POWER AND COMMUNICATION CABLES Theory and Applications

Transcription

1 POWER AND COMMUNICATION CABLES Theory and Applications Edited by R. Bartnikas, Editor Institut de Recherche dhydro-quebec Varennes, Quebec, Canada K. D. Srivastava, Coeditor University of British Columbia Vancouver, Canada IEEE Dielectrics and Electrical Insulation Society, Sponsor IEEE Industry Applications Society, Sponsor IEEE Power Electronics Society, Sponsor POWER ' ENGINEERING _ - P. M. Anderson, Series Editor IEEE McGRAW-HILL PRESS New York San Francisco Washington, D.C. Auckland Bogota Caracas Lisbon London The Institute of Electrical Madrid Mexico City Milan Montreal and Electronics Engineers, Inc., New Delhi San Juan Singapore New York Sydney Tokyo Toronto

2 CONTENTS PREFACE XIX ACKNOWLEDGMENTS XXI CHAPTER 1 CABLES: A CHRONOLOGICAL PERSPECTIVE R. Bartnikas 1.1 Preliminary Remarks 1.2 Power Cables Oil-Impregnated Paper Power Cables Oil-Pressurized Power Transmission Cables Solid-Dielectric-Extruded Power Transmission Cables Solid Extruded Dielectric Power Distribution Cables Underwater or Submarine Cables Low-Loss Power Transmission Cable Systems Compressed SF6 Gas Power Transmission Cables Superconducting Power Transmission Cables 1.3 Communication Cables Introduction Twisted-Pair Communication Cables Coaxial Cables Optical Fiber Cables CHAPTER 2 CHARACTERISTICS OF CABLE MATERIALS R. Bartnikas 2.1 Introduction 2.2 Metallic Conductors 2.3 Conductor and Insulation Semiconducting Shields 2.4 Insulation Dielectric Characteristics of Solid and Solid-Liquid Systems Oil-Impregnated Paper Extruded Solid Dielectrics Natural Rubber Butyl Rubber Ethylene-Propylene-Rubber Silicone Rubber Polyethylene VII

3 VIM Contents Crosslinked Polyethylene Comparison of EPR and XLPE Insulation Tree-Retardant XLPE Synthetic Solid-Liquid Insulations Gas-Solid Spacer Insulating Systems 2.5 Materials for Protective Coverings Nonmetallic Sheaths Metallic Sheaths 2.6 Armoring Materials 2.7 Coverings for Corrosion Protection 2.8 Conclusion 2.9 Glossary of Cable Materials Technology CHAPTER 3 DESIGN AND MANUFACTURE OF EXTRUDED SOLID-DIELECTRIC POWER DISTRIBUTION CABLES H. D. Campbell and L J. Hiivala 3.1 Introduction 3.2 Design Fundamentals Inductance Capacitance Electric Stress Insulation Resistance Dissipation Factor 3.3 Design Considerations Ampacity Shield Circulating Currents Proximity, Skin Effect, and Eddy Currents Emergency Overload Rating Earth Interface Temperatures Short-Circuit Currents Electric Stress Cable Insulation Levels Dielectric Loss 3.4 Design Objectives Partial Discharge Temperature Ratings Conductor Constructions Shields and Jackets Portable Cables Aging of Underground Cables 3.5 Solid-Dielectric Insulation Techniques Compounding Extrusion Vulcanization Recent Developments 3.6 Related Tests CHAPTER 4 EXTRUDED SOLID-DIELECTRIC POWER TRANSMISSION CABLES L J. Hiivala 208

4 Contents IX 4.1 Introduction Historical Overview Development Trends 4.2 Design and Construction Conductors Semiconducting Conductor and Insulation Shields Insulations Thermoplastic Polyethylene Crosslinked Polyethylene Ethylene-Propylene-Rubber Metallic Shields and Sheaths Tapes and Wires Laminate Shield Lead Alloy Sheaths Corrugated Sheaths Protective Coverings Polyvinyl Chloride Polyethylenes 4.3 Manufacturing Methods Compounding Extrusion Crosslinking (Curing) Methods 4.4 Testing Development Tests Prequalification Tests Type Tests Sample Tests Routine Tests Electrical Tests after Installation 4.5 Accessories Preparations for Installation Extruded Cable Terminations Extruded Cable Joints (Splices) Tape-Wrapped Joints Field-Molded Joints Prefabricated/Premolded Joints Extrusion-Molded Joints Transition Joints 4.6 Concluding Remarks CHAPTER 5 DESIGN AND MANUFACTURE OF OIL-IMPREGNATED PAPER INSULATED POWER DISTRIBUTION CABLES W. K. Rybczynski 5.1 Brief History of Development 5.2 Elements of Solid-Type Oil-Paper Cable Design Voltage Rating Insulation Levels Selection of Conductor Size Selection of Conductor Material and Construction Selection of Insulation Thickness Cable Impregnation Metallic Sheaths Protective Coverings

5 Contents Extruded Nonmetallic Coverings Fibrous Nonmetallic Coverings Metallic Coverings 5.3 Cable Manufacture Hot Rolling of Copper Wire Bars Cold Drawing of Wires Annealing Conductor Stranding Insulating and Shielding Laying-Up Operation Impregnation Application of Lead Sheath Application of Protective Coverings and Armor 5.4 Tests 5.5 Electrical Characteristics 5.6 Conclusion CHAPTER 6 LOW-PRESSURE OIL-FILLED POWER TRANSMISSION CABLES W. K. Rybczynski 6.1 Introduction 6.2 Elements of Oil-Filled Cable Design Voltage Ratings Insulation Levels Selection of Conductor Sizes Selection of Conductor Material and Construction Selection of Insulation Thickness and Electrostatic Shields Dielectric Liquid Impregnants Metallic Sheaths Reinforcement of Lead-Alloy-Sheathed Cables Protective Coverings 6.3 Cable Manufacture Self-Supporting Conductor Insulation and Shielding 6.4 Tests Routine Tests Tests on Specimens 6.5 Electrical Characteristics Dielectric Power Factor Ionization Factor Alternating-Current Withstand Voltage Level Impulse Withstand Voltage Level 6.6 Principles of Oil Feeding 6.7 Notes on Sheath Bonding 6.8 Limitations of LPOF Cables 6.9 Self-Contained High-Pressure Oil-Filled Cables 6.10 Self Contained Oil-Filled Cables for dc Application CHAPTER 7 HIGH-PRESSURE OIL-FILLED PIPE-TYPE POWER TRANSMISSION CABLES W. K. Rybczynski 296

6 Contents xi 7.1 Introduction Principles of Operation Elements of Cable Design Voltage Rating Insulation Levels Selection of Conductor Sizes Selection of Conductor Material and Construction Selection of Insulation Thickness and Electrostatic Shield Impregnating Oil Moisture Seal and Skid Wires Carrier Pipe and Pipe Coating Coordination of Pipe and Cable Sizes Pipe Filling Oil Cable Manufacture Tests Routine Tests Tests on Specimens Electrical Characteristics Dielectric Power Factor Ionization Factor Alternating-Current Withstand Voltage Level Impulse Withstand Voltage Levels Principles of Oil Feeding Cathodic Protection Limitations of HPOFPT Cables Development of HPOFPT Cable for Higher Voltages in the United States Gas-Type Cables Gas-Filled EHV Cable Beaver and Davy Gas-Filled Cables Hunter and Brazier Impregnated Pressure Cables Pirelli Gas-Filled Cable High-Viscosity, High-Pressure, Gas-Filled Pipe-Type Cable Gas Compression EHV Cables Concluding Remarks CHAPTER 8 VOLTAGE BREAKDOWN AND OTHER ELECTRICAL TESTS ON POWER CABLES H. D. Campbell 8.1 Introduction 8.2 Alternating-Current Overvoltage Test 8.3 Direct-Current Overvoltage Test 8.4 Voltage Testing of Production Lengths Test Sets for Routine Measurements Routine Test Terminations 8.5 Tests on Specimens 8.6 Impulse Tests Necessity of Impulse Tests Lightning Impulse Waveform Impulse Generator Test Specimens Test Specimen Preparation Calibration Procedures Polarization Effects

7 XII Contents Impulse Testing as a Development Tool CHAPTER 9 DISSIPATION FACTOR, PARTIAL-DISCHARGE, AND ELECTRICAL AGING TESTS ON POWER CABLES R. Bartnikas 9.1 Introduction 9.2 Dissipation Factor of a Cable 9.3 Bridge Techniques for the Measurement of tan S 9.4 Partial-Discharge Characteristics 9.5 Partial-Discharge Measurements 9.6 Partial-Discharge Site Location 9.7 Discharge Pulse Pattern Studies 9.8 Electrical Aging Mechanisms 9.9 Accelerated Electrical Aging Tests CHAPTER 10 FIELD TESTS AND ACCESSORIES FOR POLYMERIC POWER DISTRIBUTION CABLES H. H. Campbell and W. T. Starr 10.1 Introduction 10.2 Alternating-Current Overvoltage Test 10.3 Dissipation Factor (Power Factor) Test 10.4 Insulation Resistance Test 10.5 Partial-Discharge Test 10.6 Direct-Current Overvoltage Test 10.7 Direct-Current Test Procedures 10.8 Interpretation of Test Results 10.9 Question of Test Levels Direct Stress versus Alternating Stress Considerations Practical Test Levels Joints and Terminations Some Current Practices Taped Designs Shrink Back Modular Designs Tests Separable Connectors izj CHAPTER 11 POWER CABLE SYSTEMS G. Ludasi 11.1 Introduction 11.2 Comparison of Overhead Lines and Cables Resistance Inductance Capacitance Overall Parameter Effects 11.3 Radial Power Systems

8 Contents xiii Radial Branches for Underground Residential Distribution Secondaries Looped Systems Open Loop :4.2 Closed Loop Current-Carrying Capacity: Rating Equations Direct-Current Cables Calculation of Losses Resistance of the Conductor Skin Effect Proximity Effect Skin and Proximity Effects in Pipe-Type and SL Cables Dielectric Loss Losses in Cable Screens, Shields, and Sheaths Circulating Current Losses Losses in the Sheaths or Shields of Specially Bonded Systems Eddy Current Losses in Sheaths or Shields Calculation of Losses in Nonmagnetic Armor or Sheath Reinforcement Losses in Magnetic Armor Concentric Neutral Cable Pipe-Type Cable Losses and Losses in the Sheaths of SL Cables Losses in Steel Pipes Thermal Resistance of Cables Thermal Resistance of Insulation Single-Core Cables Three-Conductor Cables Thermal Resistance of Coverings over Sheaths, Shields, Armor, and Pipe (Oversheaths, Jackets, Bedding, Outer Serving) Pipe-Type Cables, Cables in Metallic Ducts External Thermal Resistance Thermal Resistance between Cable and Duct or Pipe (7 4 ') Cables, Ducts, or Pipes Laid in Free Air Thermal Resistance of a Single Buried Cable or Pipe Influence of Soil Conditions on the Design of Underground Lines Thermal Resistance of Groups of Buried Cables (Not Touching) Groups of Buried Cables (Identical) Equally Loaded and Touching Thermal Resistance of Duct or Pipe (r 4 ") External Thermal Resistance of Ducts or Pipes (T"\) Cables or Ducts (Pipes) Embedded in Special Backfill, Duct Banks Cables in Buried Troughs Cyclic Loading External Thermal Resistance of a Single Buried Cable, Duct, or Pipe External Thermal Resistance of Groups of Equally Loaded Identical Cables Cables, Ducts, or Pipes Embedded in Special Backfill, Duct Banks Comparison of the Neher-McGrath and IEC Methods Short-Term Overloading 492

9 xiv Contents Representation of the Dielectric: Long-Duration Transients (> \ of TQ, Also for cyclic rating) Single-Core Cables Three-Core Cables Representation of the Cable: Long-Duration Transients (Also for cyclic rating) Self-Contained Cables with Impregnated, Laminated (Taped), or Extruded Insulation, Unarmored, and Thermally Similar Constructions Oil-Filled (Liquid-Filled) Pipe-Type Cables (High Pressure) Gas Pressure Pipe-Type Cables (No Filling Material or Armor) Also Three Single-Conductor Cables in Metallic Duct Cables in Ducts (Nonmetallic) Other Types of Cables and Installations Long-Duration Partial Transient of the Cable (Also cyclic loading) Long-Duration Partial Transient of the Cable Environment (Also cyclic loading) Buried Cables (Directly or in Ducts) Cables (Ducts) in Air Short-Duration Transients (Duration < ± of TQ) Calculation of the Complete Temperature Transient Buried Cables (Directly or in Ducts) Cables (Ducts) in Air Correction to Transient Temperature Response for Variation in Conductor Losses with Temperature Dielectric Loss Dielectric Losses in Cables at Voltages Up to and Including 275 kv Dielectric Losses in EHV Cables, Higher than 275 kv Emergency Ratings General Remarks about Overloads and Emergency Ratings Other Methods for the Calculation of Short-Term Overloading Fault Currents Calculation of the Thermally Permissible Short-Circuit Current Adiabatic Method Comparison of the Adiabatic and Nonadiabatic Methods Nonadiabatic Method Cable System Economics Calculating Procedure Calculating Cost of Joule Losses Total Cost Determination of Economic Current Range for Given Conductor Size Economic Conductor Size for Given Load Dielectric Loss and Losses Due to Charging Current Design Considerations Choice of System Voltage Cable Selection and Installation Methods Directly Buried Cables Cables Installed in Ducts Pipe-Type Cables Cable Pulling, Clearance between Cable and Duct or Pipe 533

10 Contents xv Jam Ratio and Configuration in Duct or Pipe Choice of Lubricant Pulling Forces in Pipe-Type Cables and Ducts Allowable Pulling Force Pulling Force in Bends and on Slopes Composite Curves and Angular Offsets Sidewall Pressure Bending Radii Cable Training in Manholes and at Terminations Curves on the Cable Route Choice of Cable Route and Manhole Location Manhole Design for Duct Installations CHAPTER 12 CRYOGENIC AND COMPRESSED GAS INSULATED POWER CABLES 551 K. D. Srivastava 12.1 Introduction Compressed Gas Insulated Transmission Line System Conductor and Sheath Insulating Gas Solid Spacers Power Rating Field Experience Cryoresistive Cables Taped Insulation Cables Vacuum Insulated Cryocable Superconductive Cables Union Carbide Design Brookhaven Design General Comments on Low-Temperature Superconducting Cables High-Temperature Superconducting Power Cables Economic Considerations CHAPTER 13 UNDERWATER POWER CABLES 582 R. T. Traut 13.1 Introduction Underwater Power Cable Design Configuration Single-Conductor Cables Three-Conductor Cables Mode as Related to Configuration Alternating-Current Systems Direct-Current Systems Electrical Core Design Conductor Insulation and Shields Sheath Design Reinforcement and Jacket Design Power Transmission Requirements System Power Transfer Requirements 596

11 XVI Contents Selection of Voltage and Mode Ampacity and Electrical Losses Additional Shield and Sheath Design Consideration Additional Factors Regarding Cable Sizing and Losses 13.4 Armor and External Protection Design Design Considerations Armor Size and Specification Armor Material Armor as Protection Special Application Designs 13.5 Underwater Power Cable Manufacture Splicing Jacketing Armoring Handling Testing 13.6 Cable Transport 13.7 Underwater Power Cable Installation CHAPTER 14 HIGH-VOLTAGE DIRECT-CURRENT CABLES C. Doench and K. D. Srivastava Introduction 14.2 Electrical Behavior of DC Cables Stress Distribution and Maximum Current Direct-Current Cable Design: Numerical Example 14.3 Transient Electric Stresses on HVDC Cables 14.4 Design of HVDC Cables Parameter Contraints Outline of Design Procedure 14.5 Selection of Materials 14.6 Direct-Current Cable Accessories Background Hydraulic Systems 14.7 Testing of DC Cables Load Cycling and Polarity Reversal Test Combined DC and Impulse Voltage Test 14.8 Emerging Trends in HVDC Cable Technology CHAPTER 15 TELEPHONE CABLES R. Bartnikas Historical Background Transmission Parameters of Copper Conductor Telephone Cables Digital Transmission Characteristics of Metallic Conductor Telephone Cables Twisted-Wire Multipair Cables Electrical Characteristics of Coaxial Cables Metallic Conductor Telephone Cable Design and Manufacture Twisted-Wire Multipair Telephone Cables Paper Ribbon Twisted-Wire Multipair Telephone Cables Paper Pulp Twisted-Wire Multipair Telephone Cables 697

12 Contents xvii Plastic Insulated Cables Electrical Tests of Twisted-Wire Multipair Telephone Cables Outside Plant and Station Connection Wires and Cables Coaxial Cable Design and Construction Video Pair Cable Design and Construction Optical Fiber Telephone Cables Optical Fiber Manufacture Transmission Parameters of Optical Fibers Construction and Design of Optical Fiber Cables Fiber Cable Installation: Splices and Connectors Optical Fiber Transmission Systems CHAPTER 16 UNDERSEA COAXIAL COMMUNICATION CABLES 782 R. T. Traut 16.1 Introduction Undersea Cable Telecommunications History of Undersea Telecommunications Via Cable Technical Challenges First Undersea Telegraph Cables First Undersea Telephone Cables Installed Transoceanic Cable Systems Undersea Coaxial Cable Design Design Requirements: Electrical Power Supply to System Repeaters Transmission Signal Multiplexing Undersea Coaxial Cable Design for Communications Transmission System Requirements versus Practical Design Limitations Design Requirements: Mechanical Fundamental Mechanical Requirements Evolution from External to Center Strength Designs Protection from Damage Practical Considerations Regarding Manufacturing, Installation, and Recovery Influence on Design of Undersea Digital Fiber-Optic Cables CHAPTER 17 TERRESTRIAL AND UNDERWATER OPTICAL FIBER CABLES 818 W. F. Wright 17.1 Introduction Low-Signal Loss and High Bandwidth Immunity to Electromagnetic Interference Small Size and Low Weight Security Safety Historical Perspective Optical Fiber Characteristics Physical Description Refractive Index and Total Internal Reflection Mechanical Characteristics 823

13 xviii Contents Basic Optical Performance Characteristics Introduction to Fiber-Optic Cables Fiber-Optic Cable Design Criteria, Terrestrial Outside Plant Fiber-Optic Cable Submarine Fiber-Optic Cable Specialized Fiber-Optic Cable Designs Optical Ground Wire Cable All-Dielectric Self-Supporting Cable Flame-Retardant Fiber-Optic Cable Hostile Environment Fiber-Optic Cable Introduction to Undersea Fiber-Optic Communication Systems Repeatered Undersea Fiber-Optic Communication System Technology Optical Amplifier Undersea Fiber-Optic Communication System Technology Concluding Remarks AUTHOR INDEX 846 SUBJECT INDEX 847 ABOUT THE EDITORS 857