March 2013 Tratos High Voltage cables Cables for a moving world www.tratos.eu
Introduction High Voltage Cables Tratos is an international manufacturer and supplier of High & Extra High Voltage cable up to 245 kv. Since 1966, we have entered a new market segment producing high voltage cables up to 220 kv. In collaboration with our suppliers of new generation joints and terminals we are able to supply turnkey solutions incorporating design project management, production, installation and maintenance. Characteristics Advanced technology and construction Flexibility Lightness Strength Low maintenance and simpler accessories Applications Instruments, ignition systems, AC and DC power transmission Typical Usage In apparatus generally short lengths Within buildings or as buried cables in an industrial plant or for power distribution generally variable lengths As submarine cables under the ocean for power transmission as long as required 2
Introduction Cable construction Conductor consists of stranded Aluminium or soft drawn copper produced by two technologies: Circular Compacted (One or multi layers of stranded wires are assembled together to form a circular compacted conductor), Segmental Conductor (Five segments of compacted conductor in triangle shape of 72 degree are assembled together with separation of non metallic tapes to reduce the skin effect which reduce the AC conductor resistance. Segmental conductors are applied for conductor cross sectional area of 1000 mm2 and above). Swelling powder or water blocking tapes can be applied between the conductor strands to block the ingress of water inside the cable conductor (if required). An extruded layer of cross linkable semi conducting to reduce and control the electrical stress beneath the insulation layer of cross linked polyethylene (XLPE). The semi conducting layer shall be firmly bonded to the inner layer of the insulation. An extruded layer of cross linked polyethylene (XLPE) of high grad is extruded in dry cooling and curing continuous vulcani sation line. The thickness of insulation should be calculated as per the operating voltage, impulse voltage and expected cable life which should be verified by carrying out type tests as per the applicable standards. An extruded layer of cross linkable semi conducting is applied over the insulation layer to insure that the electric stress is homogenous around the insulated core. The semi conducting layer shall be firmly bonded to the outer layer of the insulation. Conductor screen, insulation and insulation screen are applied simultaneously in one process (triple extrusion process) to insure that all extruded layers are firmly bonded together. One or multi layers of metallic screen / sheath such as copper wires, lead, aluminum, etc. shall be applied as a return path of earth fault current. Metallic sheaths may be used for water blocking protection and mechanical protection. An extruded layer of PVC, PE (HDPE, LDPE, MDPE) shall be applied over the metallic layers for protection against chemical reaction, mechanical and electrical protection. Extruded semi conductive layer or graphite coating shall be applied over the outer sheath for testing purpose. 3
Introduction Faraday Cage Test Measuring 24m x 16m and standing at 14m high the cage enables Tratos to effectively administer AC Resonant Tests on site, allowing testing of up to 220kV of nominal voltage cables and up to 20km of medium voltage cable. The facility incorporates a new innovative locking system to ensure perfect shielding from any sort of external interference. Inside are sophisticated tools for testing and an adjustable high voltage reactor which, together with the exciter and the regulator, comprise the heart of the system. 4
Introduction Faraday Cage Test The reactor is insulated in oil. Its upper part includes space for oil expansion and it offers 12MW of resonance power, allowing three taps of 350kV, 150kV and 70kV. The exciter section is mounted in a separate oil-filled steel tank and contains a single phase, step-up transformer which supplies the AC voltage required for the resonant circuit. The regulator provides an adjustable input voltage to the exciter and controls the input voltage of the reactor. This sophisticated equipment can detect even very low levels of picocoulombs immunity to electrical noise, and resistance to vibration and impact. This allows incredibly precise measurements to be recorded, ensuring that Tratos meets industry standard ISO 9001, that Tratos is approved by BASEC and that the company s own exceptional standards of quality are granted. 5
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Quality Approvals Facilities 7
Case Studies
Case studies Emirates Steel Industries Company: Danieli Type: HV cable 72 kv Tratos signed a contract with Italy's Danieli Corporation for the expansion of the Emirates Steel Industries (ESI) steel manufacturing factory located at Abu Dhabi's prestigious industrial city ICAD several kilometres of HV 72 kv cable have been supplied for this project. 9
Case studies Kent PHK Ltd Company: Kent PHK Ltd. Type: HV cable 66 kv In 2007, Tratos supplied Kent PHK Ltd with HV cables of 66 kv for railways. 10
Case studies Project Name: Altahullion - County Londonderry, Northern Ireland - Onshore wind farm Company: RES/B9 Energy Services Developed by: RES/B9 Energy Services Operator: RES Owner: RES Cable: HV cable and fibres Installation date: 2003 Commissioning: 2003 Description: Wind firm 26 MW - 20 turbines Siemens SWT-1.3-62 (power 1300 kw, diameter 62 m) - Total nominal power: 26 MW Altahullion is situated near Dungiven, County Londonderry and is owned by RES. It was designed and built by RES using local contractors and commissioned in 2003. Altahullion's 20 turbines can generate up to 26MW. Electricity from the wind farm is sold to Belfast based Energia who supply hospitals, schools and Northern Ireland businesses. The public can visit the site by following the signs from the A6 Dungiven to Derry road. There is car parking, an information board and a special path up to the visitor turbine. 11
Case studies Project Name: Altahullion II - County Londonderry, Northern Ireland - Onshore wind farm Company: RES Developed by: RES Operator: RES Owner: RES Cable: HV cable and fibres Installation date: 2007 Commissioning: 2007 Description: Wind firm 11.7 MW - 9 turbines Siemens SWT-1.3-62 (power 1300 kw, diameter 62 m) - Total nominal power: 11.7 MW The nine turbine extension to Altahullion Wind Farm, near Dungiven County Londonderry, was commissioned in 2007. The nine new turbines provide an additional 11.7 megawatts of power. The extension takes the total number of turbines at Altahullion to 29, with a total power capacity of 37.7 megawatts. The extension was developed and built by RES, with the help of local contractors. 12
High Voltage Cables
High Voltage Cables TRATOS HV - 38/66 kv-(72.5 kv) CU/XLPE/AT/HDPE Construction Conductor: stranded circular or segmental compacted copper Conductor screen: semi-conducting layer Insulation: XLPE Insulation screen: non metallic - semi-conducting layer and copper wire as metallic Tape: non-conductive water blocking Tape: copolymer aluminium tape Outer sheath: HDPE sheathed with graphite coating or extruded semi-conducting layer Standard colour: black Standards Design and Tested: IEC 60228, 60840 and 60811 14
High Voltage Cables TRATOS HV - 38/66 kv-(72.5 kv) CU/XLPE/PB/HDPE Construction Conductor: stranded circular or segmantal compacted copper Conductor screen: semi-conducting layer Insulation: XLPE Insulation screen: non metallic - semi-conducting layer Tape: non-conductive water blocking Sheath: lead Outer sheath: HDPE sheathed with graphite coating or extruded semi-conducting layer Standard colour: black Standards Design and Tested: IEC 60228, 60840 and 60811 15
High Voltage Cables TRATOS HV - 76/132 kv-(145 kv) CU/XLPE/AT/HDPE Construction Conductor: stranded circular or segmantal compacted copper Conductor screen: semi-conducting layer Insulation: XLPE Insulation screen: non metallic - semi-conducting layer Screen: copper wire as metallic Tape: semi-conductive water blocking Tape: copolymer aluminum tape Outer sheath: HDPE sheathed with graphite coating or extruded semi-conducting layer Standard colour: black Standards Design and Tested: IEC 60228, 60840 and 60811 16
High Voltage Cables TRATOS HV - 76/132 kv-(145 kv) CU/XLPE/PB/HDPE Construction Conductor: stranded circular or segmantal compacted copper Conductor screen: semi-conducting layer Insulation: XLPE Insulation screen: non metallic - semi-conducting layer Tape: semi-conductive water blocking Sheath: lead Outer sheath: HDPE sheathed with graphite coating or extruded semi-conducting layer Standard colour: black Standards Design and Tested: IEC 60228, 60840 and 60811 17
Tratos on demand Cables Tailor Made Our Cables Tailor Made" service can offer custom design and built solutions to the most demanding of circumstances. In conjunction with our clients Tratos can offer you: Variety of lengths Large overall diameter (above standard products) Cable designs Bespoke cables Environmentally specific cables (mud, chemicals, UV, water, oil, radiation) Case Study Tratos has manufactured and supplied Superconducting conductors to ITER (International Thermonuclear Experimental Reactor), an international nuclear fusion research and engineering project, which is currently building the world's largest experimental tokamak nuclear fusion reactor at the Cadarache facility in the south of France. www.iter.org 18
Tratos Group Cables for a moving world www.tratos.eu