XLPE CABLE The ultimate guide

Chapter 1: Introduction

SSG Cable is the leading manufacturer and supplier of XLPE cable. Our XLPE Cables are manufactured in accordance with British, European and international standards.

We have over decades experience of supplying XLPE  insulated cable worldwide.

For over the years SSG Cable has been bestowed with many certifications. We have a broad portfolio of cable and wire products. Phenomenal success has enabled us to achieve excellent status as the largest cable manufacturer.

SSG Cable has ensured sophisticated research and development capabilities. We have maintained a constant upgrading system for our XLPE Cables.

Our XLPE Cable has gained worldwide recognition for its premium quality. If you are in need of XLPE Cable and you have a clear mind of what you won’t let us know. We have customer care services available 24/7 to receive your orders. Make your order today and get to enjoy an exclusive discount.

Our delivery services are fast, efficient and effective. We can over shipment services regardless of your destination. Once you make an order it takes us 5 days to process it and deliver. Work with us today and let us know how best we can serve you.

We uphold our universal values to ensure total customer satisfaction. We have received prestigious certifications from our incredible services. We are also ISO certified.

Our XLPE  Cable is designed to operate under any sever environments.

No minimum order quantity. Make an order of your choice and we will deliver promptly. For more information read through our outline to know more about XLPE Cable.

What is XLPE Cable?

XLPE cable are simply refers to XLPE insulated cable, which can be XLPE power cable, XLPE armoured cable, XLPE swa cable based on applications.

XLPE is an abbreviation for cross-linked polyethylene. We produce XLPE Cable from polyethylene under very high temperature and pressure.

We use organic peroxide as the additive.  The high temperature and pressure are for the cross-linking effect. Cross-linking is where individual molecular chain link with one another. This linking causes the material to change from thermoplastic to elastic.

Our XLPE has a low dielectric loss. This makes them important insulation for low and high voltage cables. The good thing with or cable is that the dielectric loss is about one decimal lower than other cables. Since the dielectric of XLPE Cable is constant the mutual capacitance is also lower. This reduces the charging and earth-leakage currents without the rigid star pointing the earthing in networks.

You can use XLPE Cable in building services, cooling systems, domestic water piping, etc. You can also use it for offshore oil and gas transportation. Chemical and sewage transportation is also another use of XLPE Cable.

Make your project a success by using XLPE Cable from SSG Cable. Our support team will ensure one year guarantee for every single order. `
<h2id=”Chapter 2″>Chapter 2: How are XLPE Cables Manufactured?

We manufacture XLPE Cable at SSG Cables. We manufacture both medium and high voltage XLPE Cables.

We make use of the recent technology available in the field. Our plant uses an integrated high-performance extraction line. This extraction line we use it to minimize the risk of introducing external contamination. This line comprises of a triple layer crosshead and water-free curing.

It also has a cooling gas vulcanization process.

At first, the conductor is made through a metering capstan. We also refer to it as the line speed master point. In order to manufacture XLPE Cable we use the following components;

• A triple extruder crosshead
• A vulcanizing tube
• A monitoring unit
• Haul-off caterpillars.

The triple crosshead allows simultaneous extraction of the cable insulation. It also allows 2 semi-conducting screens with a high degree of smoothness.

All this is done to ensure no voids or external contaminants are introduced. To achieve precise temperatures at the cross-head we use multiple zone control temperatures.

At the vulcanization stage, we cure the triple extruded cable in an inert pressurized gas tube. After it’s heated to the required temperature material to enable cross-linking. We vary the curing temperature and time in order to achieve different cure percentages. Our customers might require different cure percentages.

In the monitoring unit, various functions of our integrated excursion line are monitored and controlled. Some of the functions include; line speed, curing tube temperatures among others.  We have automated computers to ensure the production of quality ramps.

Some of the calculated parameters are present in our control unit. We have a closed-circuit TV system for ensuring the running of the cables.

What is the structural design of XLPE Cable?

Our XLPE Cables design conforms to the international standards and those of IEC. Our XLPE Cable is designed to have circular conductors. We are also thinking of introducing single core construction later. The conductors are made of stranded aluminum and copper which is compacted.

Special care should be taken to the conductors to ensure a smooth profile free from sharp juts. This jut may damage the insulation of the cable due to high electric stress.  We supply all medium XLPE insulated Cable with extruded semi-conducting screens. This screen helps to protect the main solid XLPE insulation.

The conductor screen provides a smooth circular envelope around the conductor. This diminishes the concentration of the flux lines around the individual wires. It also diminishes electrical stress around the conductor.

Our insulating screen can either be strip cable or bonded. It depends on the order specifications you give us. You can use a bonded screen for high voltage cables.

An earthen envelope will be provided by the copper wires over the extruded insulation screen.

We pass the XLPE Cable through a testing program to ascertain its quality and performance.

We test them for;

– Partial discharge stability

–  Its ability to withstand the impulse

– Moisture resistance

– Dielectric stress and overload current.

Testing procedures of  XLPE Cable

We employ the following testing procedure for XLPE Cable.

Routine test- this text involves monitoring overall cable quality and function. Some the test we perform in this process include;

• High voltage test for our XLPE Cable
• The conductor resistance
• Insulation resistance
• We also perform a voltage test on protective sheath coverings.

Type test- We also perform the type test for calibrating and validating cable design type. This type of test includes;

• Corona level test
• Dielectric thermal resistance test
• Heat distortion test
• Thermal stability test
• Bending text and impulse voltage test.

Special purpose test- we conduct a special purpose test to ensure major design cable changes conform to a proper performance threshold.

After installation test- We conduct this certain test to ensure the cable installed is in optimum operating conditions. We can do this test after installing the XLPE Cable in your machine. Some of the activities under this test include;

• Conductor resistance test on the completed circuit
• Verification test of the cross bonded system
• Surge diverge test.

After all this test now the XLPE Cable is safe for use. All these tests are done at SSG Cable labs. We have a team of qualifies engineers to ensure every test is run effectively. We also have a support team that provides you with any support you might need to be thought your project.

We ensure standards and high compliance is maintained. Our technical experts are available via our technical hotline.

Chapter 3: What are the benefits of using XLPE Cable?

There are a lot of benefits accrued from using XLPE Cable from SSG. The polyethylene material itself has excellent dielectric strength.

It also has high insulating resistance and a low dissipation factor at all frequencies. All these make the polyethylene an ideal insulator.

XLPE Cable is flexible- they can bend into a wide radius turn. It can also accommodate turns by using elbow joints.

It can also handle short radius turns supported with a metal brace. We also provide elbow joints in case of sharp turns.  This elbow joints can help you connect two XLPE Cable on a 90˚ turn.

Easier installation- Installing the XLPE Cable is very easy. It’s also labor-intensive to some extent. Once you have worked with XLPE Cable you will never change your mind.

Non- corrosive- XLPE Cables don’t corrode. They are not subject to corrosion from minerals or moisture.

Environmental friendly- polyethylene does not cause any environmental degradation. It is not harmful at all to the environment.

Excellent electrical and physical properties- XLPE Cables are the best cable for transmission and distribution lines. There physical properties and electrical properties are excellent.

Capabilities of carrying large current- the excellent resistance of XLPE Cable to thermal deformation permit it to carry a large current. They also have excellent aging property.

It does not experience height limitation and maintenance- You can install XLPE Cable anywhere without special consideration of the route profile. It does not contain oil and thus free from failures caused by oil immigration.

It doesn’t require metallic sheath- Our XLPE Cable doesn’t need a metallic sheath. This makes it free from failures peculiar such as corrosion and fatigue

 

Chapter 4: What are the different types of XLPE cables?  

We supply different types of XLPE Cables depending on our customer’s instructions. Some of the top listed in our sales include the following;

XLPE insulated unarmoured sheathed Cable 0.6/1 (1.2) kV

• It’s a single-core and multi-core cable. The conductor is made of copper or aluminum. They conform to IEC requirements.
• The conductor is a plain circular shaped traded copper or aluminum.
• The insulation is cross-linked polyethylene rated at 90˚C
• Colors for core identification we have;

-single core is natural black. The two cores are red and black. For 3 cores we have red, yellow and blue. For 4 cores we have red, yellow, blue and black. Brown may also be an optional color.

• The sheath is made of PVC type and it’s black in color.
• These cables are designed for general use. You can use them even in underground levels where they are not likely to suffer mechanical damage.

XLPE insulated armored sheathed cable 0.6/1 (1.2) kV

Use these cables for underground burial where there is a risk of mechanical damage. It’s a single-core and multi-core cable. The conductor is made of copper or aluminum. They conform to IEC requirements.

The conductor is a plain circular shaped traded copper or aluminum.

The insulation is cross-linked polyethylene rated at 90˚C

Colors for core identification we have;

-single core is natural black. The two cores are red and black. For 3 cores we have red, yellow and blue.

The armor can be single-core or multi-core. Single-core armor the aluminum wire is applied over the PVC bedding. For multicore the galvanized steel wire is applied over the PVC bedding.

The sheath is PVC type ST2 color black.

XLPE insulated, per inner sheath, screened and per sheathed underground cable 0.6/1 (1.2) kV

The conductor is circular compacted and aluminum shaped stranded.

It is made up of four cores assembled together with a non-hygroscopic filter.

The conductor is a plain circular shaped traded copper or aluminum.

The insulation is cross-linked polyethylene rated at 90˚C

The colors for the identification of the 4 cores are red, yellow, blue and black.

The inner sheath is made of medium-density polyethylene

The metallic screen is copper taped.

They can be used for general use since they are not likely to suffer from mechanical damage.

Single-core XLPE xlpe cable insulated unarmoured sheathed cable for voltages 6.6kV up to 33 kV

• The conductor is circular stranded with copper or aluminum.
• The conductor screen is made of an extruded layer of semi-conductive compound
• The insulation is cross-linked polyethylene rated at 90˚C
• The insulation screen can be metallic or non-metallic. The metallic part is made of copper wire or copper tape. The nonmetallic is made of an extruded layer of semi-conductive compound.
• The outer sheath is color black
• This cable is installed on trays, ducts or direct burial.

If you are in need of any of our cable they are available. We manufacture XLPE Cables according to your specifications.  Also, PE out sheath is available upon request.

Chapter 5: When should you use XLPE cable?

XLPE Cable should be used in industries that expose wire and cable to extreme temperature conditions. Extreme temperatures can be high or low.

The cable should also be used in applications that require high voltage electricity. XLPE Cable is also used in chemical and other hazardous materials. They also find application in conditions requiring abrasion, stress, water, and other liquid environments. It can also be used in plumbing, mining, and various electrical applications.

Cross-linked cables can also be found across the chemical industry and heating industry.

In dental application during dental restoration.

In automotive ducts and housings- XLPE Cable is widely used in the automotive industry for cold air and filter housings. Its properties of high-heat deflection and good impact resistance makes it considerable.

In artificial joints as a wear-resistant material.

Chapter 6: What are some of the industries using XLPE cables?

Many different industries across the world have taken advantage of our XLPE Cable. Some of the common industries which use XLPE Cable from SSG include;

• Plumping industry

XLPE Cable has become more popular in mot plumping industries due to its flexibility during installation. It also resists corrosion and performs well under a wide range of temperatures. This allows it to transports both heated water and cold water.

To easily differentiate the cable for cold and hot water check the color. Hot water is red and cold water is blue.

• Mining industry

A lot of money is spent on installing, repairing and maintaining mining cables. XLPE Cable due to its installation characteristics reduces all of those factors. Because it can withstand extreme pressure and a temperature it performs efficiently in mine industries.

• Chemical industry

XLPE Cables can withstand all kinds of chemicals without reacting with them. Its ability to withstand acidic corrosion and heat make it a perfect choice for these chemical industries.

It also helps in decreasing the chance of stress cracks in the lining. The final process lasts longer due to the strength and durability of these XLPE Cables. This saves you money over the long run due to less maintenance repair costs.

Chapter 7: What’s the difference between XLPE cable and PVC cables?

XLPE Cable is a cross-linked polyurethane material. PVC Cable polyvinyl chloride insulated.

XLPE Cable can be used for both high and low tension applications. PVC Cable is used for low tension applications.

XLPE Cable structure provides great resistance to stress, wear, and tear. PVC Cable cannot withstand much pressure.

XLPE Cable insulation tends to last longer than that of PVC Cable. XPLE Cable is more environmentally friendly compared to PVC since it doesn’t contain chloride.

XLPE Cable insulation can withstand high temperatures compared to PVC Cable.

The cross-linked polyethylene features in XLPE Cable provides more moisture resistance. PVC Cable doesn’t contain polyethylene hence no moisture resistance.

Looking at the differences you find that XLPE Cable is better than PVC Cable. Make a wise choice today and let us offer you the best.

Chapter 8: What are the properties of XLPE cables?

Low-temperature impact strength- XLPE Cable does not melt on exposure to high temperatures.

Hardness and rigidity- through cross-linking the hardness and rigidity are somehow reduced.

It is resistance to environmental stress cracking. The crosslinking enhances the temperature properties of the base polymer.

We have modified XLPE insulation to limit the number of gases generated during crosslinking. This is particularly useful for high and low voltage cables.

Our XLPE Cable has a maximum rated temperature of 90˚C. They have an emergency rating of up to 140˚C. The required degree of crosslinking according to the IEC standard is between 65% and 85%.

A higher degree of crosslinking could result in stress cracking of the XLPE Cable. A lower degree will result in poor properties of the Cable.

The conductor of the cable is plain stranded copper or aluminum. We have the best cables with the best properties.

Chapter 9: Why use XLPE lug and XLPE ferrule with XLPE Cable?

We fix Lugs and ferrule to our XLPE Cable by inserting the conductor into the tube of the device. Then we squeeze the barrel onto the conductor to form a secure mechanical and electrical joint.

In order to achieve that mechanical joint, the right lug or ferrule needs to be selected. The method of selection depends on the cable used and the area of application.

Some of the reasons we use ferrule and lug on our XLPE Cable include;

Lugs have a thicker wall, improving the crimp and therefore better heat dissipation

Lugs have no inspection window which aids the sealing of the cable end.

XLPE Cable is a compacted cable meaning it has smaller core sizes than the standard cable.

The internal diameters of lugs and ferrules are smaller than the standard lugs and ferrule. This helps o fit the XLPE core size and prevent over crimping.

XLPE Cables are used mainly in distribution networks to prevent moisture content.

Chapter 10: Where can I order XLPE cable?

You are in the right place. At SSG Cable you can get an XLPE Cable of your desired specification. We offer various types of XLPE Cables like mining cable, marine cable, high voltage cable, solar cable, submarine cable, offshore power cable etc.

Contact us today or give us a call. Our delivery services are incredible. Our expert team will help you identify which XLPE Cable is perfect for your next job.

SSG Cable is the leading manufacturer and supplier of many different types of cable. XLPE Cable continues to become more and more popular. Welcome to SSG Cable both old and new customers all over the world. We have the best prices for your XLPE Cable.

 

Things to consider when selecting XLPE Cable manufacturers

You need to look at the certifications – cable must carry the required ISO certification.

Check the specification- XLPE is only the insulation. So you are essentially looking for the right writing.

Check also the voltage capacity

Check whether you need single or multiple core cable. Multiple cables are more flexible.

XLPE Cable is usually bought for long term use. So you need to invest in a good quality cable from a reliable XLPE cable manufacturer.

Chapter 11: XLPE Cables at SSG Cable Inc. R&D Co., Ltd

SSG Cable is proposing future directions by developing differential technologies in cables. Our key search areas include preparing a foundation for XLPE insulated cables and MV insulation. A study on increasing reliability of existing cable by securing CAE development.