energy (kJ/mol)
Weather resistant
Hydrophobicity Si-O 444
C-O 339
C-C 348
Light (300nm) 398

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Wacker Chemie
 High Voltage Cable Accessoriees
Outdoor terminations
Porcelain terminations
Composite terminations
Switch gear/Transformer terminations
Fluid filled type
Dry type
Prefabricated/pre-molded Joints
Slip-on joints (or cold shrink joints)
single piece
three piece joints
Plug-in joints
Screen bonding

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 Outdoor Terminations

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Outdoor Head Armature
Conductor Connection
Termination Bolt
with Insulating Fluid

porcelain Porcelain Insulator

Stress Cone
insulator
Sealing
FEV170-P Base Plate
Support Insulator
Cable Gland

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 Head Armature

Outdoor Conductor Connection

Bolt
Termination
with Insulating Fluid

composite Composite Insulator

insulator Stress Cone

ES-s145 Sealing

Base Plate

Support Insulator

Cable Gland

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Outdoor Connection Bolt
Termination
Composite Insulator
with
composite Conductor Connection Bolt

insulator
Stress Cone
-dry type-
KFEV145 Cable Gland

Base Plate

Support Insulator

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 Outdoor Termination KFEV145

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 Non-selfsupporting Outdoor Terminations

THV 72, (EBX145) THV 145

Slip-on stress-cone combinated with silicone
slip-on sheds

Light weight
Dry Type
Non self-supporting

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Non-selfsupporting Outdoor Terminations

Application Samples

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Creepage and Flash-over
distances

Flash-over distance
Normal sheds
Creepage distance

Protected creepage
distance

Alternating
sheds

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 porcelain vs. silicone insulators
Properties Composite Insulator Porcelain Insulator
Weight low high
Hydrophobic properties Excellent, good
Self cleaning properties
reducing incidence of
flashover due to airborne
contaminants

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 porcelain vs. silicone insulators
Properties
Risk of bursting in case of
inner explosion
Insulating properties
Handling and
transportation
Outage due to earthquake
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Composite Porcelain
Insulator Insulator
Low, High, Brittle easily
Non brittle construction chipped or broken
excellent insulating
properties when used in
areas with highly
contaminated atmosphere
easily More difficult
Higher weight for higher
voltage levels use of crane
may be neccessary
Risk of brittle careful
transportation
low high
 GIS and transformer terminations

Source: Sdkabel

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 GIS Termination
IEC 62271-209
Fluid Filled Head Armature
SEV 145
Conductor Connection Bolt

Insulating Oil

Cast Resin Insulator

Stress Cone

Flange Ring

Sealing

Cable Gland

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 GIS Termination for XLPE Cables
Dry type IEC 62271-209

KSEV 245 Head Armature

Conductor Connection Bolt

Cast Resin Insulator

Stress Cone

Earth Point Connection

Cable Gland with Sealing and

Cable Sheath Fixing

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 Transformer Termination for XLPE cables
dry type EN 50299

KTEV 145 Corona Shield

Head Armature

Conductor Connection Bolt Cast

Resin Insulator

Stress Cone

Earth Point Connection

Cable Gland

Sealing

Cable Sheath Fixing

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 GIS termination KSEV 245 S6
trockene Version, IEC 62271-209

Adapter

620
960
Head armature

Conductor connection bolt

Cast resin Insulator

Stress cone

fixing flange

Cable flange with earthing

connection, sealing and
sheath fixing

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 Dry-type GIS Termination KSEV 550 S9

NEW !

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 Joints for Um = 72,5 kV ... 420 kV

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Prefabricated/Premoulded HV and EHV Joints

Slip-on joints (or cold shrink joints)

single piece

three piece joints

Composite joints /Plug-in joints

Heat/Cold shrink joints (for the lower voltage range)

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 SME 145:245 One-piece slip-on joint
with screen interrupting

NEW ! Copper
Joint Body housing with
Screen
interruption

Parking
position

Plastic Housing

Earthing cable

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 SME 145:245 One-piece slip-on joint
with screen interrupting
Step for Sheath Interruption
LSR Joint Body
Outer Semiconductive Coating

Compact design 530/750mm

Prefabricated Splitted Inner Electrode

Prefabricated Outer Electrodes

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 SM 145 Three-Piece Slip-on Joint for XLPE Cables
without screen interruption

Main Joint Sleeve Contact Adapter

Sleeve

Metallic Screen Mechanical Outer protection

Connection Connector (Shrinkage sleeve) with
radial water barrier

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 KSM 145-S Three-piece slip-on joint for XLPE cables
with screen interrupting compact

Main Joint Contact Outer protection Cable to Link

Sleeve Sleeve (Shrinkage sleeve) with Box
radial water barrier

Adapter Mechanical Metallic screen HV Cable

Connector connection

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 SM 420-S Three-piece Slip-on Joint for 420kV cables
with screen sectionalising
Main Joint Sleeve Adapter
Coax
Cast Resin Contact Bonding
Insulation Sleeve Cable

Metallic Screen Mechanical Insulating Housing

Connection Connector

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 HV Joints
Outer Protection Versions

Metallic Screen Connection Versions

Straight Through Joint InsulatingJoint

Straight Through Joint with Earthing Connection

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 JTT 145 Transition Joint
from LPOF Cable to XLPE cable

XLPE Cable LPOF Cable

with Plug-in with taped
Epoxy Resin stress cone
Termination
Insulator with
integrated electrode
Coffin Box

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 KUSM 145-EX Transition Joint from Gas Pressure Cable
to Three Core HV Cable

Slip-on
Joint

City
Gas Pressure Cable
Cable

Pressure Seal

Expansion
Vessel

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 Bonding systems

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 Bonding of Cable Screens
R

Subsection 1 Subsection 2 Subsection3

Main Section

Crossbonding

Single Point
Bonding

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 Linkboxes Principle design

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 Cross Bonding Box

Stainless Steel Housing

(EHP 0657/1 12.05.2005)

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 Bonding box for special grounding

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 Link Box - Sample

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 Link for connection at termination

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 Installation
Outdoor Composite
Insulator

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 Peeling of Outer
Semicon Layer

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 Cable Core
Preparation

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 Installation of
Stress Cone

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 Installed Stress
Cone

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 Stress Cone

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 Compression Tool

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 Erection of
Insulator

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 Installation Tools

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 Testing
Development Tests
Type Tests
Prequalification Tests
Sample Tests
Routine Test
Electrical Tests after Installation

Field Tests

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 Development Tests

Step test
Heating Cycles with and witthout load
Short Circuit
Material Properties
Mechanical Tests
Visual Examinations
Imaging Test (X-ray etc.)
Tests up to destruction, breakdown-

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 Typetests
Tests to demonstrate satisfactory performance characteristics to
meet thee intended application

Test carried out at accessories, cables or cable systems

Electrical Tests
Tan Measurement
20 Heating Cycles under load
PD Measurement
Impulse Voltage Tests
AC Withstand Tests
Non-electrical Tests, i.a.:
Tensile strength and elongation of materials before and after ageing
Watertightness

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 Prequalification Tests
Tests to demonstrate satisfactory long term performance
characteristics to meet thee intended application

Actual: Cable Systems 220KV (IEC 62067)

Future: Cable systems with higher electrical stress

Cable Systems: Cable, Accessories, Installation

Systems of min. 100m length (IEC 62067)
180 heating cycles under load
8760 h
Impuls voltage test after finishing of heating cycles
Visual Examination

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 Routine Tests
Tests made on each manufactured component to check that the
component meet the specified requirements

Voltage Test
PD test
Visual Examination

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 Electrical Tests after Installation

Tests to demonstrate the integrity of the cable system as

installed

High voltage test (optionally with PD Measurement)

Sheath Test

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 Field Test City Cables
SF6 Terminations
Outdoor
termination

Test voltage 2Uo

Field 17,2 kV/mm
Strength
Duration 3 years
Different load situations Control system

Buried Part Joints

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 Standardisation
High Voltage Cable and Accessories
High Voltage Level:

Um > 36kV DIN VDE 0276-632 1999-05

- HD 632 S2:2008 2008-11
Um = 170kV IEC 60840 Ed.3 2004-04

Extra High Voltage Level:

Um > 170kV No German Standard

- No European Standard
Um = 550kV IEC 62067 2001-10

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 Standardisation

Definition of mechanical connection and interface:

IEC 62271 High-voltage switchgear and control gear - Part 209

Cable connections for gas-insulated metal-enclosed switchgear for
rated voltages above 52 kV - Fluid-filled and extruded insulation
cables - Fluid-filled and dry-type cable-terminations (formerly
IEC/TS 60859)

EN 50299
Oil-immersed cable connection assemblies for transformers and
reactors having highest voltage for equipment Um from 72,5 kV to
550 kV

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