Kenneth E. Bow, Consultant Richard M. Ellis Kable Consult LLC Cable Materials Inc. Freeland, Michigan USA Atlanta, Georgia USA k.bow@ieee.org rellisga@cablematerialsinc.com Abstract— This paper deploy more UG power that are free of voids all conductor shield, and the recommends new test media cables, it is important to contributed to the reduction conductors. Water can and methods for underground continue to analyze the in water tree occurrences [3]. contribute to water tree power cables with performance of the cable In the 1980’s, SAP, in growth as well as introduce superabsorbent water swelling materials (SAP) . The tests materials under in-service various forms, were corrosive ions that are should reflect actual service conditions. This paper introduced to the cable present in the ground water conditions in the field. The focuses on the effect of water manufacturing industry. into the core of the cable. type of water chosen for blocking in controlling the These materials were in the The water in the cable can swelling tests should have radial and longitudinal flow form of loose powders, also eventually migrate into ionic content to reflect the of water and moisture in powders encapsulated within cable terminations and composition of actual soil cable. non-woven fabrics and splices and cause further water. The cable tests should applied as tapes, and damage to the power system. also reflect actual conditions. The significant powders encapsulated on For this reason, global The tests should measure the performance of the cable deployment of UG cables yarns. The SAP can also be standards have been under simulated thermo- began in Europe in the late used in the conductor region developed to guide the mechanical loading 1970’s, with The Netherlands of the cable to block the flow proper selection and conditions, under water leading the conversion from of water. The presence of application of suitable water pressure at the operating overhead cable to UG cable, SAP in the conductor region blocking materials that work voltage. The testing should primarily for low and also helps prevent corrosion, in conjunction with highlight the water-blocking medium voltage products. thus reducing the potential optimized insulation and performance of the SAP in its As of 1999, 100% of low and for subsequent formation of jacketing compounds. The functional state, that is, in the form of a hydrated gel. Such medium voltage cables in the water trees [4]. materials used to provide this requirements are already a Netherlands were installed in The objective of this water blocking functionality part of International the underground. In high paper is to propose a include tapes and yarns made Electrotechnical Commission voltage networks, the modified test media and test with SAP powders or SAP (IEC) test methods and are percentages are much lower, method for more accurately fibers. SAP powders can also a requirement for certain with 4 countries predicting the performance also be applied directly onto Insulated Cable Engineers (Netherlands, United of an in-service UG power the cable where the Association (ICEA) test Kingdom, Denmark, cable over the life cycle of additional functionality of a methods thereby allowing Switzerland) having reached that cable. Harmonization of tape or yarn, such as harmonization of the global requirements for water- the 10-20% range. In extra the ICEA and the IEC bedding, binding, or blocked cables. high voltage networks, the standards related to water separating is not required. percentages are very low, but blocked UG power cables is Index Terms— IEC standards, solid dielectric 380 to 500 another intended result of III. SAP MATERIAL materials reliability, materials kV systems are becoming these changes. PROPERTY testing, polymer gels, power more common [2]. The REQUIREMENTS system reliability evolution of solid dielectric, polymeric insulation material II. EASE OF USE UG SAP polymers are I. INTRODUCTION was driven in part by the CABLE CONSTRUCTIONS AND typically formed from a further understanding of the SAP MATERIALS cross-linked sodium salt of According to a recent study by the Edison Electric influence of ground water on acrylic acid, though other Institute [1], power utilities the performance and life It is well understood that chemical formulations are continue to make significant span of those cables. As the water can cause problems available. SAP can be investments in underground understanding of the causes when introduced into the formulated for targeted (UG) facilities. Their study of water tree formation core of a power cable. applications that require indicates utility spending of advanced, materials and Radial water penetration can specific performance over 4% of transmission process design changes were be prevented using metallic characteristics. A fast dollars and 20% of made to reduce their impact shields or by the use of SAP swelling, high absorbency distribution dollars on UG on cable service life. Cross- materials under the jacket SAP may be perfect for a construction. The materials linked polyethylene (XLPE) [5]. The longitudinal water single use, disposable used in these UG power insulations designed to migration in the area under hygiene product such as a cable designs continue to inhibit the growth of water the jacket/around the baby diaper, but not for an evolve due to advancements trees, semiconductor screens neutrals, or through the application with a multi-year in the understandings of their designed to be free of stranded conductors, can life cycle. Through a contribution to cable excessive ionic have an adverse effect on the combination of careful performance and life span. concentration, and smooth insulation, the insulation control of cross-linker type, As the industry continues to surface insulation shields shield, the neutral wires, the amount and reaction conditions during the 3/ Permeability: The absorbency and swell speed parameters. The solution manufacture of the SAP, hydrated SAP must form of the SAP that is based on used for water penetration permeability, stability and an impervious mass to the reaction of the SAP to testing was often specified to rheological properties can be prevent capillary distilled, deionized or tap be distilled or deionized modified or controlled. transport of the water. water is not representative of water, though tap water is the performance of the now the more commonly As described by 4/ Resistance to material under actual specified medium for testing Bringuier and Clyburn [6], hydrolysis/gel conditions of field water the functionality of SAP. the water swelling degradation: The ingress. It has been shown Two methods are used to performance of a SAP hydrated SAP must that an SAP that absorbs introduce the water into the product, whether as a tape, maintain gel integrity approximately 300 g/g in cable. One method of yarn, or as a direct powder over the operating life of distilled or tap water will introduction for the water application, depends on the the cable and at the only absorb 30-40 g/g in 1% head is the “L type”, where ionic content of the water. range of temperatures NaCl solution, and even less the water head is attached to “The positive ions present in that the cable is in CaCl2 solution [8]. A the end of the cable. The ground water position designed to operate. typical USA cable water head can be adjusted to themselves next to the manufacturer’s specification apply various degrees of carboxylate ions, thus The typical United may also require heat-aging pressure to the end of the limiting the swelling and States of America (USA) data for the SAP in the dry cable. Thus, the “L type” absorbency capacity of the cable manufacturer’s raw state. Again, while this essentially becomes a test for SAP”. Raw material swell material specification for dry evaluation is somewhat water flow in the conductor. testing and cable water water blocking products relevant to the field service The “T-type” allows the penetration testing were requires data on swell speed conditions, it evaluates the water to intrude around the performed using a variety of and swell height in SAP in an inactive state. It is circumference of the cable ionic solutions. These distilled/deionized water or far more important to and becomes a primary test included manhole waters in tap water. These data evaluate the performance of for the flow of water along from around the USA, were obtained through the SAP in its functional the length of the cable within American Society for Testing various iterations of the “cup state when fully hydrated. the interfaces of the sheath. and Materials (ASTM) and ram” test method that The stability of the hydrated Regardless of the Ocean Water, and other measures the displacement of gel at the operating configuration of the test specifically formulated ionic a ram over time from the temperature of the in-service sample, (L or T type), the solutions. The results swelling action of the cable is the only true test of duration of the water clearly demonstrated a very hydrated gel. The data are the ability of the SAP to penetration test, and other good correlation between typically reported at 1- perform its intended function factors or test conditions ionic content (and related minute and at 3-minute in a cable. Thermal cycling were devised to try to pH) to swell and water intervals. Distilled/deionized during water penetration simulate the actual field penetration performance. water was originally selected testing is a necessary circumstances of a water The results also verified that as the standard so that requirement as a condition of insult. The ICEA T-31- cables designed to account different SAP products could the IEC 60840 and others. 610-2007 test duration is one for the effect of these ions be characterized using a hour at ambient. The ICEA could pass all existing common, universal media. IV. WATER T-31-610-2007 and the ICEA industry requirements. However, in the field, where PENETRATION TESTING T-34-664-2007 do not the actual SAP performance specify the type of water, The most important is critical, the water to which For the most part, the while the IEC 60840 application specific the SAP is exposed is water penetration standards specifies the test media as properties of an SAP as a typically common ground used in North America were tap water. The ICEA T-31- blocking agent for power water, or possibly storm or developed with the idea that 610-2007 requires thermal cables are [7]: floodwater in a manhole, a a rapid swell speed and large cycling of the conductor conduit or in the ground. swell capacity were the cable core sample with the 1/ Absorption and Ground, storm or floodwater critical parameters that SAP in the “dry” state while retention: The SAP contains many cations that ensured reliable resistance to ICEA T-34-664-2007, must absorb and hold a have a significant effect on water penetration in the field. Qualification Test Part B, certain quantity of water. the swelling properties of the As a result, the related water and IEC 60840 requires SAP. Storm or floodwater penetration test protocols thermal cycling of the cable 2/ Absorption speed: The can even be brackish or in focused on the relative short- while the cable sample is SAP must react quickly the ionic range of seawater in term performance of the subjected to water to the ingress of water. coastal areas. Test data on materials under predictable penetration and the SAP is in a swollen state. The ICEA T- the cable can be increased The only standardized end-use application, and the 34-664-2007 requires 20 water tree growth and method to determine the conformance should be heating cycles at the rated corrosion. The water must swell height of water measured using standard conductor emergency not only be blocked with the blocking materials is methods that most accurately temperature, with each cycle initial formation of gel, but currently specified under reflect field conditions. The consisting of heating applied the gel must continue to Cenelec HD 605 S2, section performance of the SAP in for four hours followed by bond the water and the ionic 2.5.9, which defines the field conditions can be most four hours of natural cooling. contaminants over time to be measuring apparatus (cup accurately predicted using an The IEC 60840 calls for the truly effective. and ram) and the test ionic solution that best waterhead to be applied at protocol. The “cup and ram” simulates the water that will ambient and allowed to stand V. PROPOSED NEW TEST swell test is a common need to be blocked in the for 24 hours. The sample is MEDIA AND METHOD method developed and used event of a breach in the then subjected to 10 heating FOR SAP PROPERTY by raw material vendors and sheath of an UG cable. The cycles of 5K to 10K above CHARACTERIZATION end users alike. However, thermal stability of the the maximum conductor AND WATER specifications for the cup, the hydrated superabsorbent is temperature in normal PENETRATION ram, the “load” imparted by critical to the water blocking conditions. The temperature PERFORMANCE TESTING the ram, etc., can vary from function of the SAP during cycles are 8 hours at elevated one vendor/end-user method the life cycle of power temperature, followed by 16 This paper proposes that to the next. There is a need cables. The gel stability hours of natural cooling. a standard ionic solution be for an ICEA standard swell ensures that the longitudinal The ICEA T-34-664-2007 developed for use in both height method and apparatus flow of water is stopped. It Qualification Test Part B, raw material characterization that brings conformity to the also ensures that the free and the IEC 60840 test and cable performance results. water is bonded within the procedures more accurately testing. The current use of SAP, thus reducing potential simulate in-service field distilled, de-ionized or tap The ICEA water damage from water trees and conditions. water does not accurately penetration test method used corrosion. The thermal reflect the service conditions to verify the performance of stability of the hydrated gel It is important that an under which the SAP must the cable in the field should should be a design ionic solution be used to be functional. Tap water is be modeled after IEC 60840 consideration for all UG simulate the ground water typically treated to remove that requires temperature cables. Consideration should insult. It is equally Ca++ and Mg++ ions to cycling at cable operating be given to amending current important that the water “soften” the water [10]. This temperatures be conducted standards relating to penetration testing be eliminates two of the cations while the sample is longitudinal water blocking conducted while the sample that have the most adverse undergoing water penetration of power cables to reflect the undergoes simulated service effect on SAP. One proposed testing. This procedure is importance of this property, conditions, such as those option is to use a diluted required to understand how and the method and media required by IEC 60840 and solution of the existing ionic the SAP will perform under used to characterize it. others. It is during this solution prepared per ASTM simulated field conditions. cycling at conductor D1141 - 98(2013) “Standard The gel formed by the The following changes operating temperature that Practice for the Preparation ingress of water is subject to are recommended in the the dynamic blocking of Substitute Ocean Water.” hydrolysis, which can be industry standards dealing property of the SAP This ionic solution is significantly accelerated by with qualification of water- chemistry is more easily intended to be equivalent to the standard operating swelling materials both as demonstrated. Water seawater, so at full strength it temperatures of a medium or materials and as components blocking products made with is not representative of high voltage power cable [5]. of cable: correctly formulated SAP ground water. However, the The cable should be will be able to resist formula contains a subjected to thermal aging 1/ Standardize the test hydrolysis of the gel under representative sample of the during the water penetration media as an ionic the simulated field cations that exist in ground test cycle, to verify solution based on known conditions [9] When the gel water and that have the most performance under field groundwater breaks down under the dramatic effect on the conditions. constituents. simulated field conditions, it performance of SAP. The releases the water and the user community should also VI. CONCLUSIONS 2/ Standardize the swell associated ionic consider other options for cup test apparatus and contaminants from their such a standard ionic The functional method. bond, creating free water. solution. properties of SAP should be The result of free water in designed for the intended 3/ Standardize on a water Term Stability of Superabsorbent Gel for Cable penetration test method Water-blocking Performance”, that includes the International Wire and Cable requirement that the Symposium 2010. cable sample undergoes [10] Ohio Dept. of Natural Resources, “Ground Water thermal loading cycles Quality”, 10/07/2011. at or above normal conductor operating temperature while undergoing water penetration testing.
REFERENCES
[1] Kenneth L. Hall, P.E., Hall
Energy Consulting, Inc., Edison Electric Institute “Out of Sight, Out of Mind 2012” [2] Commission of the European Communities, Background Paper, Undergrounding of Electricity Lines in Europe, Brussels, 10 Dec. 2003. [3] N. Hampton, R. Hartlein, H. Lennartsson, H. Orton, R. Ramachandran “Long Life XLPE Insulated Power Cable”, Jicable ’07. [4] Sverre Hvidsten, Mildrid Selsjord, Hans Saeternes, SINTEF Energy Research “Initiation of Vented Water Trees by Severe Degradation of the Conductor Screen of Laboratory Aged MV XLPE Insulated Cables.” Insulated Conductors Committee Fall 2011. [5] Guerts, Steennis, Poorts, Meijer, Kema Netherlands, “Water diffusion through sheaths and its effects on cable constructions”, JICABLE, Versailles 1995. [6] Anne G. Bringuier, Clinton E. Clyburn III, Siecor Corporation “Reliability of Dry Waterblocking Materials”, International Wire and Cable Symposium 1996. [7] Martin Tennie, Evonik Stockhausen GmbH, “Superabsorbent Polymers as Water-Blocking Components in Cables”, Insulated Conductors Committee Fall 2012. [8] Catarina L. Tedder, Christopher M. Quinn, David A. Seddon, Mike Ellwanger “The Reliability of Completely Dry Gel-free Optical Cables, International Wire and Cable Symposium Proceedings, pg. 467, (2012). [9] Clyburn, Clinton E., Stewart Superabsorbents LLC, “Long-