High voltage cables

For populated areas like cities and towns the power transmission is done by
means of high voltage cables. Power transmission is also done by cables across seas.

Insulating material for cables:

Jute or VIR is usually employed for L.V cables. Paper is mostly used insulating
material in high voltage cables. The paper is mostly used in India. Paper is by itself
porous and hygroscopic. It requires impregnation with suitable oiling compound, which
is mineral oil used with resin. Resin increases the viscosity so that there is no drainages
from one part of the cable to other part at the winding temperature.

Lead sheath is invariably used over the insulation in the cables .It prevents the
accesses of moisture to paper and provides some mechanical protection against rough
handling.

Single core cables

Paper Insulation

H.V Conductor
Lead Sheath
Hessian or Jute with
bituminous Compound

Armoring is not used over single core cable because of large power loss and high
resistance drop. Because of large flux developed in high permeability steel. But sheath
loss is present in single core cables. This cannot be avoided as the single core cable. This
cannot be avoided as the cable must be provided with a sheath.

1
Sheath

In order to provide an impervious layer to protect the cable from moisture, which
affects the insulation, metal sheathing is provided. Lead is widely used as sheath material
.At present some alloys of lead is also used. These alloys can withstand the internal
pressure of the pressurized cables.

Aluminum is also as a material for cable sheath. Aluminum sheath has a small
weight and higher mechanical strength than the lead sheath .It has a greater conductivity
and is ease to manufacture and install. It has good screenings properties for a c work. It
eliminates the use of armour usually required in lead sheath cables. An aluminum sheath
can withstand the required gas pressure without reinforcements, Owing to its greater
conductivity the aluminum sheath of low voltage cable may be used as neutral conductor.
Thus there is no need of separate fourth neutral conductor.

Recently corrugated seamless Aluminum (CSA) sheath is finding favour these

days. It has better bending property, reduced thickness and less weight. It has mainly
used in high voltage oil filled cables and Telephone cables. The corrugated cables are
very flexible and can be bent easily. Also by repeated bending the sheath is not distorted
unduly and therefore, it is not damaged.

Protective Covering

Lead sheath cables are subjected to mechanical damage, corrosion and electrolytic
action when laid direct in the ground .To protect them from these actions no protective
covering are applied to the sheaths. For protecting against corrosion and electrolytic
action bitumen and bituminized material (paper, hessian etc) or Polyvinyl Chloride are
used. Layer of fibrous permeated material with waterproof compound applied to the
exterior of the cable is called serving.

Armouring

One or two layer of galvanized steel wires or two layer of metal tape armoring is
applied aver Hessian or jute bedding to protect the sheath from mechanical damage .For
longitudinal sheath requirements, steel wire armour is preferred. The steel tape is coated
with preservative compound .The two tapes are wound helically in the same direction
such that the outer layer covers the spaces between the twins of the inner layer. Single or
double wire armour is used depending on the degree of protection required. Single wire
armour consists of wire applied over a compounded bedding. In the case double wire
armour a fabric tape is used as a separator between two layers of wires .The direction of
lay of the two layers are opposite to each other. This reduces torsion effects and gives

2
extra mechanical strength. Double wire armour is used for cables with higher tensile
strength, for example, along sloping routes, in mines, under water etc.

The presence of magnetic material within the alternating magnetic field of a single
core cable produces excessive losses For this reason single core cables are either left
unarmoured or, if necessary, they are armoured with non magnetic materials likes tin
bronze or silicon bronze tapes or wires. In the case of multi-core cables the resultant
alternating magnetic field is zero. There is no heating loss in the armour.
Aluminum has been used recently as an armour material due to its non-magnetic
properties, high conductivity and mechanical strength. It is particularly use full for single
core cables working on a.c. Aluminum or aluminum alloy wires are used for armouring.

Three core cables (Belted cables)

Each of the three-conductor cores is wrapped with oil-impregnated paper, in a

three core cables. The cores are then assembled with a filler material. The assembled is
enclosed by a paper insulating belt .A sheath is provided above the belt .The other things
are done in the usual manner. A belted cable is shown below.

Jute filler
Lead sheath

Belt insulation (paper)

a b
Core insulation (paper)
H.V. Conductor

Jute Bedding

Armouring

Hessian or Jute with

bituminious Compound(Serving)

Belted cables are usually used up to 22 kV. Belted cable has one disadvantage
that as the field develops in side the cable is rotating one, a tangential stress alone the
surface of the core insulation i.e. on the paper is developed. The tangential stress
ultimately lead to development of partial discharge since paper can withstand very little

3
tangential stress .The discharge starting in the region a b, gradually damage whole of the
paper insulation. This is the reason for which belted cables cannot be used for very high
voltage above 22kV.

H-type cable

The elimination of the tangential stress can be accomplished only screening each
core separately so that the cable becomes, in effect, three separate single core cables laid
up within the same protective covering. The H- type cable, invented by the Hochstadter
consists of three paper-insulated cores, and over the insulation of each is wound a
perforated moralized paper. Perforated aluminum foil or copper tape is used so as to
maintain the homogeneity between the outside-impregnated paper and inside paper. By
the use of metallic screen (which is maintained at earth potential) electric field is made
radial.

Perferated Al or Cu foil

Filler

Lead sheath
Bedding
Armouring

Seving

4
S.L. Type cable

In this type each core has its own lead sheath and overall lead sheath as usual.
The lead sheath over 3- core and overall lead sheath should make good electrical contacts
with each other.

H.S.L Type cables

In this type individual cores are covered with a layer of Al foil or Cu – tape inside
the lead sheath. This screen eliminates the bad effects of the any void between insulation
and sheath.

Stress in the Cable

Let the charge per unit length be q in coulomb. The flux density at a radial distance x be
q
Dx  C / m2
2 x
 The stress at a radial distance x is

Dx q
Ex   V /m
 2 x

The potential difference between the conductor and sheath is

R R
q q
V   E x dx   dx  ln( R / r )
r r
2 x 2

5
 2 V
 q C
ln( R / r )

q V
And E  v/m
2 x x ln( R / r )

The maximum stress occurs on the conductor surface i.e. when x = r

V
 Em  V /m
r ln( R / r )

The stress distribution is as shown in fig below

r R x

From the stress distribution it is clear that maximum stress occurs at the conductor
surface. So, in order to reduce stress on the conductor surface R may be increased.

Alternatively, better quality insulation is to be employed to withstand the stress on

the conductor surface. However when R is increased additional insulation is to be
provided due to increase in overall dimension. When better quality insulation is used it is
not utilized properly because the magnitude of stress away from the conductor is small.
So the optimum dimensions for the cable are to be determined.

Optimum dimensions
Optimum cable dimensions for the following three conditions are to be determined.

a) Em & V specified, condition for minimum R?

b) Em & R specified, condition for maximum V?

c) R & V specified, condition for minimum E?

6
Again maximum stress on the conductor surface

V
Em 
r ln( R / r )

V Vp
And let R/r = p  Em  
R R ln P
(ln p)
p

p p
For all the three cases is to be minimum. Since is minimum hence
ln p ln p

1
ln p  ( p. )
d p p
( )0 or 0
dp ln p ln( p) 2

Or ln p  1  p = e = 2.718

R
e
r
i.e.

For economical cable

R  e.r

V V
Again, Em  
r. ln( R / r )  e.r 
r. ln  
 r 
V

r
V e.V
Or r  and R 
Em Em
Now in order to maintain the ratio R/r =e=2.718 the diameter of the conductor has to be
much higher than that required by its current rating. For that reason either Al conductor
can be used in place of Cu or Cu stranded wires can be used around a central wire of
hemp or lead.

7
 hemp or lead

Cable can be made economical by grading. The following two types of grading
are generally employed.
I) Capacitance grading
II) Inter-sheath grading

I) Capacitance Grading

V
r
1
2 g .1
R
.2

Capacitance grading

r R x
Normal cable

The stress distribution shows that the potential gradient over the conductor
surface is much higher than that away from the surface. In other words if a single

8
dielectric is used the cable insulation is not utilized properly. One of the solutions is to
use better dielectric over the conductor surface and cheaper dielectric near the sheath.
Further it can be shown that the cable can be made more economical if the dielectric near
to the conductor has higher ‘’ than that away from it. This is known as capacitance
grading.

If the permittivity of the insulating material away from the conductor is

made less there is sudden rise in stress from inner dielectric to outer dielectric as shown
in fig .As the area under the stress curve is the cable voltage, smaller overall cable
diameter R' R can be used and the cable becomes economical.

Alternatively with the same overall dimensions the cable can be

separated at higher voltage.

2  1
q
E1  [E1 stress at point 1, r1 = radius at pt 1]
2 1r1

q
E2  [r1= r2 since pt ‘1’ is just inside the dielectric & pt '2’ is just
2 2 r2
outside the dielectrics.]

E2  E1

Capacitance grading –Maximum stress in different dielectrics

r3
Em3
3 E m1 Em 2
2
1 r
r2
r1

9
 Let q be the charge per unit length .The maximum stress in deictic 1 will be
q q
E m1  . Similarly maximum stress in the dielectrics 2 & 3 are E m 2  &
2 1 r 2 2 r1
q
E m3  respectively.
2 3 r2

q
i.e. E m1 1 r  E m 2  2 r1  E m 3 3 r2  ..........  Const
2

The above relation shows that the product of maximum stress allowable in a
dielectric, dielectric permittivity & the inner arduous of the dielectric must be constants.
Let G1, G2 &G3 be the strength of the dielectrics i.e. the breakdown stress in different
dielectrics and let  be the safety factor in the dielectric then

q G1 q G2 q G3
 E m1  ;  Em2  & 
2 1 r  2 2 r1  2 3 r2 

q.
G1 . 1 r  G 2  2 r1  G3 3 r3  .........
2

i.e. the product of strength of the of the dielectric, permittivity & inner radius for all
dielectric should be the same for economic cable. However it is very difficult to
obtain dielectric material of widely varying permittivity. For this reason cheaper
quality paper having lower dielectric strength is used where as better quality paper of
higher strength is used near the conductor.

For optimum conditions

Em1 . 1r  E m 2 2 r1  E m3 3 r2

10
 Em1 Em2 Em3

(1) (2) (3)

r r1 r2 x

V3
V2
V1
V
r
r1
 r1
 r2
r2
 r3
r3

Let r = 0.5, Em1=50 kV/cm, Em2 = 40kV/cm & Em3 =30kV/cm;  r1 = 4,  r 2 =3

&  r 3  2.5

For economical cable,

E m1 . r1r  E m 2 r 2 r1  E m3 r 3 r2

5040.5 =40 3  r1 =30  2.5  r2

r 1 =100 /120 =0.833cm

r 2 =100 /75 =1.33cm

V  V1
E m1  or V  V1  12.76kV
0.5 ln( 0.833 / 0.5)

11
 V1  V2
Em 2  or V1  V2  15.59kV
0.833 ln(1.33 / 0.833)

 V  V2  28.35kV

 V2  66  28.35kV  37.65kV [Let V = 66 kV]

V2  V3
 30
 r3 
r2 ln  
 r2 
or V2 – 0 [ since outer layer of the cable is earthed] =30  r2 ln(r3/ r2)

r  37.65
or ln  3  
 r2  30  1.33

or r3 =3.41 cm

Problem: Find the maximum voltage of a 1-core lead sheath cable with conductor

diameter 1 cm & inner diameter of the sheath is 5cm. Two insulating material are used (a)

Maximum working potential gradient 60kV/cm;  r  4 & (b) Maximum working potential

gradient 50kV/cm;  r  2.5

V V1 V2  0
r
 r2  r1 r1

r2

r =0.5 cm; R =2.5cm

Em1 . r1r  Em 2 r 2 r1

12
 60  4.0  0.5
 r1   0.96
50  2.5

V  V1
E m1  or V  V1  19.57kV
r 
r ln  1 
r 
 

V1  V2 ( 0)
 50 V1  45.94kV
 r2 
r1 ln  
 r1 

V  V1  19.57  65.5kV

Problem: What will be the working voltage if the cable in last example has some better

quality dielectric (  r  4 ) all through its thickness?

V 0
 Em
R
r ln  
r
or
R
V  E m .r. ln  
r
 2.5 
 60  0.5  ln  
 0.5 
 48.28kV

Thus it is seen that capacitance grading makes it possible to use the cable for higher
voltage.

Problem: A single core, lead covered cable is to be designed for 66kV to earth. Its
conductor radius is 0.5 cm and its three insulating materials, A, B&C have relative
permittivity of 4, 4and 2.5 with maximum possible stress of 50, 40&30 kV/cm
respectively. Find the minimum internal diameter of the lead sheath.

For economic cable,

E m1 . r1r  E m 2 r 2 r1  E m3 r 3 r2

13
or 5040.5 = 40  4  r1 =30  2.5  r 2

 r1  0.625cm & r2  1.33cm

V3

V2

V V1
r
 r1 r1
 r2
 r3
r2

We have to find out minimum value of r3

V  V1
E m1  or V  V1  5.578kV
 0.625 
0.5 ln  
 0.5 
V1  V2
E m1  or V1  V2  18.879kV
 1.33 
0.625 ln  
 0.625 

V  V2  24.457 kV V2  66  24.457  41.543kV

V2  V3  r  V 0
Again  30 or ln  3   2
 r3   1.33  1.33  30
1.33 ln  
 1.33 

[Since outer layer of the cable is earthed. V3 = 0]

or
 r  41.543 r3
ln  3    1.0411   e1.0411  r3  3.76cm
 1.33  1.33  30 1.33

 Minimum diameter = 7.53 cm.

14
Problem: A single core lead sheath cable joint has a conductor of 10 mm dia and two
layer of different insulating material, each 1mm thick .The relative permittivity are 3
inner and 2.5 outer. Calculate the potential gradient at the surface of the conductor when
the potential difference between conductor and lead sheath is 60kV.

V V1 V2  0
r
r1
 r1  3

 r 2  2.5 r2

r = 0.5cm

r1= 0.5 +1 = 1.5 cm

r3 = 2.5 cm [1.5 +1]

Let q be the charge per unit length.

E at any distance x can be written as

q
E
2 0  r x

V   E.dx
r1
q
V  V1   .dx
r
2 0  r x

q r 
V  V1  ln  1 .............................(1)
2 0  r1  r 

q r 
Similarly, V1  V2  ln  2 .............................(2)
2 0 r 2  r1 

15
Adding (1) and (2) we get,

q  1 1 
V  V1   ln( r1 / r )  ln( r2 / r1 )
2 0   r1  r2 

q  1 1 
V  ln( r1 / r )  ln( r2 / r1 )
2 0   r1  r2 

V2  0

q V
or 
2 0  1 1 
 ln( r1 / r )  ln( r2 / r1 )
  r1  r2 

q 60
  105.26
2 0 1 1 
 3 ln(1.5 / 0.5)  2.5 ln( 2.5 / 1.5)

 Stress at the conductor surface

q  q  1
=   .
2 0 r1 .0.5  2 r1  3  0.5

=70.17kV/cm.

Inter-sheath Grading

In this method of grading, the same insulating material is used through out the
thickness of the cable, but it is divided in to two or more layers by providing inter-
sheaths. Inter-sheath are their metallic cylindrical sheaths, usually made up of brush or
aluminum, concentric with the conductor. These inter-sheaths are placed between the
conductor and the outside sheath and maintained at suitable potentials by connecting
them to tapping from the supply transformer. The stress on the inter-sheath surface is
same as that on the conductor surface.

16
 V V1
r
r1

Em

with intersheath

without intersheath

r r1 R' R x

Optimum Dimensions

(V  V1 )
Let r1/ r2 = p1 , R/r2 = p2 , E m 
r 
r ln  1 
r

17
 (V  V1 )
Em  = maximum stress in the first layer i.e. on the conductor surface.
 r1 
r ln  
r
V1
Similarly, maximum stress in the second layer i.e. in inter-sheath layer= E m 
R
r1 ln  
 r1 
When maximum stress is same on both the layers,

(V  V1 ) V1
Em  
r  R
r ln  1  r1 ln  
r r 
 1

By the method of addendo

a c
(V  V1 )
 if  k
b d
Em 
r  R ab
r ln  1   r1 ln   then k 
r r bd

V V p1 p 2
=  .
R R R ln p1  ln P2
ln p1  ln p 2
p1 . p 2 p2

Normally, out of the three variable s Em, V& R, two are specified and one is to be
optimized for all these cases. As in the single core cable the optimum size is obtained
when

p1 p 2
X   Minimum
ln p1  p1 ln p 2

X X
  0, 0
p1 p 2

 1 
p 2 ln p1  p1 ln p 2   p1 p 2   ln p 2 
X  p1  0

p1 ln p1  p1 ln p 2  2

18
X p ln p1  p1 p 2 ln p 2  p 2  p1 p 2 ln p 2
 2 0
p1 ln p1  p1 ln p 2 2

or
p2 ln p1  p2  0 or ln p1  1 or p1  e

Substituting p1  e in X we get,

e. p 2
X 
1  e ln p 2

X e(1  e ln p 2 )  e. p 2 (e / p 2 )
 0
p 2 1  e ln p2 2

X e  e 2 ln p 2  e 2
 0
or p 2 1  e ln p2 2

e(1  e ln p2  e)  0

e 1
or 1  e ln p2  e  0 or ln p 2   0.632
e

or p 2  e 0.632  1.88.......................(3)

V p1 p 2 V e.1.88 V 1.88 V
Em  .  .  .  .(1.88)
R ln p1  ln p 2 R  e 1 R  e 1 R
1  e  1  e 
 e   e 
1.88V
Em  ...................(4)
R

The potential of inter-sheath (V1)

V1 V p1 p2
Em   .
 R  R ln p1  ln p2
r1 ln  
 r1 

19
 V1 r ln( R / r1 ). p1 p 2 1 / p 2 . ln p 2 . p1 . p 2
or  1 
V R(ln p1  p1 ln p 2 ) (ln p1  p1 ln p 2 )

e 1
e.( )
V1 p1 ln p 2 e e 1
  
V (ln p1  ln p 2 )   e  1  e
1  e. 
  e 

V1
 0.632 or V1  0.632V ...........................(5)
V

Therefore inter sheath is to be maintained at 63.2% of conductor potential.

Comparative gain

For an optimum size normal single core cable

V ' eV ' 2.718V '

Em    ..........................(6)
r' R' R'

For the same voltage V’= V, same maximum stress and same dielectric material,
comparing (4) with (6)

1.88
R .R '  0.693R '
2.718

i.e. Cable size is reduced to 69.39% of an optimum cable without inter-sheath .

V 2.718
  1.445 or V= 1.445V’
V ' 1.88

i.e. for the same out side diameter s , the cable with inter-sheath can be operated with
44.5% higher conductor potential compared to single core cable.

Limitation of grading

Following difficulties are encountered in practice in the application of

grading methods.

20
 1. Disadvantage of capacitance grading is that the range of permittivity
values of insulating materials available for cable insulation is limited. Moreover, the
permittivity of the layers may not remain constant during the service period of the
cable. Consequently, the stress distribution may change and may result in insulation
breakdown at normal working voltage.

2. The inter-sheaths, being very thin are liable to be damaged during

transformation or installation. High local stress may develop at the points of damage
leading to breakdown. Also thin inter-sheaths are not able to carry the charging current
of long cable line and thus the current carrying capacity of the cable is reduced. Inter-
sheath grading also presents difficulties in fixing the inter-sheath potentials.

Problem: An 85kV, 1-core metal sheath cable has dielectric material, which can
withstand maximum stress 60kV/cm. This cable is to be graded by means of metallic
sheath. Find the diameter d of inter-sheath and voltage at which the inter-sheath must
be maintained in order to obtain minimum overall diameter. Compare the conductor
and out side diameter with those of an ungraded cable. What will be the maximum
allowable voltage if inter-sheath supply is disconnected in 1st case?

1.88.V 85  1.88
Em  Or R  2.66cm
R 60

R
 D  5.32cm; Again p2   1.88
r1

D 5.32
or  1.88    d1   2.83cm
d1 1.88

r1 d1
Again p1   e
r d

d1 2.83
d    1.04cm
e 2.718

V1  0.632.V  85  0.632  53.72kV

Ungraded Cable

2.718.V
Em 
R

21
 85
or R  2.718   3.85cm  D  7.7cm
60

R R
Again e r 
r e

D 7 .7
d   2.83cm
e 2.718

When inter-sheath supply is disconnected it behaves like an ordinary cable with

conductor diameter1.04cm & sheath radius 2.66 cm.

V R
Again E m  or V  E m .r. ln
R r
r ln
r

 2.66 
V  60  0.52  ln    50.93kV
 0.52 

There fore cable voltage is to be reduced from 85kV to 50.93kv so that cable stress
remains within limit.

Requirements of E.H.V cables

Following are the requirement s of the extra high voltage cables.

a) The insulation must be free of voids with special arrangements for paper
insulated cables and special manufacturing process for (1) poly-ethylene & Cross
linked poly-ethylene cables & (2) Conductor shield.
b) Stranded conductor has rough surface developing high stress. A smooth
conductor surface is obtained by lapping the conductors with several layers of
metallised paper, carbon paper or moralized carbon paper or carbon filled cloth

c) Similarly the shield should also be provided over the insulation to

reduce high stress due to high conductor surface. This shield is known as insulation
shield.

22
 conductor
Conductor shield
Insulation
Insulation shield

Metal sheald
protecting covering

Special cable for extra high voltage ratings (above 100 kV)

Prevention of void formation has been achieved in the following types of

paper cables so the dielectrics can be operated at higher stress reducing cable size.

Oil filled cable (OF Cable)

Sheath
Paper
Helical metal ribbon
Oil duct

Spacers
Sheath channel

The dielectric is impregnated by low viscosity mineral oil and oil

channels are included within or adjacent to the conductor or near the sheath. The oil is
fed from reservoir, situated at regular intervals & is maintained at a pressure of 3.5
kg/cm2 so that there is no tendency to forms voids and gas bubbles. When there is a

23
tendency of void formation oil fills up the space for voids. The oil channel within the
conductor has the disadvantage that the oil reservoir and other accessories are to be
maintained at the potential of the conductor. In 3- phase cables 3- perforated oil ducts
near the sheath can be used. In sheath channels and in such oil ducts oil remains at
ground potential. Providing sheath channel disadvantage of oil duct maintained at line
potential can be avoided.

Perforated oil
duct

Pipe type OF cable (POF)

The bulk of the underground cable systems installed in USA are high-pressure oil
impregnated paper insulated oil-filled pipe type cable. In contrast OF cables are
common practice in Europe and Japan.

Pipe –type cable consists of three phase conductors, each individually

insulated, sheathed and contained within a steel pipe.

Protective layer
steel pipe

Oil at 2000psi
Insulation
Conductor Shield
Conductor

24
Gas filled cables

There are two kinds of gas filled paper cables available.

a) Gas compression OF cables (External pressure cable)

Conductors are usually oval shaped; so that the conductors can follow
thermal expansion and contraction caused by load variation. Three insulated
conductor are accommodated in a common steel pipe, each single cable core being
covered with lead or Al or plastic sheath. Pipe is filled with N2 gas at a pressure of 15
kg/cm2. This acts on the lead sheath to pressurize the oil impregnated paper
insulation, thus preventing oil migration & void formation.

Conductor
Conductor shield

Insulation shield

Lead sheath
N 2 at
15 kg cm 2
Steel pipe
Protecting Cover

b) Gas filled oil filled (OF) cables:

The difference w.r.t. to the gas compression OF cables is that there is no

lead sheath or any other sheath around the insulation and N2 gas pressurized to 15
kg/cm2 in steel pipe can be diffuse in to the insulation and fill any void may
eventually formed.

Compressed gas insulated cable (C G I C)

25
 SF6 at 50 kg m 2

Spacer
(Epoxy rasin)

Conductor

Steel pipe

Advantages

1. High dielectric strength (2.5 times as that of air)

2. Low dielectric loss.

3. Excellent heat transfer characteristics.

4. Can withstand very high temperature (1500c) so very high power can be
transferred.

Disadvantage

Since the cables are usually rigid, there unit length is short (up to 60ft or 18 m),
resulting in a number of joints in field insulation. Special precautions are required for
making such joints at the time of insulation to prevent gas insulation being contaminated
and leakage .SF6 is very costly.

26
Solid insulted cable – PE and XLPE

Solid insulation is usually extruded over the conductor. Many different materials are
available of which Polyethylene (PE) and cross linked polyethylene (XLPE)are most
widely used.

Advantage of P.E

1. Cost is decreased

2. Dielectric loss is 10% less compared to paper cable.

3. Reactance power is reduced by 40%

Disadvantage

The disadvantage of PE is that very high temp reduces its mechanical strength.
By using XLPE cable this disadvantage can be removed. The maximum rated
temperature is 700 c and for XLPE it is 900 c. Other characteristics are same for both the
types.

Non-XLPE cables are used in France and especially for EHV cable, although
XLPE cables have almost replaced them in some other countries like USA & Japan.

XLPE Cable (cross linking process)

In cable fabrication, chemical cross linkage is used almost exclusively. Certain

peroxide compound such as DCP (Di-Cromyl peroxide) are added to polyethylene
granulates before extrusion.

In wet curing process (steam curing process) the vulcanizing is carried out within
after extrusion at about 1700c in a steam tube. Both temperature and pressure are supplied
by steam. This presses though most popular, it has got some problem.

I) Comparatively long time is required to dry XLPE insulation so as to eliminate

water molecule which has been trapped in it .

ii) Small voids often remain after the water is removed. These voids cause
dielectric breakdown.

To eliminate these difficulties in dry curing process N2 or CO2 in place of steam

are employed. Two methods have been devised: One uses this gas only as a pressure
medium, heat being applied to the insulation by radiation (Radiant heating or curing
method) and other uses gas for both purposes.

27
Void formation & Cable breakdown

Insulation
Void

Lead Sheath

Void formation

The formation of voids or air spaces in the dielectrics of a cable is due to the
effect of load cycles. The void may be formed due to faulty material and defective
manufacturing processes.

The void formation due to loading cycles can be explain in the following
manner

On heating due to load current the compound expands and stretches the sheath.
When the cable cools down during light load, the compound contracts but the sheath
cannot contracts developing voids.

Process of breakdown

The voids have much higher stress times the stress in the surrounding dielectrics,
where r is the relative permittivity of the dielectric. But the dielectric strength of the void
is much less, so the partial breakdown of the void takes places, especially in the region
near the conductor where the stress is very high.

28
 C Void

Vp
C dielectric
V1
t

When the supply voltage is d.c capacitance of the Cv of the void is shorted during
discharge. The series capacitance Cd of the dielectric takes up the full line voltage. As the
voltage across void Cv remains at zero, there is no further discharge.

With a.c when the void voltage reaches V1, a discharge takes places, the voltage
across the void collapse and the ionization in the void vanishes. But the supply voltage
rises further and the voltage across the void increases producing a series of discharges in
every cycles. Therefore in a.c the bombardment of ions on the void walls causes erosion
and carbonization which gradually proceeds both way leading to breakdown between
core and sheath. This short of breakdown normally takes a long time and known as
tracking & coring.

Usually when the tree has proceeded for a certain distance, the dielectric loss due
to discharge increase leading to high temperature rise and dielectric decomposition
causing final breakdown. This latter type of breakdown is known as thermal instability.

29
 Bushing

Purpose of using bushing

Bushing is an insulating system for taking the terminals out of the

transformers, circuit breakers, PTs, CTs, etc.

1. Oil filled bushing

Porcelain

Transformer or Circuit
Breaker body
Oil

There must not be any air bubble left between conductor and porcelain and any
air space between conductor and porcelain must be filled with oil .Oil filled porcelain
bushing are cheaper and are used for voltages up to 33kV.

Problem: A conductor 2.8 cm diameter is passed centrally through a porcelain bushing

(r = 4) having internal and external diameters of 3cms and 9cms respectively .The
voltage between the conductor and earth clamp surrounding the porcelain is 15kV rms.
Determine whether or not corona will be present in the air space round the conductor.
What is the voltage stress on the conductor if oil fill is used? Give rel permittivity of oil is
2.5.

30
 2.8

r = 1.4 cm, r1 = 1.5 cm, r3 = 4.5 cm.

Let q be the charge per unit length

q 1

2 0 1 r1 1 r2
ln  ln
1 r  2 r1

15 2
=
1.5 1 4.5
ln  ln
1.4 4 1.5

= 61.73 kV

Maximum stress on the conductor surface

q 61.73
=   44.1kV / cm
2 0 r 1.4

Since the value is more than 30kV/cm, corona will take place.

31
In case of oil filling

q V

2 0 1 r 1 r
ln 1  ln 2
 r 1 r  r 2 r1

15 2
  70.18kV
1 1.5 1 4.5
ln  ln
2.5 1.4 4 1.5

q 70.184
Maximum stress on the conductor surface =   20.05kV (rms )
2 0 r r 1.4  2.5

2. Compound – filled bushing

In the case of compound filled bushing synthetic resin bonded paper (SRBP)
or epoxy bushing are used. Epoxy bushings are suitable for indoor use. On the other
hand SRBP bushings have wide range of application. Surface of SRBP is heard and
polished, so porcelain need not be used over SRBP.

Conductor

SRBP

Porcelain
(may or may not
be persent)

Synthetic resin coated hard paper is wound into a cylindrical form under heat and
pressure and at appropriate radial distance conducting layers of paper in the form of
concentric cylinders are used.

For limited capacity for coating and winding machine it is rather difficult to
manufacture SRBP bushings beyond 300kV, on the other hand OIP bushing can be
made for voltages up to 750kV with conducting cylindrical layers at appropriate radial
distances.

32
 Problem: A transformer bushing for 50 kV consists of the following;

Outside diameter Permittivity

Copper rod: 4cm --
Treated paper 5cm 3
Compound 10cm 2.5
Porcelain 15cm 5

Find the minimum and maximum voltage gradients.

r  5

 r  2.5
r  3

4
5
10
15

r1 = 2; r2 = 2.5; r3 = 5 & r4 = 7.5

Let q be the charge per unit length,

q 50
  115.54kV
2 0 1 2.5 1 5 1 7.5
ln  ln  ln
3 2 2.5 2.5 5 5

q
Maximum stress on the conductor surface =  19.26
2 0  3  2
And this is the maximum stress on paper. Minimum stress on paper will be at a distance
of 2.5 cm from center.

33
 q
 E min  paper   15.4kV / cm
2 0  3  2.5

Maximum stress on the compound will be at a distance of 2.5 cm from centre and r
=2.5.

q
 E max Compound   18.48kV / cm
2 0  2.5  2.5

Minimum stress on compound will develop at a distance r = 5 from centre .

q
 E min Compound   9.24kV / cm
2 0  2.5  5

Maximum stress on the porcelain will develop at a distance r = 5 but with r = 5

q
 E max  porcelain   4.62kV / cm
2 0  5  5

& Minimum stress on porcelain will develop at a distance r = 7.5cm.

q
 E min  porcelain   3.08kV / cm
2 0  5  7.5

34
Stress distribution

100%

75% 75%

50% 50%

25% 25%
0% 0%

The diagram shows the equi-potential lines for a normal bushing. The axial stress
near the earth tank and radial l stress over the conductor surface are very high. For this
reason bushing should have a large diameter and considerably large axial length so that
stress is reduced. But this is not practically possible for system above 33kV. For this
reason condenser type construction i.e. Capacitance grading is employed for and above
33kV.

Condenser bushing

In condenser bushing a layer of Ai or Tin foils in the form cylinders are introduced
inside the dielectric. This reduces the axial stress near the earth plate of the bushing. As
shown in figure 20 % equi-potential line is raised much above the earth plate. This
reduces the axial stress considerably .By proper shaping of the dielectric the redial stress
can also be reduced i.e. by the use of condenser bushing both the diameter and axial
length can be reduced, As a matter of fact all the bushing for voltage ratings above 33kV
employing condenser type construction.

35
 100%

90%
80%
60%
40%
20%

36