Basic Structure of Power

Cables
Š Introduction
„ Definition of a cable

LINK
SOURCE RECEIVER

1
 Basic Structure of Power
Cables
z What is it ?
Š Connection or Link to send Electric Power from Source to
load

z What is it used for ?

Š To Send Electric Power From One Point to Another Point

2
 Basic Structure of Power
Cables
Š Power Cables
• Low Voltage Cables
• Medium Voltage Cables
• High Voltage Cables

3
 Basic Structure of Power
Cables
™Construction of Low Voltage Cables

R
Y R
BK
B Y

LV MV B

Power Transformer 4
 Basic Structure of Power
Cables
„ Conductor
z Main Part of the Cable
z Carries Low Voltageg Power or Signal
g from Sending g to
Receiving End
z Made of Copper or Aluminum

z Bigger Size--> More Current

z Solid or Stranded (Depends on Required Flexibility)

z Different
Diff t Sh
Shapes(Round,
(R d Sectoral,Oval)
S t l O l)

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Basic Structure of Power
Cables

6
 Basic Structure of Power
Cables
„ Insulation
z Provides Electrical Protection Against Contact with
Surroundingg
z Main Types Produced in RCGC
ƒ PVC
ƒ XLPE

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 Basic Structure of Power
Cables
Š PVC Material(Thermoplastic)
( p )
„ Chlorination of Ethylene
„ Additives Are Introduced to Get the Required
q
Characteristics: eg:
Š Plasticizers
Š Colouring Pigments
Š stabilizer
Š Anti-termite
Š Fire Retarding Material
Š Oil Resistance Material
Š etc..

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 Basic Structure of Power
Cables
Š Chlorination of Ethylene
PVC Material

H H H H

--C--C--C--C--

H Cl H Cl

Maximum Operating Temperature :70 oC

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 Basic Structure of Power
Cables
•Additives Are Introduced to Get the Required Characteristics:
eg: Plasticizers,Coloring Pigments , Stabilizers..etc

PVC + Additives = Required Characteristics

PVC COMPOSITION
Additives

MINERAL STABILIZER LUBRICANT

COLORING help in preventing
PLASTICIZERS FILLERS to improve
PIGMENT
deterioration of plasticizers workability

DIDP DOP
Di-isodecylphthalate Di-2-ethylhexylphthalate Lead Sulphate Lead Phthalate

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 Basic Structure of Power
Cables

XLPE Material
M t i l

(Thermoplastic)
H H (Thermosetting)
-CH2-CH-CH2-CH2
Crosslinking
--C--C-- Crosslink
-CH2-CH-CH2-CH2
H H
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 Basic Structure of Power
Cables
Polyethylene Catalyst Coloring

Partially Crosslinked
EXTRUDER Polyethylene(XLPE)

Crosslinking by Diffusion of Moisture into Material :

• Steam Bath
• Boiled
B il d Water
W t Bath
B th
• Long Duration at Normal Humidity
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 Basic Structure of Power
Cables
Š Properties of Crosslinked Polyethylene
„ Higher operating temperature : 90oC for Normal
Operation &250 oC for Short Circuit Condition

Š Additives to XLPE
„ Antioxident to Prevent Oxidation at Elevated
T
Temperatures
t
„ Coloring

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 Basic Structure of Power
Cables
Š Filling and Bedding
„ Used to Fill Gaps in Assembled Cores
z PVC or P
Polypropylene
l l Fill
Fillers(PP
(PP Fillers)
Fill )

Small Gaps Big Gaps

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 Basic Structure of Power
Cables
Š Armouring
„ Protects the Cable against Mechanical Damage
D i Handling
During H dli andd Installation
I t ll ti
z Steel Tape or Steel Wire ( Sometimes Tinned copper
is added to the Armour to Increase Earth Fault
Capabilities )

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 Basic Structure of Power
Cables
Š OUTER SHEATH
• To Prevent Water Ingress into the Cable
• To Prevent Corrosion of the Armour
• To Insulate the Armour from Ground

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 Basic Structure of Power
Cables
™Construction of Medium and High
g Voltage
g Cables
• Conductor
• Conductor Screen
• Insulation
• Insulation Screen (non-metallic )
• Insulation Screen (Metallic)
• Bedding
• Armoring(MV)
• Outer Sheath
• W
Water Blocking
Bl ki
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Basic Structure of Power
Cables
R
Y R
BK
Y
B
B
LV MV
R
R

Y
Y

B B
MV HV
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 Basic Structure of Power
Cables
Š Conductor
• Aluminum or Copper
• Stranded and Compacted

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 Basic Structure of Power
Cables
• Electric Field at Surface at the Conductor is
Important
• Irregular Surface=> High Electric Field =>
Partial Discharge
• Solution:
S l ti Semi-conducting
S i d ti Layer
L Over
O
Conductor

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Basic Structure of Power
Cables

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 Basic Structure of Power
Cables
Š Conductor Screen (Semi-Conducting Layer)
• Carries Extremely Low Current
• Carries the Same Voltage as the Conductor
• Any Damage, Deformation, Protrusion or Other
Contaminant Can Cause Partial Discharge

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 Basic Structure of Power
Cables
Š Insulation
„ Better Quality than LV Insulation
„ Withstand Higher Electric Stresses
No Voids
No Partial
No Contamination No Total Failure
Discharge
No Protrusion

GOOD CABLE

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 Basic Structure of Power
Cables

C ti
Continuous Catenary
C t Vulcanization
V l i ti (CCV)
Extrusion

Crosslinking
Cooling

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 Basic Structure of Power
Cables
Š Crosslinking
g by
y Peroxides

Organic Peroxide High Reactive Radicals

Decomposition at
High Temperature

Interlinks the
Polyethylene Molecules

Crosslinked -CH2-CH-CH2-CH2
P l h l
Polyethylene I t li k
Interlink
(Thermosetting) -CH2-CH-CH2-CH2
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 Basic Structure of Power
Cables
Š Insulation Screen(Semi-conducting Layer)

• To Control the Electric Field at the Surface of

Insulation. It carries the same potential as the
insulation surface
• Any Damage to This Screen can Cause Partial
Discharge and the Cable may Fail the Final
Routine Test

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 Basic Structure of Power
Cables
Š Triple Extrusion
„ The Conductor Screen, the Insulation and the
Insulation Screen are Extruded Simultaneously
(Triple Head Extruder)

Conductor
C d S
Screen
Insulation
I l ti Screen
Insulation S
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 Basic Structure of Power
Cables
Š Triple Extrusion

• Economical
• Well Controlled Core
• Reduce Contamination of Insulation

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 Basic Structure of Power
Cables
Š Metallic Screen
• Copper Wire
• Copper Tape
• Both

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 Basic Structure of Power
Cables
„ In Case of Earth Fault,, the Metallic Screen Will
Carry the Earth Fault to the Control Room to
Operate the Protection System and the Cable
Will be Automatically Disconnected

Screen
Cable
Insulation

Power
Generator Load

Earthh Fault
l
Current
Control
Room 30
 Basic Structure of Power
Cables
Š Filling
„ Used to Fill Gaps in Assembled Cores
z PVC or Polypropylene Fillers(PP Fillers)
„ Beddingg
z Layers of Polypropylene, PVC or Hessian Tape
GAPS
Š Armouringg
„ Protect the Cable against Mechanical Damage During
Handling and Installation
z Steell Tape
S T or Steel
S l Wire
Wi
z Copper or Aluminum Wires(for Single Core Cables)

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 Basic Structure of Power
Cables
Š Outer Sheath
• Protection of Armour from Corrosion
• Protection of Core
• Isolation of Armour & Screen from Ground
• Can be Used to Check the Cable On Site if
Covered
Cove ed with
w Graphite
G p e

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 Basic Structure of Power
Cables
Š Water Blocking Water (Longitudinal
Cable damage Blockage)

Conductor

Insulation

Al or Cu Foil for Swellable

Water (Radial Tapes
Water
Blockage )
(Longitudinal
Cable Blockage)
Damages
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