WG B1.
11
Upgrading & Uprating of Existing Cable Systems
Members
Frédéric LESUR, Convenor (FR), Christian ROYER, Secretary (CA), Pierre ARGAUT (FR),
Gregorio DENCHE (SP), Marc JEROENSE (SE), Didier LIEMANS (BE),
Roberto GASPARI (IT),Marco MARELLI (IT), Dietmar MEURER (GE),
Jan PELLIS (NL), Lars RASMUSSEN (DK)
Corresponding Members
Steve SWINGLER (GB), Jay A. WILLIAMS (US)
General
The life expectancy of an underground cable system is
usually more than thirty years. It makes difficult the prediction
of the change in the cable environment or the evolution of the
operation conditions. Meeting a higher demand raises a major
issue. The replacement of a power link or the installation of an
additional circuit requires a significant investment cost. Some
congested areas even prevent the operator from this extension.
The difficulties involved in obtaining planning permission
for new sites also favour the life extension of existing facilities,
often with the goal of transmitting higher power, with higher
reliability to minimise the duration of unavailability of assets.
The challenge is to upgrade the existing cable system with
reasonable and relevant solutions.
“Upgrading” is generally the improvement of the equipment
performance by the replacement of components independent
of the current condition in order to meet new operation
requirements. But other solutions are discussed in this
Technical Brochure. In this way, transmitted power, service life,
environmental impact and safety can be improved.
“Uprating” applies a physical solution that allows the system
to be operated at a current level above its rated current, or applies
a method or a calculation that leads to improve the assessment
of the performance of the system. In the Technical Brochure,
uprating is treated as a subset of upgrading.
CIGRE B1.11 Working Group proposes a simple step-by-step
methodology with flowcharts in order to guide the engineer
into the upgrading process. The steps are described, from the
definition of the target for upgraded situation, the assessment
of the existing situation and the identification of issues, up to
the selection of potential upgrading techniques, the evaluation
of their impacts and the decision making.
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The assessment of the actual condition and performance of
the cable system is the first step of any upgrading process. A list of
the main influent parameters is given for a thorough evaluation,
not only of the specific performance to be upgraded (usually
transmitted power), but also of the many other aspects of the
link that could be impacted by the upgrading process itself.
Increasing the transmitted power is the main part of the
report. The possible parameters to explore are the voltage
level, the current rating and the phase difference between
voltage and current for AC systems. A fourth possible solution
is also described, namely to convert a system from AC to
DC. The techniques explore a panel of various solutions:
increasing the current rating by reassessing the current capacity
(overload conditions, new calculation procedures, temperature
monitoring), by assessing lower losses, by improving heat
transfer (ventilated tunnels, special backfill, hot spot smoothing,
heat pipes, forced cooling, reconductoring , etc.).
The purpose of the upgrading process extends to other aspects
of performance. It covers environmental and safety topics.
The impact of existing transition compounds, audible noise,
electromagnetic fields, fluid leaks, etc. is discussed. Regarding
safety issues, interesting solutions can be implemented to
prevent from risk of fire or explosion, and fault containment is
also considered.
Once upgrading solutions have been identified, it is highly
recommended to assess the impact of the upgrade on other
systems functions, because the change in the existing cable
system may interfere with other parameters, technical or
environmental.
To illustrate possible applications, a chapter describes
interesting case studies of upgrading, ranging from a simple •••
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Fig 1: Step by Step Methodology
reassessment of a link current capacity to more complicated case
of forced cooling and retrofitting new cable in existing pipes.
Other examples can be found in the given bibliography.
Introduction of the Technical Brochure
Engineers consider the design of underground cable systems
with great care. Since the life expectancy of such a system is often
more than thirty years, its specification has to take into account
possible evolutions of the operating conditions of the power
link. The spread of urban areas, the establishment of industrial
estates, or the evolution of the customers’ expectations, may lead
to the need to transmit more and more power. Some operating
rules require the redundancy of the circuits, in order to face the
loss of a deficient line. In this case, the remaining systems must
allow an emergency extra power to provide the reliability and
availability of the global network.
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Sometimes, the existing power network becomes insufficient
or inadequate. The replacement of a link or the installation of
an additional circuit may require an important investment cost.
A reasonable solution may be to alter the existing line or its
environment. In accordance with the electrical engineering laws,
transmission of more power implies increasing either the voltage
level or the load current, or both.
Structure of the document
The Technical Brochure is divided into twelve main chapters.
After the introduction and a summary of the Working Group
history in Chapter 1, the Chapter 2 reminds the main definitions
(Refurbishment, Upgrading, Uprating), then describes the basic
concepts of upgrading versus refurbishment, and introduces the
simplified methodology used in upgrading process together •••
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Fig 2: Ladder network as a thermal model (steady-state operation)
with the thermal/electrical concepts that are detailed in the
Brochure. It is important to understand that upgrading an existing
system can be considered as the feasibility study of re-designing
the cable system, taking into account higher stress levels. This can
result for example in replacement of components, modification
of the cable environment, or installation of monitoring device
Chapter 3 is a list of the main parameters to be eventually
assessed during the upgrading process.:
· Technical parameters
· Environmental Characteristics
· Safety factors
· Remaining life / economic value
Chapter 4 is the main chapter and describes the techniques
available to increase the transmitted power:
· Increase of voltage level
· Increase of current rating by reassessing the current
capacity
· Increase of current rating by assessing lower losses
· Increase of current rating by improving heat transfer
· Increase of current rating by forced cooling
· Reconductoring
· Improving the phase difference between voltage and
current: compensation
Chapter 5 describes how to increase performance by changing
from AC to DC.
· Intrinsic Characteristics
· Suitability of the existing cable and its components for
DC operation
· Transmittable real power
· Retrofitting of steel pipe
Chapter 6 and 7 describe the application of the upgrading
process to environmental or safety parameters.
· In Chapter 6, the Impact of Transition Compounds on
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Fig 3: Heat Transfers in Tunnel
Environment, EMF and fluid leak detection are addressed.
· In Chapter 7, the Risk of Fire or Explosion, Fault
Containment issues and issues regarding induced voltages
and currents are covered.
Chapter 8 deals with the assessment of the Impact of the
upgrading process of one parameter (usually transmitted
power) or on all other parameters of the line.
Chapter 9 describes a detailed methodology used in the
upgrading process :
· Step 1: Defining target for upgraded situation
· Step 2: Assessment of existing situation
· Step 3: Selection of potential upgrading techniques
· Step 4: Evaluation of Impacts and decision making.
Chapter 10 describes various interesting case studies of
upgrading, ranging from a simple reassessment of a link current
capacity to a more complicated case of forced cooling and
retrofitting a new cable in existing pipes.
Chapter 11 is the conclusion of the Technical Brochure, and is
followed by Chapter 12 which is a useful bibliography.
Conclusion
In conclusion, the Technical Brochure has been written by WG
B1.11 to help the engineer to review the required assessments and
to guide him along the different steps of upgrading, with a panel
of various solutions. Each case is specific and must be studied
with great care because of possible interference of parameters.
Some significant improvements can be found. However, it may
appear rapidly that no upgrading is possible or that the effect of
upgrading one parameter is causing a negative effect on others.
Cable system designers have to remind than the opportunity to
upgrade is more likely if the original design made provision for
such upgrading … 
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