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• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France
Cable Systems, Cables and Accessories
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
22th June 2015
Andreas WeinleinUlrich Peters, Uwe Laage, Horst Memmer
Südkabel GmbH, Mannheim (Germany)andreas.weinlein@suedkabel.com, ulrich.peters@suedkabel.com, uwe.laage@suedkabel.com, horst.memmer@suedkabel.com
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France © 22.06.2015 - Andreas Weinlein - Slide 2
Topic
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
Content of Presentation
Introduction
500 kV Moscow project
400 kV London project
Advanced calculations and tests
Conclusion
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France © 22.06.2015 - Andreas Weinlein - Slide 3
Introduction
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
experience of more than 1,300 kmunderground XLPE cables
more than 2,650 accessories (almost 1,700 joints)
operation voltages 330 - 500 kV
period of 20 years
technical solutions & concepts for development, manufacture, assembly, testing & operation are largely confirmed by the manufacturer
special highlight of the EHV cable technology: one of the longest500 kV cable systems installed in Moscow (Russia) - Skolkovo project -completed in May 2012
second highlight: replacement of fluid filled buried 275 kV cable circuits in the city of London (UK) by 400 XLPE systems known as the London Power Tunnel Project - the first stage commissioned in March 2015
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France © 22.06.2015 - Andreas Weinlein - Slide 4
Introduction
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
advanced tests: mechanical load test of buried joints
short-circuit current test on connections of longitudinalwelded aluminium sheath
flexible cleat evaluation under cable sealing ends
heating concept of accessories down to -45 °C
high reliability, reduced repair times & decreasing cable and accessory prices make the EHV XLPE cable system competitive with overhead lines, especially in difficult terrain or environment, urban areas, industrial plants & with high land prices
in addition to the major projects with large system lengths in metropolises, cable projects are found in the most remote regions of the world, very often connections within cavern hydropower plants between main transformer and switchgear
very high wealth of experience in design, grounding concepts, transportation, laying and fixation concepts is required for such projects
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France © 22.06.2015 - Andreas Weinlein - Slide 5
500 kV Moscow project
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
infrastructure project to establish the Skolkovo Innovation Center
replacement of 500 kV double system overhead transmission line
customer: FSK-Meszentra (Russian National Grid Company)
70 km 500 kV XLPE cable
system length ca. 11 km (double system)
individual lengths between 400 - 600 m
138 joints, 12 outdoor sealing ends
project time: 17 months
dry plug-in sealing end installed ingas filled outdoor bushing
adapted to temperatureconditions < -30°C
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France © 22.06.2015 - Andreas Weinlein - Slide 6
500 kV Moscow project
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
cable arrangement in trefoil formation, buried
buried joints in joint pits
one piece SiR type joint
cross bonded system
conductor size: 2500 mm²
insulation thickness: 27.5 mm
outer diameter: 150 mm
laminated sheath / weight: 39 kg/m
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France © 22.06.2015 - Andreas Weinlein - Slide 7
500 kV Moscow project
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
commissioning in May 2012 /17 months after order intake
on-site test set-up with 5 reactors
test voltage: 320 kV AC @ 26.5 Hz
test current: 129 A
test power: approx. 42 MVA
offline PD measurement by inductive sensors at sealing ends
additional online PD measurementby inductivesensors at alljoints / 6 unitssynchronous
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France © 22.06.2015 - Andreas Weinlein - Slide 8
400 kV London project
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
currently a number of 275 kV fluid filled buried cable circuits by National Grid (UK) to provide electrical power to the city of London
nearing the end of their service life are to be replaced
new 400 kV cable circuit connections installed in tunnels St Johns Wood - Highbury – Hackney
Willesden - Kensal Green - St Johns Wood
Kensal Green - Wimbledon
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France © 22.06.2015 - Andreas Weinlein - Slide 9
400 kV London project
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
four of ten 400 kV cable circuits between St Johns Wood - Kensal Green - Willesden already installed and commissioned in March 2015
double cable system each tunnel
one section 4 m tunnel to accommodate in addition to the two 400 kV circuits another four 132 kV cable circuits
in total about 32 km of cable tunnel is built
depth between30 - 60 m in theunderground of theCity of London
accommodate nearly200 km of 400 kVXLPE cables
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France © 22.06.2015 - Andreas Weinlein - Slide 10
400 kV London project
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
round segmental conductor of oxidised copper wires (2500 mm²)
central plastic core
ks-factor confirmed by routinemeasurements < 0.35
insulation thickness: 25 mm
longitudinal welded aluminiumsheath of 1.5 mm
outer PE consisting of two layers:red HDPE and black flameretardant MDPE identify damages
no conductive layer on the outersheath to avoid earth potentialproblems in the tunnel
no earthing system at all inside tunnel
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France © 22.06.2015 - Andreas Weinlein - Slide 11
400 kV London project
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
max. installation length: 1100 m
drums picked up in lots of 18 drumsto store on-site
flexible saddle system in verticalflat formation
axial spacing of 500 mm
spacing between brackets of 8.4 m
> 22,000 saddles
rating in forced ventilated tunnel: 2555 A / 1770 MVA (winter)
2310 A / 1600 MVA (summer)
airflows of 3.5 m/s - 8.0 m/s
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France © 22.06.2015 - Andreas Weinlein - Slide 12
400 kV London project
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
186 pcs. sectionalising joints: one piece body made of SiR
field control elements & screen separation integrated in the body
open cross bonding / SVL design inside tunnel with 21 kV surge arrester in delta connection at each joint
60 pcs. GIS plug-in compact sealing ends
completely dry & solid insulation
absolutely maintenance free & no need of any fluid or gas monitoring
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France © 22.06.2015 - Andreas Weinlein - Slide 13
400 kV London project
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
commissioning test: 260 kV AC / 1h (stage 1 in March 2015)
voltage supplied via test bushing to GIS CSE
inductive PD measurement with HFCT at each accessory synchronously via with optical fiber interconnected acquisition units
further commissioning tests: cable conductor resistances
circuit positive and zero sequence impedance
verification of cross-bonded sheath system
sheath system contact resistances
SVL operating voltage test
SVL visual inspection andinsulation resistance test
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France © 22.06.2015 - Andreas Weinlein - Slide 14
Advanced calculations and tests
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
side wall pressure test onEHV cable with longitudinal welded aluminium sheath
short circuit test of sheath connections on EHV cable with longitudinal welded aluminium sheath
mechanical load test of buried joint followed by waterimmersion & heat cycling test
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France © 22.06.2015 - Andreas Weinlein - Slide 15
Advanced calculations and tests
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
mechanical parameters of cables have increasing impact on the design of fixings & support structures for cables & their accessories
cable is fixed & no expansion is possible cable will exert a longitudinal force (cable thrust), e.g. at sealing ends
cables with a 2500 mm² copper conductor thrust potential in the range of 90 kN
sealing ends usually do not allow high axial forces or axial movement measures to reduce them
alternative to rigidly built bend below sealingends flexible bend cable can extend toand from (recommended for EHV cables)
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France © 22.06.2015 - Andreas Weinlein - Slide 16
Conclusions
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
technical solutions & concepts for development, manufacture, assembly, testing & operation are largely confirmed by the manufacturer
in 2 current huge projects - 500 kV Moscow project & 400 kV London project - with laminated sheath and longitudinal welded aluminium sheath - both with oxidised copper wire conductor - the reliability of the EHV XLPE cable system is shown
in contrast to alternative cable designs with e.g. enamelled wires, the oxidised wires allow jointing of the conductor without special treatment of single wires, accelerating overall jointing, while still gaining from the same ks-factor (AC resistance) improvement
laminate sheath design likewise allows for aresilient and easy handling of the screen on sitefor cable layings and accessory installationscompared to lead or (corrugated) aluminiumsheaths
• Jicable’15,21‐ 25June 2015‐ Versailles‐ France• Jicable’15,21‐ 25June 2015‐ Versailles‐ France
A1.1 Worldwide experiences and challenges with EHV XLPE cable projects 330 kV to 500 kV
Thank you for your attention
© 22.06.2015 - Andreas Weinlein - andreas.weinlein@suedkabel.com
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