Power Cable Technology provides a precise understanding of the design, manufacture, installation, and testing of a range of electric power cables—from low-voltage, 1,000/1,100V cables to extra-high-voltage, 400kV cables—with reference to future trends in the industry.
The authors’ mantra is: know your cable. Thus, the book begins with a comprehensive overview of power cable design and manufacturing through the ages, and then:
- Describes the characteristics of the materials currently used in the production of various power cables
- Explains how to calculate the die orifice for drawing wires, how tolerance in manufacturing affects material weight and consumption, and how and why lubricants are used
- Addresses the formation, stranding, and insulation of the electrical conductors, as well as the sheathing, armouring, and protective covering of the power cables
- Delivers an in-depth discussion of quality systems, quality control, and performance testing
- Covers the many nuances of cable installation, including laying, jointing, and terminating
Throughout, the authors emphasise consonance between design theory and practical application to ensure production of a quality power cable at a reasonable cost. They also underscore the importance of careful handling, making Power Cable Technology a must read for power cable engineers and technicians alike.
Introduction
Basic Materials for Manufacturing Various Types of Electric Power Cables
Conductor Material
Insulating Materials
Fillers
Other Chemicals
Wire Drawing: Copper and Aluminium
Wire Drawing
Wire Drawing Machine
Conductor Formation–Stranding: Theory and Practice
Sector-Shaped Conductor for an 11,000 V cable
Elliptical-/ Oval-Shaped Conductor for a 33,000 V Cable
Manufacturing of Conductor with Profiled Wire (Profiled Wire Manufacturing Is Elaborated in Chapter 3—Figure 3.23)
Insulation and Insulated Conductors
Insulation
Application of Insulation on Conductors
Pay-Off
Horizontal Continuous Vulcanisation System
Degassing: For HV and EHV Cables
Sioplas System of Curing and Manufacturing XLPE Cables
Irradiation System of Curing Polythene Insulation
Basic Concepts of Radiation Processing
Processing Methods
Assembling and Laying Up of Multicore Cable and Protective Metal Sheathing
Taping
Protective Sheath for Laid-Up Cable Core (Mechanical and Electrical Protection)
Metal Covering (Lead)
Aluminium
Corrugated Steel Tape
Calculation of Short-Circuit Rating Capacity for Metal Sheath
Earth Bonding of HV and EHV Cable Sheath
Armouring and Protective Covering
Armouring
Protective Covering
Electrical Parameters for Designing Cables
Insulation
Thermal Resistivity
Voltage Induced in the Conductor of a Control Cable When Laid alongside an Electrified Railway Track
Transmission of High-Frequency Signal through HV and EHV Cables
Quality Systems, Quality Control and Testing
What Is Quality?
Testing of Cable
Tensile Strength
Elongation
Ageing Test
Hot Set Test (A Measure to Determine the Amount of Cross-Linking Achieved) for Cured Materials such as XLPE and Elastomers
Solvent Extraction
Null Detector
Interface Suppression
Protection
Resistance of the Conductor
Measuring Low Resistance using the Kelvin Double Bridge
Wheatstone Bridge to Measure Conductor Resistance on Completed Cables
Wheatstone Bridge Theory
AC Voltage Test
Partial Discharge Test
Impulse Voltage Test
Dimensional Check
Measurement of Armour Wires and Tapes
Voltage Test for 4 h
Type Tests, Electrical
Cables Having Conductor Screens and Insulation Screens
Bending Test
Heating Cycle Test
Resistivity of Semiconducting Screens
Test for Longitudinal Watertightness
Flame Propagation Tests under Different Conditions
LOCA Test for Nuclear Plants
Test and Measurement Facilities
Synergism Simulator
Cables for Offshore Wind Firms and Oil Exploration Rigs: Hyperbaric Test
Checking for Leakages in Each Test
Some Special Cables
Aerial Bunch Cables
Direct Current Cables
Umbilical Cables
Power Cable Laying, Jointing, and Installation
Backfilling of Trenches and Pipes
Selected Materials Such as Sands as Backfill Material
Ducts
Cable Laying on Steel Trays and Racks (Both for LV Distribution and MV, HV, and EHV Transmission Cables)
Joints and Terminations
Desirable Design Features
Jointing of Cable and Conductor
Crimping and Compression Joints
Welding Methods
Insulating the Joint
Insulation: Low-Voltage Cable from 400/440 to 3000/3300 V PVC Insulated
HV and EHV Joints
Stress Control
Straight Through Joint on EHV Cable
Termination
HV and EHV Cable Terminations
Thermomechanical Problems
Aerial Bunch Cables and Screen Terminations (11 and 33 kV Cables)
Tests Conducted after Installation
References
Biography
Sushil Kumar Ganguli has more than 50 years of experience in the electrical cable industry. After graduating in physics from St. Xavier’s College, he was trained as a cable technologist in the reputable German cable industry, then appointed technical and production manager at Universal Cables Ltd., where he researched, designed, and developed new, better performing, more competitive types of cables for railways and defense. He subsequently worked in various capacities with Gloster Industries; joined Cable Corporation of India (in collaboration with Siemens Germany) as head of R&D and took charge of the Technical Department as technical manager; helped develop cable manufacturing machinery at Vidhya Kabelmats India Pvt. Ltd.; and served as technical advisor to Paramount Communication Ltd., AEI Cables Ltd. UK, Hindusthan Vidyut Products Ltd., and Uniflex Cables. Widely published, he has lectured at the Institute of Electrical Engineers, Electrical Contractors Association, National Test House, Calcutta Electric Supply Corporation Ltd., and Electrical Cable Development Association.
Vivek Kohli has 37+ years of experience in running businesses with P&L responsibility, and has led core functions, projects, business development, administration, operations, and technology. After earning his BE in electrical engineering from the Birla Institute of Technology, he began his career as chief operations manager with RPG Cables Ltd. He subsequently worked with Hindusthan Vidyut Products Ltd. as technical vice president, Polycab, Ravin Cables Ltd., and Sterlite Technologies Ltd. as CTO and business head. He is currently CEO for power business and group HR, and IT lead in Hindusthan Group. Prior to CEO, he was president of strategic new business and projects at Hindusthan Group. Widely known as an EHV cable and HTLS conductor expert and business head for several startups in the wire and cable industry, he was instrumental in making the first XLPE cable and HTLS conductor in India. He is an Indian Institute of Plant Engineers corporate member, as well as a member of the Society of Power Engineers, Cigré, and Belgian-Luxembourg Business Association.
"This two-volume set thoroughly details system-level design, micro design, logic verification, and testing of integrated circuits. Electronic design automation (EDA) is a category of software tools for designing electronic systems such as printed circuit boards and integrated circuits. The tools work together in a design flow that chip designers use to design and analyze entire semiconductor chips. EDA is also referred to as electronic computer aided design (ECAD).
There is a wealth of information contained in these two volumes for readers working with or interested in learning about microprocessor design, testing, and verification."
—John Shea, IEEE Electrical Insulation Magazine, March/April 2017 Issue"... very useful for everybody in the cable industry and studying electrical engineering. ... theory meets with experience in this book. ... an extraordinary masterpiece in this field. Fills many gaps, and answers a lot of questions that never could have been answered so well before."
—Erkan Muslu, Colleague"Power Cable Technology, offers an understanding of the design, manufacture, installation and testing of a range of electric power cables—from low-voltage, 1000/1100 V cables to extra-high-voltage, 400 kV cables. The book offers an overview of power cable design and manufacturing."
— Wire & Cable Technology International, June 2016 Issue
