Public Interest Energy Research

February 25th, 2008

MODELING ELECTROMECHANICAL
PHENOMENA CONTRIBUTING TO CABLE
DETERIORATION

Piero Marcolongo & James W. Evans

SECURE
SENSOR-BASED CABLES FOR UNDERGROUND RELIABILITY OF
ELECTRICITY INFRASTRUCTURES
 Outline

ƒ What does the electromagnetic

g field look like on a
macroscale?
ƒ What does it look like on the microscale (a void)?
ƒ Can electromagnetic forces be high enough to damage
the insulation?
ƒ What
Wh t are th
the mechanical
h i l properties
ti off PE iinsulation,
l ti
both old and new?
ƒ What should be done next on this topic at UCB?

2
 A macroscopic view: the model adopted for the simulations

ƒ A 12 000 V difference has been set between CC and CNs.

Material σ (S/m) εr μr

CC (Al) 3.030*107 1 ~1
Semicon 100 10 ~1
XLPE 1*10-15 2.3 ~1
CNs (Cu) 5.998*107 1 ~1
Jacket 0.1 2.3 ~1
Air 1*10-15 1.00059 ~1

Sketch of the cross section of a 12kV distribution cable, with 15 CNs.

3
 Electric field and CNs

In the figure to the right (generated

by finite element solution in
COMSOL):

- Arrow plot of the electric field.

- Color indicates the magnitude of

the electric field.

- Notice the electric field leakage

between the CNs.
CNs

∇ ⋅ ε r ε 0 ∇φ = 0
where
ε r = relative permittivity
ε 0 = permittivity of vacuum
φ = potential (voltage)

4
 Magnitude of electric field along the outer circumference

5
 Electric field along the outer circumference with one failed CN.

ΔE = 1
1.2*10
2*105
ΔE = + 947%

Failed CNs generates clear “signature”

signature that could be easily detectable.

6
 A real case: asymmetric CNs distribution

a)) A typical
t i l hihigh
h voltage
lt cable
bl with
ith 15 CNs
CN and
d 600A going
i through
th h the
th CC and
da
ΔV of 12 000V between the CC and the CNs;

b) The same cable with an asymmetric distribution of the CNs.

7
 Asymmetry and CNs failure: ELECTRIC FIELD

ƒ The plot starts from 9 o’clock and goes counterclockwise

ƒ There is no more baseline that could be used as a reference.
ƒ The failure of the CN is masked by the proximity of the other healthy CNs.

8
 A microscopic view: the model
A small sample of the dielectric in which an inclusion has been incorporated.
incorporated

While electrical trees consist

of connected channels,
th
there is
i no evidence
id ffor the
th
presence of channels for
water trees. They is a large
density of voids. No cracks
or crazes have
h b
been
revealed by SEM.

¾ Th
The water tree should
h ld rather
h considered
id d as a poorly-conductive
l d i medium;
di will
ill distort
di electric
l i
field.
¾ The inclusion has average conductivity and permittivity (since the exact composition is not
well known).
known)
¾ The dielectric is polyethylene (XLPE).
¾ A potential of 1000V is set at the bottom of the rectangle (zero at the top).

9
 Electric field and electric potential around the void

ƒ Void is an ellipsoid, i.e.axisymmetric,

therefore just half of the void is simulated.

ƒ The arrow plot represents the electric field

f
(E) while the surface plot represents the
electric potential (a potential of 1000V is set
at the bottom of the domain of calculation)

• Dielectrophoretic force =

(ε 0 / 2 ) ∇ (ε r − 1) E 2
• Stress due to surface charge =

−ρ E

10
 Space charge distribution: an interface phenomenon
The equation
Th ti describing
d ibi theth The Charachteristic Time (time necessary
space charge generation: for the space charge to reach the stable
condition) is:
ε ∂ρ ⎛ε ⎞
ρ+ = J ⋅∇ ⎜ ⎟ XLPE = 20,365s
σ ∂t ⎝σ ⎠
where
ε = ε 0ε r
Void = 8.58 *10-10 s
ρ = charge density
J = current density

• Working conditions: AC regime at 60 Hz frequency.

• Hence, the space charge in the dielectric is negligible, while it

will track the applied potential in the inclusion (in particular
close to the interface between the two media)
media).

11
 Dielectrophoretic and Electric stresses
Dielectrophoretic + Surface charge effect Dielectrophoretic effect

The stresses due to the presence of space charge tend to increase the
stress acting on the void.

12
 Forces acting on the void

Void size: 2*10-5 x 5*10-5m

ƒ Maximum stress at poles; increases remarkably as void is made longer (holding diameter at
equator constant).

ƒ On
O the
th right,
i ht surface
f plot
l t off Von
V Mises
Mi stresses
t acting
ti on an elippsoidal
li id l void.
id

13
 Mechanical Properties of XLPE

DENSITY (g/cm3): 0.92

ELASTIC MODULUS (GPa): 0.152 – 0.290

ELONGATION AT BREAK (%): 500
TENSILE STRENGTH (MPa): 18
COMPRESSIVE STRENGTH (Mpa): 9

WATER ABSORPTION (%): 00.01

01

DIELECTRIC STRENGTH (MV/m): 21

DIELECTRIC CONSTANT: 2.3

MELTING TEMP. RANGE (°C): 150 – 170

UTILZATION TEMP. (°C): -60 – 90

Sketch and real MTS apparatus adopted for the compression of

the sample along the longitudinal direction, after stripping the
conductor out and tearing off the outer insulation jacket

14
 Experimental Stress-Strain curve beyond the elastic region

Max displacement set is 1cm

(50% of the sample length)

Here the sample

started buckling

15
 5 Aged + 1 New Cable Samples under study

SAMPLE JACKET LABELING YEAR OF

MANUFACTURING
A ROME CABLE 1971
PE AWG AL 22 KV
B GENEARL CABLE CA 1970
PE 220 MILS 2 AWG AL 15KV
C KAISER ALUMINUM – A 1972
PE 2 AL 22 KV
D GENERAL CABLE CA 1971
PE 220 MILS 1/0 AWG AL 15 KV
E GENERAL CABLE CA 1972
PE 295 MILS 1/0 AWG AL 22 KV
G BICCO BRAND - MT 2006
TRXLPE 175 MILS 15 KV

16
 Experimental Stress-Strain curve in the ELASTIC region

SAMPLE Young’s
Modulus [Pa]
[ ]
A 0.17*109
B 0.10*109
C 0 13*10
0.13 109
D 0.12*109
E 0.14*109
G 0.12*109

ƒ Testing has been carried out under stroke control: constant compression rate.
ƒ Each curve is the average of 3 different tests on the same type of sample.
ƒ Comparison among the Young’s modulus (different sample = different stiffness)
ƒ In literature the Young’s
Young s Modulus for extruded PE is in the range of 0
0.15
15 to 0
0.29
29 GPa

17
 Experimental stress-strain curve beyond the elastic region

ƒ Cable tested: (A) Rome Cable - PE AWG AL 22 KV - 1971

ƒ Hysteresis losses are highlighted in the graph.
ƒ Relaxation time τ= η/E = 3.2*106 Pa*s / 1.2*108 Pa = 2.6*10-2 sec

18
 All cables tested show non-elastic
behavior of PE beyond a few MPa
1 cycle: loading and unloading
(final rod displacement = 0.15 cm)
10

6
A) PE 22 KV 1971
ss [Pa]

5 B) PE 15 KV 1970
Stres

C) PE 22 KV 1972
4 D) PE 15KV 1971
E) PE 22 KV 1972
3
G) TRXLPE 15 KV 2006
2

0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
Strain

19
 Possibilities for mechanical failure

ƒ At about 3MPa the PE samples show non-elastic behavior.

For a void 4 microns in diameter at the equator and a
height to diameter ratio greater than approximately 30,
stresses greater than are 3MPa are generated at the
poles. Deformation of the void should be expected.
p p

ƒ Materials can fail byy fatigue

g if their elastic limit is
exceeded, even in compression.
30 years at 60 Hz (actually 120Hz) = 1.14x1011 cycles!

20
 Sequence of optical micrograph of a Mode I fatigue crack which propagated from the
root of the notch in the compact specimen of UHMWP after (a) 0, (b) 1, (c) 10 000
and (d) 2 500 000 cycles of uniaxial compression loading.

Image from : L. Pruitt, R. Hermann, S. Suresh, Journal of Material Science, 27 (1992), pp 1608-16

21
 Conclusions

• The simulations showed some possibiliy of detecting failed CNs by looking

at the variation of the electric field around the outside of the cable (but this
is only if CNs have a reasonably symmetric distribution around the cable).

• The simulations revealed the possibility of insulator failure due to

electromechanical forces acting on the void
void.

• Mechanical testing shows that PE insulation might be unable to resist

electromagnetic forces established around heterogeneities in the PE.

• The mechanical properties of aged and new cables (TRXLPE 2006) have
been compared; they are in good agreement with literature data.

22
 Future Work

ƒ Fatigue and creep testing on aged and new

samples.

ƒ Carry out elasto-plastic and visco-elastic

simulations with COMSOL®.

ƒ Verify the results of the simulations.

ƒ Role of chemistry.

23
 Electrical properties of the media: why our choices

XLPE Void
Conductivity (S/m) 1*10-15 5*10-2
Permittivity 2.3 5
Density (kg/m3) 920 --
Young’s Modulus (Pa) 7*108 --
Poisson’s ratio 0.42 --

ƒ Th
The influence
i fl off the
h temperature
t t on conductivity
d i i is i negligible
li ibl (usually
( ll
there is an average thermal excursion of just 15°C along the radial
direction of the insulation)
ƒ Water trees propagate and grow faster on the outward side of bent cable.

24
 Data provided by www.MataWeb.com
25
 Forces acting on the void: the best and worst case

ƒ The void has been stretched along the radial direction to simulate the water tree growth.
ƒ The increase of the width/height radio brings the overall forces to reach remarkable
levels (the worst case).
ƒ Comparison of: a) final stress due to dielectrophoretic forces and presence of space
charge, b) final stress due to the dielectrophoretic forces

26
 The overall force is: COMPRESSION

• The dielectrophoretic forces as well as the

ones due to space charge generate a
compression status on the void.

• It is likely these compression forces lead the

void to crack in a cyclic environment
(= FATIGUE 30 years = 11x1010 cycles).

• This trend has been verified for all the

geometries analyzed so far.

27
 All cables tested show non-elastic
behavior beyond a few MPa
1 cycle: loading and unloading
((final rod displacement
p = 0.05 cm))
4

3.5

2.5
ss, MPa

A) PE 22 KV 1971

2 B) PE 15 KV 1970
Stres

C) PE 22 KV 1972

1.5 D) PE 15KV 1971

E) PE 22 KV 1972

1 G) TRXLPE 15 KV 2006

0.5

0
0 0.005 0.01 0.015 0.02 0.025 0.03
Strain

28
 Possibility of carrying out elasto plastic simulations

With the experimental data we can “feed” COMSOL to check the elasto
plastic module.

29
 Magnetic Flux Density for a Healthy Cable [Tesla]

• Plot of the Magnetic Flux Density [Tesla] of a 15 CNs cable, with a 600 A current thorugh the CC 
along the cable Jacket (RED LINE in the picture) = perfect symmetry. Field only varies from 7.1‐
7 15x10‐33 Tesla. 
7.15x10 Tesla
• All the following plots refers to the outer circumference of the cable jacket.

30
 Magnetic Flux Density “Sick” Cable [Tesla]

• Plot of the Magnetic Flux Density [Tesla] of a 15 CNs cable, with a 600 A current thorugh the CC. Three of 
the CNs (see insert) are failed ones failed (current density = 0).
• Probes can reach a sensitivity of 0.01 Gauss without problems, however the delta (2%)might be too small 
to guarantee precise measurements .
• These data were obtained imposing a 600 A current through the CC, as soon as we scale down to 6 A or 
31
0.06 A, the absolute variation scales down by a 100 or 10,000 factor.
 2D simulation of the electric field perturbation
due to water tree presence
p

A vented water tree has been created.

created It grew from the outer insulator shield toward the
center of the cable

32
 Electric Field along the Jacket in presence of Water Treeing

Δ 3 103 V/m
Δ=3*10
Δ=25%

The electric field variation decreases remarkably if compared with the case of a
failed CN. Furthermore when the water tree starts g growingg from the CC
shield, the variation along the outer jacket is almost negligible.

33
 Two schools of thought
El t
Electromechanic
h i forces
f cause breakdown
b kd VS Electrochemical
El t h i l oxidation
id ti causes breakdown
b kd

Hypothesis supported by the mechanical Hypothesis supported by the chemical

engineers:
g engineers:

Distortion of the electric field generates Oxidation of the polymer chain creates
mechanical forces cavities with hydrophillic surfaces

Forces induce local stress (in particular in The products of the oxidation are
the p
proximity
y of a defect in the insualtion)) carboxylates that can react with the chain of
the polimers degrading it

Stresses break the polymer chain and lead to

the formation of void and water trees The defect promotes other defects

Higher concentration of forces at the tip of

the water tree lead to ppropagation
p g of water Being materials engineers we have to
trees consider
id both
b h approaches.
h

34
 The electric forces: a combination of dielectrophoretic
and Coulombic forces
In presence of a potential difference, the forces acting on the sample are the dielectrophoretic
ones (due to the migration of the water dipoles toward the higher potential region):

Mechanical forces in the material = Electric fields + Properties of the Media

Strong deformation of E2 around the ellipsoid, 6 The arrows represent the dielectrophoretic forces
times higher if compared with the value in clean PE acting on the inclusion

35
 The presence of a space charge distribution
In case of a space charge distribution (ρ) the Coulombic forces show up:

Moreover the electric field is remarkably distorted by its presence.

The equation describing the space

charge generation:

ε ∂ρ ⎛ε ⎞
ρ+ = J ⋅∇ ⎜ ⎟
σ ∂t ⎝σ ⎠
where
ε = ε 0ε r
ρ = charge density
Critical threshold for space charge injection in J = current density
polymeric media (notice the hysteresis)

36
 Range of space charge in high voltage cables

37
 Fatigue plays an important role

ƒ High frequencies remarkably increase

the water tree growth rate and the
electrical
l t i l aging
i pace off th
the cables.
bl

ƒ The inception time varies almost with

the inverse of the frequency.

ƒ A better understanding of the water

treeing phenomenon comes adopting
the number of the AC electric field
(normalising factor) instead of the time
(same length for the same number of
cycles, therefore it is indipendent of
the test frequency).

38
39