XLPE ARMOURED CABLES GUIDE
Introduction:
XLPE armoured cables are becoming popular day by day due to their unique characteristics. SSG is one of the leading manufacturers which supplies a wide variety of cables including XLPE cables.
If you are in need of XLPE cables, we are here to provide you best-quality XLPE armoured cables. Contact us and our experts will provide you perfect XLPE cables.
SSG is always here to offer you unique and polished material.
Chapter 1: What are the XLPE armoured cables?
They are hydronic tubing consist of polyethylene plastic. That is why XLPE cables are also known as polyethylene cables. XLPE molecules are bonded three-dimensionally and are usually used in both low and high temperatures.
XLPE insulation is used in XLPE armoured cables that make the cables tremendously resistant to scratch, damage, high voltage electricity, and harmful materials.
So, XLPE armoured cable is a reasonable option.
XLPE armoured cable is a type of multi-conductor control and power cable. This type of cable is a cross-linked and a flexible cable.
By applying this process of cross-linking a very hard material is generated that is very much heat resistant and it doesn’t get soft at high temperature. These cables are ideal for power transmission.
Chapter 2: what are the applications of XLPE armoured cables?
XLPE armoured cables can be used in various situations.
They can be used in extreme conditions of temperature whether it is low or high.
They are applicable in electrical applications of high voltage.
XLPE armoured cables are also useful in mining.
They can be used in plumbing as well.
They are used in cable ducting and underground systems.
They are commonly used in chemical industries.
Cross-linked polyethylene wires are utilized in residential as well as commercial heating industry.
They are also found in medical institutions and stadiums as well.
Chapter 3: What is the Structure of XLPE insulated armoured power cable?
XLPE insulated armoured cables are made up of copper or aluminum to make the stranded conductor. The conductor is insulated with PE, PVE or XLPE compound.
The accumulated cable is full of PVC compound to fill the gap between cores and solidify the cable. They are armoured with a single layer of steel wires of a suitable size.
A sheath of PVC compound is used as the armour.
Aground aluminum conductor is first curtained as a semi-conductor extrusion that gives a flat conductor surface.
Moreover, it stops cavity formation at the conductor’s surface during the cable bending. The conductor that is screened is shielded with the XLPE compound.
The insulation material is also screened with a non-metallic semi-conductor layer.
Chapter no. 4: What is the manufacturing process for XLPE cables?
For producing XLPE cables of high and low voltages, the latest technologies are used.
These cables are produced by integrating a high-performance expulsion line which contains a three-layered water-free dry curing and cooling process.
The benefit of using this type of expulsion line is that it lessens the risk of exterior impurities. Also, it yields a higher quality of XLPE cables.
The conductor is applied by a metering capstan, a triple extruder crosshead, and a vulcanizing tube and some monitory unit.
By using a collection of these three extruders, a triple crosshead enables immediate expulsion of the insulating material of cable. It also allows semiconductor screens with a higher amount of smoothness and introduces outdoor impurities.
By using multiple zone temperatures controls are achieved at crossheads by using stable and detailed temperatures.
When performing the process of water-free CDCC gas vulcanizing, the triple extruded cable core is an inert gas tube. Then this is heated to the temperature which is needed for material cross-linking.
According to the customer’s needs, temperature and times can be achieved. Also, different cure percentages can be achieved in accordance with the user’s requirements and needs.
There are computer systems that are used to monitor and control the extrusion line and curing tube temperatures. This automation by computers is done to ensure the production of quality products.
The ramp parameters are collected and can be preset on the control unit. A closed television system is also used for the purpose of running the lines.
Modern XLPE cables contain a metallic armour, solid cable core, and a non-metallic outer sheath. The XLPE cable core contains a conductor which is covered with semiconductor tapes.
Its core also consists of an inner semiconductor layer and solid main insulation and outer layer.
The three layers are all ejected in one process. The conductor used in high voltage XLPE cables is produced by copper or aluminum.
It can also be a strand of single wires so that there should be a lesser current loss.
The designing of XLPE cables complies with international standards which similar to IEC 60502 and IEC 60840.
Generally, only one single-core construction is done in XLPE cables insulated for higher and medium voltages. Also, circular conductors are used in these XLPE wires.
The conductors used may be made up of compact aluminum or stranded copper.
Also, special care is taken to make sure that a smooth profile should be made so that there is no damage from high local electric stresses.
For the protection of the main solid XLPE insulation, XLPE cables for medium voltages are supplied with cross-linked semiconducting screens.
These conductor screens provide a smooth circular casing around the conductor. Also, it fills the spaces between the wires.
This thing reduces the attentiveness of flux lines covering individual wires. Also, it lessens the electrical stresses about the conductor.
A thick layer of copper wires is also used over insulation screens and provides an earthed covering.
Chapter no. 5: What are the varieties of XLPE armoured cables?
XLPE Steel wire armoured cables
SSG provides you with all kinds of XLPE cables. They include low voltage XLPE cables and high voltage XPLE cables. Moreover, steel wired XLPE cables, as well as BS5467 cables, are also provided by SSG.
There is a range of XLPE armoured cables. For instance, steel wire armour XLPE insulated cables and aluminum wire armour XLPE cables.
These cables are manufactured to be used in appliances where there is a threat of mechanical stress. They are also used in situations where safety is required for mechanical destruction.
Steel wire XLPE cable is usually used for the transfer of main power and for supplementary control cables in diverse situations.
These situations may involve aerial power networks, underground systems and cable ducting.
Steel wire XLPE cables are installed directly. They can be installed into draining soil because they are not damaged easily.
These wires are appropriate to clip straight onto a surface, a tray or in free air.
XLPE cables are available as single-core as well as multicore cables. These cables are accessible with PVC outer sheath and steel wire armour. The conductor is armoured with XLPE insulation.
They can also be available with LSZH sheath for the situation where the discharge of smoke and noxious fumes can make a dangerous moment to life and sensitive apparatus in fire breaking.
HV XLPE Armoured Cables
Most of the high voltage cables that are sold currently in the market for power transmission are insulated by a sheath of XLPE.
Some cables may have a conjunction of XLPE insulation with a lead or aluminum jacket to allow for fiber optics.
Before 1960, power cables which were undergrounded ran in a rigid steel pipe, or a semi-rigid aluminum or lead jacket or sheet were insulated with oil and paper.
To prevent the formation of voids within the cable insulation, the oil was kept under a pressure that would allow partial discharge.
Worldwide there are still many cables in use which are oil-and-paper insulated. Polymers became more widely used mostly EPDM rubber (ethylene propylene dyne M-class), between 1960 and 1990 at distribution voltages.
However, their relative unreliability resulted in a slow adoption, particularly early XLPE, at transmission voltage.
This has occurred in recent decades that cables of 330kV are commonly constructed using XLPE.
XLPE BS5467 cables
These cables are thermosetting armoured cables with voltage about 600/1000V. These cables are made according to a British standard BS5467.
Specifications of British standard BS5467 include the demands for armoured cables having low voltage. These armoured cables can be both multicore and single core.
These wires are insulated with thermosetting of voltages up to 1000V.
XLPE BS 5467 are single-core wires. They are made up of copper and aluminum conductors. The conductors are insulated with Cross-linked polyethylene (XLPE) bedded with polyvinyl.
XLPE BS5467 cables are used to transfer power in electric transmissions. They are used to transfer electric power in the supply system of 35kV or in lower.
It usually functions in the power fields as well as construction areas. Furthermore, it is applied to the mines, petrochemical production industries as well as metallurgy.
BS5467 XLPE insulated cables are used for mains distribution, installation of wirings in industrial areas and in those areas where there is the risk of mechanical damage.
BS5467 cables are also used in areas where protection is needed.
BS5467 XLPE insulated cables define several cores, for example, single-core, two cores and up to 48 cores of auxiliary cables.
Stranded Copper and solid aluminum can be used as the conductor to be galvanized.
This standard enables color-coded or number coded recognition. These cables having low voltage are insulated with cross-linked polyethylene (XLPE) and polyvinyl chloride.
BS5467 XLPE insulated cables are power cables which are used at a large scale internationally.
These cables are resistant and are ideal for underground, indoor and outdoor areas that don’t need additional protection.
These cables don’t need additional protection because of their mechanical protection which made them UV stable and water-resistant. These cables are used in applications with low smoke zero halogen armour.
Standard core colors of BS5467 XLPE insulated cables
| Single-core: BS5467 single-core cables can be available in two colors; blue or brown. |
| 2 core: BS5467 2 core cable is also available in blue and brown color. |
| 3 core: BS5467 3 core cable is available in three colors; brown, black and grey. |
| 4 core: BS5467 4 core cables are available in brown, black, blue and grey color. |
| 5 core: BS5467 5 core cable is available in black, grey, brown, blue, green or yellow color. |
| 7 to 48 cores: These BS5467 cables are available in white with printed numbers. |
These cables can be customized in different colors on the customer’s request.
Chapter no. 6: What are the advantages of XLPE cables?
- Outstanding Physical and Electrical characteristics:
Due to the brilliant electrical and physical properties of XLPE cables, these are ideal cables for transmission and distribution lines.
- Ability to carry large currents:
XLPE cables can carry a larger amount of currents under normally 90-degree centigrade and in an emergency 130-degree centigrade.
Also in the case of the short circuit, it can carry current under 250-degree centigrade.
This capability of carrying a larger current is due to its excellent resistant to thermal deformation.
XLPE cables are able to endure small radius ending and these are very lighter in weight as well. Due to its lighter weight and small bending radius, they provide easy and reliable installation.
Moreover, the method of joining them and the termination process is much easier than other types of cables.
It is easier to install XPLE cables anywhere without height limitations because it doesn’t contain oil. So due to this, there is less chance of failures due to oil migration in oil-filled cables.
XLPE cabled provides you an outstanding mechanical and electrical protection. Also, these cables provide resistance against water and radiation.
It is almost ideal to use these cables where electrical connection is in line. Also, they are ideal for signal control lines and for firing X-ray high voltage line and power transmission.
- No need of Metallic sheath:
These cables do not need any kind of metallic sheathing. So one of its advantages is that there are fewer chances of failures due to corrosion and fatigue.
Other benefits:
Some other benefits of XPLE cables are as follows:
- XLPE cables can perform working with voltages that range 600V to 35 KV.
- XLPE cables give mechanical protection to the wires.
- These XLPE cables can endure high pressures.
- By using XLPE cables, you are able to resist damage caused in underground areas.
- XLPE wires are so advantageous that they can resist every type of weather.
- XLPE cables provide Thermal resistance.
- These cables allow high conductor operating temperatures and reduce short circuits.
- XLPE is much flexible than other cable types.
- XLPE cable is a very cost-effective and efficient method than other cable types.
- XLPE cables improve heat deformation.
- XLPE also enhances mechanical properties and provides heat aging performance.
- XLPE improves the chemical stability of wires.
- It provides resistance to solvents.
- These wires are resistant to radiation.
- These cables are waterproof.
- These cables can be used for both high voltages and medium voltages as well.
- They can endure higher temperatures than other cable types.
- They have a high overload capacity.
- These cables are lighter in weight.
- They have a smaller bending radius and lesser installation costs.
- These cables have a high short circuit rating.
- These cables have lower dielectric power.
- Power can be saved by using XLPE cables.
- XLPE insulated cables are durable and last longer than other insulations.
- XLPE armoured cables are environment-friendly as they do not comprise of chloride.
- XLPE cables can work well even in higher temperatures.
- These cross-linked polyethylene cables are also moisture resilient.
Chapter no. 7: Which types of tests are taken during XLPE production?
In the manufacturing process of XLPE cables different types of tests are taken which are as follows:
Special Tests:
These tests are performed to make sure that the design of these cables is perfect. Major design changes are performed in this type of test.
Routine Tests:
These tests are performed by routine wise. The purpose of performing these routine tests is to maintain and monitor the quality of XLPE cable and also it’s functioning. Following tests are included in this routine testing:
- High voltage tests
- Insulation resistance testing
- Conductor resistance tests
- Voltage tests on protective armour coverings
Type tests:
Type tests are taken to verify types of cable designs. These tests include the following tests:
- Bending Tests
- Impulse voltage tests
- Heat alteration tests
- Thermal constancy tests etc.
After installation tests:
These tests are performed after the installation of the cables. These tests are taken to ensure and find that cables are installed in the best-operating conditions or not.
Following tests are taken during after installation tests:
- Conductor resistance
- Verification tests
- Surge diverter tests
Chapter no. 8: What is the Production range of power cable?
There is a range of XLPE power cables.
XLPE insulation PVC sheath power: it is used indoors, cable pipe or in tunnels.
XLPE insulation PE sheath power: it is also used indoors, cable pipes, tunnels and outdoors as well.
XLPE PVC sheath power cable (steel tape armour): This cable is used in underground cabling systems because it can bear mechanical force but cannot survive in great pulling force.
XLPE PE sheath power cable (steel tape armour): it is laid underground and is similar to XLPE PVC sheath power cables (steel tape armour).
XLPE insulation PVC sheath power (thin steel wire armour): it is suitable to the inside water and can be dropped in the bad soil.
XLPE insulation PVC sheath power (thick steel wire armour): it is appropriate to underwater with the end of the sea. It can endure the higher pressure.
Chapter no. 9: What are the features of XLPE armoured cables?
The main characteristic of the XLPE insulation is its three-dimensional bond structure. Due to the three-dimensional bonding structure, they are very strong.
As the cross-linking process is involved in the manufacturing of XLPE armoured cables, they are thermally stable.
These cables have good thermal deformation resistivity because of its ability to deal with high temperatures.
Due to this marvelous feature, they have a higher capacity to carry the electric current than other conventional cables.
Cables with XLPE insulation have dielectric power causing low dielectric loss, unlike other conventional cables.
Another feature of XLPE armoured cables is that they are sufficient for high voltage. They are even suitable for extra-high voltage e.g. up to 132kV.
They can be used in high voltage transfer systems for long routes of cables. They are applicable to long-distance cable routes where dielectric loss can play a key role.
The XLPE armoured cables can be handled with ease due to their low weight unlike other cables of high voltage.
These cables can be installed for vertical or inclined areas without being reluctant. They can installed in this way because there is no chance of oil passage from the insulation.
An excellent feature of XLPE armoured cable is its highly resilient nature for moistness. Due to this nature of XLPE, there is no need to be precautious about their joining or termination.
Connection of XLPE armoured cables takes less time than other same level conventional wires.
XLPE armoured cables can be used in a safe mode on vibrating designs such as bridges etc. furthermore they are fire-resistant as well.
Also, there is no issue of aging as they have a longer life.
