High Voltage XLPE Insulated Power Cables
(Rated Voltage: 35kV~500kV)
Key Specifications
- Rated Voltage: 35kV, 66kV, 110kV, 220kV, 500kV (IEC 60840 / IEC 62067 compliant)
- Conductor: Copper (Class 2) or Aluminum (AAC/AAAC)
- Insulation: Cross-Linked Polyethylene (XLPE) with triple-layer co-extruded screens
- Sheathing:
- Metallic Screen: Copper wire/tape or aluminum laminate (water-blocking design)
- Outer Sheath: HDPE/LSZH (UV-resistant, corrosion-proof)
- Temperature Range:
- Continuous operation: 90°C
- Short-circuit (5s): 250°C
Construction Breakdown
| Layer | Material & Technology |
|---|---|
| Conductor | Oxygen-free copper or 1350-H19 aluminum, compacted stranded |
| Conductor Screen | Semi-conductive XLPE compound, smoothness ≤5μm |
| Insulation | Super-clean XLPE, thickness tolerance ±5% (IEC 60502-2) |
| Insulation Screen | Triple co-extruded semi-conductive layers |
| Metallic Screen | Copper wire braid/helical tape (≥32% coverage) or SWA armor |
| Outer Sheath | Black HDPE (UV-stabilized) or LSZH compound (flame-retardant) |
Performance Advantages
Ultra-High Insulation Reliability
- Partial discharge ≤5pC at 1.5U₀ (PD-test compliant to IEC 60885-3)
- Impulse withstand up to 550kV BIL (Basic Insulation Level) for lightning protection
Robust Mechanical Protection
- Radial water blocking: Integrated aluminum laminate + water-swellable tape
- Armor options: Steel wire armored (SWA) for direct burial or AWA for submarine cables
Environmental Adaptability
- HDPE sheath: Resists UV, chemicals, and abrasion (IP68 rating for buried applications)
- Operating range: -40°C to +90°C, suitable for Arctic or desert environments
Smart Monitoring Compatibility
- Integrated fiber optic sensors (DTS/DAS) for real-time temperature/strain monitoring
- RFID tags embedded for asset management (ISO 14223-1 compliant)
Typical Applications
| Sector | Use Cases | Recommended Types |
|---|---|---|
| Transmission Grids | Overhead lines, underground cable tunnels | AWA/SWA 220kV Cu+XLPE+HDPE |
| Renewable Energy | Offshore wind farms, solar PV plants | Submarine 66kV 3-core+FO |
| Industrial Plants | Steel mills, oil refineries (high EMI environments) | LSZH-sheathed 110kV EPR cables |
| Urban Power Networks | CBD underground links, airport electrification | FTTO-equipped 35kV Al+XLPE |
Installation Guidelines
- Bending Radius:
- ≥20× cable OD (non-armored) / ≥15× OD (armored) during laying
- Tensile Load:
- Max 70N/mm² for copper / 40N/mm² for aluminum during pulling
- Earthing:
- Metallic screens grounded at both ends (touch potential <50V)
- Testing:
- AC withstand test: 2U₀ for 30min (IEC 60840)
- Tanδ (dissipation factor) <0.001 at U₀
Certifications & Compliance
- Standards: IEC 60840, IEC 62067, CIGRE TB 303
- Certifications: UL 1072, CE, RoHS, REACH
- Fire Safety: IEC 60332-3C (flame spread), IEC 61034-2 (smoke density)
FAQ
Q1: Why choose XLPE over oil-paper insulation for HV cables?
A: XLPE offers 50% higher current rating, zero maintenance, and eco-friendly disposal vs. oil-filled systems.
Q2: Can HV cables be spliced underground?
A: Yes – use premolded GIS joints (IP68) or resin-filled straight joints (500kV rated).
Q3: Lead time for custom HV cables?
A: 12-16 weeks for 220kV+ cables (including factory acceptance tests).