Cables

www. boreal i sgroup. com I www. borouge.com XLPE compounds for Extra High Voltage cables www.borealisgroup.com I www.borouge.com About Borealis and Borouge Borealis and Borouge are leading providers of innovative, value creating plastics solutions. With more than 40 years of experience in polyolefins and using our unique Borstar ® technology, we focus on the infrastructure, automotive and advanced packaging markets across Europe, the Middle East and Asia. Our production facilities, innovation centres and service centres work with customers in more than 170 countries to provide materials that make an essential contribution to society and sustainable development. We are committed to the principles of Responsible Care ® and to leading the way in ‘Shaping the Future with Plastics’™. Borealis is owned 64% by the International Petroleum Investment Company (IPIC) of Abu Dhabi and 36% by OMV, Central Europe’s leading oil and natural gas group. With EUR 6.3 billion revenue in sales in 2007 and 5,400 employees, the company is headquartered in Vienna and has manufacturing operations in Austria, Belgium, Finland, Germany and Sweden. It also has special compounding units in Brazil, Italy and the United States. The company’s main products are polyolefins and base chemicals. Polyolefins are the collective name for polyethylene and polypropylene. Base chemicals comprise feedstocks and olefins, phenol and aromatics as well as melamine and plant nutrients. Borouge is a joint venture established in 1998 between Borealis and the Abu Dhabi National Oil Company (ADNOC), one of the world’s leading oil companies. Headquartered in Abu Dhabi, the United Arab Emirates, its state-of-the-art world-scale petrochemical complex is located at Ruwais, where it is currently implementing a multi-billion-dollar expansion. The project, called Borouge 2, is due for completion in 2010 and will triple the company’s polyolefin production capacity. For more information: www.borealisgroup.com www.borouge.com 01 Picture 1: 400 kV XLPE cables developed and produced for the Copenhagen Metropolitan and Berlin BEWAG projects using Borealis EHV compounds Contents 02 The leading supplier of XLPE compounds for EHV AC cables 03 500 kV XLPE Porce III - Columbia 04 380 kV EHV power link - Turkey 05 Dachaoshan 525 kV XLPE cable project - China 06 BEWAG 400 kV connection - Berlin 07 500 kV XLPE power cable project - Russia 08 Borealis EHV XLPE concept 09 Recommended material systems for EHV cables 09 Sources for further information XLPE compounds for Extra High Voltage cables 02 The leading supplier of XLPE compounds for EHV AC cables Crosslinked polyethylene (XLPE) was first introduced for the insulation of power cables in the 1960s. Since then XLPE cables have become the industry standard for voltages up to and including 525 kV. The excellent electrical properties, easy installation, minimal maintenance, low dielectric losses and low environmental impact of XLPE cables are the primary reasons for the continuing growth in their adoption by power generators and distributors worldwide. In close co-operation with the cable industry globally, Borealis has been at the forefront of XLPE development. Superclean™ XLPE insulation was introduced by 1973 for the first XLPE 84 kV submarine cable – 56 km long – connecting the Swedish mainland with the Finnish island of Åland. Further progress came with the introduction of Supersmooth™ semicon compound LE0500 in 1984, which permitted cable operation at even higher field strengths. As XLPE cables advanced to Extra High Voltage (220 kV) applications, Borealis put in place many research and production technology initiatives to support cable development. Working in partnership with customers and targeting developments that directly respond to their needs, Borealis has established technology for the production and supply of compounds that enable the manufacture of high stress XLPE cables. As a result, Borealis has become the leading supplier of compounds to the largest EHV projects in the world. Table 1: EHV - XLPE cable project references Project name Conductor size [mm²] Voltage [kV] Cable length [km] Entered in service PUB, Russia 1,000 220 168 1995 Powergrid, Singapore 2,000 245 58 1997 Copenhagen 1 & 2, Denmark 1,600 400 108 1997 & 1999 Berlin 1 & 2, Germany 1,600 400 63 1998 & 2000 Dublin, Ireland 1,600 220 40 2000 Madrid, Spain 2,000 220 8 2001 Dachaoshan, China 800 525 7 2001 Taiwan 2,500 345 64 2003 Seoul, South Korea 2,000 345 66 2003 London Project, UK 2,500 400 60 2004 Madrid Airport, Spain 2,500 400 90 2004 Aarhus-Arlborg, Denmark 1,200 400 15 2004 Rotterdam, The Netherlands 1,600 400 12 2005 Zhengzhou City, China 800 220 8 2005 Bureyskaya, Russia 800 500 2.5 2005 Vienna, Austria 1,200 380 32 2006 Milan, Italy 2,000 400 13 2006 Istanbul, Turkey 2,000 380 27.9 2008 Porce III Columbia 800 500 5.4 2010 03 As part of the planned expansion of Columbia’s interconnected electrical power system, the Porce III is the latest hydroelectric project and is at an advanced stage of construction. When completed the power plant will have the capacity of 660 MW distributed in four units and, when it comes on-stream in January 2011, will generate 3,605 GWh/year. Manufactured by Südkabel, the power cable for the Porce III project is based upon Borealis’ Superclean LE4224EHV insulation, Supersmooth LE0500 semiconductive compound and Borealis Borstar HE6062 sheathing. These XLPE materials are type tested for 500 kV cable, including a one-year pre-qualification test according to the IEC 62067 standard. 500 kV XLPE Porce III - Columbia Customer Südkabel, Mannheim, Germany Application Cable materials for EHV power supply Voltage: 500 kV Cable length: 5.4 km Conductor size: 800 mm² Classification: A2XS(FL)2Y1x800 RM/150 290/500kV PE Materials used Borealis Superclean™ LE4244EHV XLPE insulation Borealis Supersmooth™ LE0500 semiconductive shielding Borealis Borstar ® HE6062 jacketing Functional Requirements Consistent Extra High Voltage performance and long-term reliability Benefits Borealis Superclean compound excludes contaminants > 100 microns and controls those < 70 microns. This gives assured high levels of cleanliness and, therefore, reliable long-term performance. Borealis Supersmooth compound provides a very smooth interface between shielding and insulation to minimise electrical stresses and ensure consistently stable powerflow. Borstar HDPE delivers good long-term abrasion and stress crack resistance, together with good barrier properties. Picture 2: XYZ Table 2: XYZ Figure 1: XYZ phreatic groundwater level Dam Scour outlet Siding Reservoir Dump Water collection Conduit tunnel Upstream surge tank Distributor Transformers cavern Machine room Sub-station Cables and ventilation vault Manifold tunnel Access tunnel Square Downstream surge tank Discharge Tunnel Figure 1: XYZ XLPE compounds for Extra High Voltage cables 04 The restructuring of the Turkish electricity Power Sector in early 2000 saw the establishment of The Turkish Electricity Transmission Corporation (TEAIŞ). At that time TEAIŞ was charged with the task of developing transmission capacity to enable the reliable bulk supply of electricity to suppliers and consumers in a timely, safe and environmentally friendly manner. A key project in its overall planning to upgrade the Turkish national transmission grid, is the strengthening of the electrical transmission network between the urban centres of Istanbul and Izmit. Known as the TEAIŞ Davutpaşa-Yildiztepe project, the network improvement requires the underground installation of three 380 kV XLPE power cables between two newly constructed gas insulated substations (GIS), one each in Istanbul and Izmit, over a distance of 9,304 meters. While most of the cable route follows existing municipal roads, one 300-meter section crosses the Golden Horn estuary which separates the historical from the modern part of Istanbul. 380 kV EHV power link - Turkey Project name TEAIŞ Davutpaşa-Yildiztepe 380 kV underground cable Customer The Turkish Electricity Transmission Corporation (TEAIŞ) Contractor and Cable Producer Demirer Kablo Application Cable materials for EHV power supply • Insulation thickness: 27 mm • Diameter of cable: 142 mm • Conductor type: copper, milliken • Jacketing: Borstar HE6062 • Voltage: 380 kV • Total cable length: 27,912 m • Weight of cable: 46,960 kg/km • Conductor size: 2,000 mm² • PE Materials used Superclean LE4201EHV, crosslinkable, low-density polyethylene insulation compound Supersmooth LE0500, crosslinkable, semiconductive shielding compound Borstar HE6062, tough, low shrink jacketing Functional Requirements Consistent Extra High Voltage performance and long-term reliability Benefits Superclean compound excludes contaminants >70 microns and controls those >50 microns. This assures the high level of cleanliness necessary for reliable long-term performance Supersmooth compound provides a very smooth interface between shielding and insulation to minimise electrical stresses and ensure consistent, stable power flow Picture 2: Golden horn Table 2: Deminer project Figure 1: Project layout for Deminer power station 05 Dachaoshan 525 kV XLPE cable project - China The Dachaoshan Dam is located on the Lancang River in China’s Yunnan Province. Its six Francis turbine-generator units develop 1359 MW and this power is taken to the grid by six 525 kV and 220 kV XLPE cables. The performance of the 525 kV XLPE cables was assured by the successful completion of a stringent test programme. ÌhIake dam secIioh Maih powerhouse ahd auxiliary Maih IrahsIormer chamber Tailrace sluice shaII OuIleI oI Iailrace Iuhhel Tailrace Iuhhel F217 PehsIocks Normal sIorage level Paihy seasoh limiI Ilood level ÌhIake level 906.00 899.00 860.00 882.00 799.22 815.20 Normal Iailrace waIer level Figure 2: Project layout for Dachaoshan power station Length Duration Voltage Load cycles Conductor temperature Switching impulse Lightning impulse 100 m 1 year (16.10.1999 - 01.12.2000) 1,7 Uo (500 kV) > 180 90°C +/- 1,175 kV +/- 1,550 kV Table 3: Connection, technical data, the "Dachaoshan project" Technical data Length of connection 400 m Total core length 7,200 m Conductor 800 mm² Table 4: Technical data, the "Dachaoshan project" Picture 3: Cables installed in the power station Picture 4: Cable installation B y c o u r t e s y o f A B B , S w e d e n XLPE compounds for Extra High Voltage cables 06 BEWAG 400 kV connection - Berlin To ensure Berlin’s power supply, BEWAG (Berliner Kraft und Licht AG, now Vattenfall Europe) built a 400 kV connection joining the power networks in the west and east of the city. In late 1993 BEWAG started an extensive qualification programme of 400 kV XLPE insulated cables. The tests followed the recommendation of CIGRE Working Group 21.03. for pre-qualification of XLPE cables with voltages of >150 (170) and ≤400 (420) kV. VEAG WolmirsIedI VEAG Neuehhageh TeuIelsbruch PeuIer Havel Schloßpark Spree MiIIe Friedrichshaih Marzahh Overhead lihe Paper-oil cable Paper-oil cable Overhead lihe Overhead lihe XLPE cable XLPE cable TB MI FRH 1997 1998 RE 2000 1994 1978 MZA Connection technical data Part I Part II Length of connection 6.5 km 4 km Total cable core length 39 km 24 km Conductor Cu 1,600 mm² Cu 1,600 mm² Figure 3: Configuration of the different elements of the BEWAG 400 kV connection in Berlin Table 5: Connection, technical data, the "BEWAG Project" 07 500 kV XLPE power cable project - Russia The Bureyskaya hydroelectric power station, which is operated by the Russian General Energy System (GES), lies at the ‘other end of the world’ in the Amur region of Russia’s far east. This location provides a highly challenging environment in which the temperatures in summer can reach 40°C and in winter drop to -57°C. Installed as part of the Bureyskaya power stations third and fourth phases of expansion, the 880 m long 500 kV XLPE High Voltage cable supplied by Südkabel GmbH of Mannheim, Germany, has now been in continuous operation for about two years. This is the first 500 kV XLPE cable connection to be used in Russia. Construction of its supporting steel structure took three weeks and actual cable construction and installation 12 weeks. Customer Südkabel, Mannheim, Germany Application Cable materials for HV power supply Voltage: 500 kV Cable length: 2.5 km Conductor size: 800 mm² PE materials used Borealis Superclean LE4244EHV, crosslinkable, low-density polyethylene insulation compound. Borealis Supersmooth LE0591 crosslinkable, semiconductive shielding compound. Functional requirements Consistent High Voltage performance and long-term reliability Benefits Borealis Superclean compound excludes contaminants >100 microns and controls those <70 microns. This gives assured high levels of cleanliness and, therefore, reliable long-term performance. Borealis Supersmooth compound provides a very smooth interface between shielding and insulation to minimise electrical stresses and ensure consistently stable power flow. Figure 4: “the Südkabel, Germany project” XLPE compounds for Extra High Voltage cables 08 Borealis EHV XLPE concept The experience gained from many groundbreaking projects has shown that the only way to ensure the provision of XLPE materials of consistently high standard is to employ dedicated EHV production technology. With all EHV insulations and semicons produced and packed on dedicated lines specifically designed for their manufacture; the EHV concept is significantly enhanced above that used to manufacture High Voltage (HV) materials. The improvements include: Figure 5: Additional technology elements integrated into the Borealis EHV concept Tighter control of extrusion and process parameters throughout the • whole production chain Lower likelihood (>5 times lower) of contamination occurring in the • insulation Smaller contaminants and pips being excluded and controlled • Less chance (>10 times less) of pips in the semicon • Higher chemical cleanliness and smoothness of semicons • E H V e x p e r i e n c e [ k m / y r s ] 1996 1998 2000 2002 2004 2006 2007 1994 25,000 20,000 15,000 10,000 5,000 0 Extra training EVH manual / procedure Special cleaning Controlled product sequence Small batch size On line segregation High level of supervision Project focus Special product package Very fine filtration Proven technology for clean product delivery In ensuring the safe production of EHV cables, the handling of compounds must be made with minimal risk of contamination. Experience with many projects (Figure 6 & Table 1) has shown that the Borealis developed “EHV Octabin System” provides a very efficient and flexible solution. The Octabin (1 T approx) is filled and emptied under clean room conditions thus preserving ‘as produced’ quality during transfer to the cable extrusion plant. The correct design of systems within the cable manufacturing facility (gravity unload for example) and effective, regular cleaning procedures to maintain high levels of purity are a necessary complement to this system. Figure 6: Global experience of EHV XLPE cable systems 09 Recommended material systems for EHV cables Sources for further information 1) D. Miller, London Infrastructure Project, ELECTRA 206 Feb 2003 p. 24-35. 2) J-O. Boström, A. Campus, RN. Hampton, H. Lennartson, A. Smedberg & D. Wald, Critical issues for the HV & EHV XLPE cables of today and tomorrow, Jicable 2003, p. 111-117. 3) IEC 62067 Power cables with extruded insulation and their accessories for rated voltages above 150 kV (Um=170 kV) up to 500 kV (Um=550 kV) – Test methods and requirements. 4) Bjorlow-Larsen et al, Large projects of EHV underground cable systems, Jicable 2003 p. 61-69. Production characteristics Semiconductive Insulation Jacket Normal viscosity Supersmooth LE0500 Superclean LE4201EHV Borstar HE6062 / HE6063 Casico™ - Flame retardant FR4805 High viscosity (Low sag) Supersmooth LE0500 Superclean LE4244EHV Table 7: Recommended material systems for EHV cables Picture 5: Routing testing confirming the good performance of EHV XLPE XLPE compounds for Extra High Voltage cables 010 011 XLPE compounds for Extra High Voltage cables 012 Borealis and Borouge – Dedicated to Wire & Cable Solutions Borealis and Borouge are the world’s leading providers of innovative, value creating plastics solutions for the wire and cable industry. Our solutions are customer-driven and designed to satisfy the industry’s continuously evolving demands for higher technical performance. Consequently, they can be found in the most challenging EHV and HV cable applications, as well as MV and LV energy transmission and distribution cables, building wires, and communications cables. In answer to the need for production, installation and cable-system lifetime enhancements, we create the innovation links that secure world-class, step-change solutions and benefit the whole wire and cable value chain. Through the introduction of unique polymer technologies, which include Supercure™, Visico™/Ambicat™, Borcell™, Borstar ® , and Casico™, we continue to pioneer the development of advanced insulation and jacketing systems for both energy and communication cables. Built on more than 40 years experience, Borealis and Borouge have a well-established track record in serving customers’ needs with the consistently high quality products expected of global leaders. We are committed to extending that leadership position and our role as reliable partners for the long-term – a commitment not only supported by our forward thinking in innovative solutions, but also confirmed by ongoing investments for our customers’ continued success. Putting customers’ needs at the centre of our planning is reflected in the commissioning of expanded XLPE production capacity in the second half of 2007 and Borealis’ EUR 370 million investment in a new 350,000 tonne/year LDPE plant in Stenungsund, Sweden, scheduled to come onstream towards the end of 2009. Furthermore, Borouge’s expansion of Borstar ® capacity in the Middle East allows us to satisfy growing customer demand for wire and cable products in emerging markets. Through ongoing research and development, investment in the future and a dedicated team with solid industry knowledge, we aim to remain fully responsive to our customers’ needs throughout the world. Disclaimer The information contained herein is to our knowledge accurate and reliable as of the date of publication. Borealis and Borouge extend no warranties and make no representations as to the accuracy or completeness of the information contained herein, and assume no responsibility regarding the consequences of its use or for any printing errors. It is the customer’s responsibility to inspect and test our products in order to satisfy himself as to the suitability of the products for the customer’s particular purpose. The customer is also responsible for the appropriate, safe and legal use, processing and handling of our products. Nothing herein shall constitute any warranty (express or implied, of merchantability, fitness for a particular purpose, compliance with performance indicators, conformity to samples or models, non-infringement or otherwise), nor is protection from any law or patent to be inferred. Insofar as products supplied by Borealis and Borouge are used in conjunction with third-party materials, it is the responsibility of the customer to obtain all necessary information relating to the third-party materials and ensure that Borealis and Borouge products, when used together with these materials, are suitable for the customer’s particular purpose. No liability can be accepted in respect of the use of Borealis and Borouge products in conjunction with other materials. The information contained herein relates exclusively to our products when not used in conjunction with any third-party materials. Borstar is a registered trademark of Borealis A/S. Supercure, SuperTR, Supersmooth, Casico, Visico, Ambicat, Superclean and Nimblicity are trademarks of Borealis A/S. © 2 0 1 0 B o r e a l i s A G © 2 0 1 0 B o r o u g e P t e L t d For more information : visit www.borealisgroup.com and www.borouge.com Borealis AG I IZD Tower Wagramer Strasse 17-19 I A-1220 Vienna I Austria Tel +43 1 22 400 000 I Fax +43 1 22 400 333 Borouge Pte Ltd I Sales and Marketing Head Office 1 George Street 18-01 I Singapore 049145 Tel +65 6275 4100 I Fax +65 6377 1233 W C B R O C H 0 7 9 / G B 2 0 1 0 0 2 B B borealisgroup. Polyolefins are the collective name for polyethylene and polypropylene. It also has special compounding units in Brazil. the United Arab Emirates. Headquartered in Abu Dhabi. is due for completion in 2010 and will triple the company’s polyolefin production capacity. its state-of-the-art world-scale petrochemical complex is located at Ruwais. value creating plastics solutions. With EUR 6.com About Borealis and Borouge Borealis and Borouge are leading providers of innovative. phenol and aromatics as well as melamine and plant nutrients.borealisgroup. Germany and Sweden.3 billion revenue in sales in 2007 and 5.com . Borealis is owned 64% by the International Petroleum Investment Company (IPIC) of Abu Dhabi and 36% by OMV. Central Europe’s leading oil and natural gas group. Finland. innovation centres and service centres work with customers in more than 170 countries to provide materials that make an essential contribution to society and sustainable development. automotive and advanced packaging markets across Europe.www. For more information: www. where it is currently implementing a multi-billion-dollar expansion.borouge. The project. we focus on the infrastructure. the company is headquartered in Vienna and has manufacturing operations in Austria. the Middle East and Asia. The company’s main products are polyolefins and base chemicals. Borouge is a joint venture established in 1998 between Borealis and the Abu Dhabi National Oil Company (ADNOC). one of the world’s leading oil companies. With more than 40 years of experience in polyolefins and using our unique Borstar® technology. called Borouge 2. Base chemicals comprise feedstocks and olefins. Belgium. Our production facilities. We are committed to the principles of Responsible Care® and to leading the way in ‘Shaping the Future with Plastics’™.com I www.com www.borouge. Italy and the United States.400 employees. China BEWAG 400 kV connection .Russia Borealis EHV XLPE concept Recommended material systems for EHV cables Sources for further information Picture 1: 400 kV XLPE cables developed and produced for the Copenhagen Metropolitan and Berlin BEWAG projects using Borealis EHV compounds 03 04 05 06 07 08 09 09 .Turkey Dachaoshan 525 kV XLPE cable project .01 Contents 02 The leading supplier of XLPE compounds for EHV AC cables 500 kV XLPE Porce III .Berlin 500 kV XLPE power cable project .Columbia 380 kV EHV power link . 9 5.600 1.500 2. Borealis has been at the forefront of XLPE development. Since then XLPE cables have become the industry standard for voltages up to and including 525 kV.500 1.XLPE cable project references Project name PUB.600 800 800 1. Table 1: EHV . Borealis put in place many research and production technology initiatives to support cable development. Denmark Rotterdam. Spain Dachaoshan.600 1.200 2. The excellent electrical properties. Borealis has established technology for the production and supply of compounds that enable the manufacture of high stress XLPE cables.000 1.000 800 2.4 Entered in service 1995 1997 1997 & 1999 1998 & 2000 2000 2001 2001 2003 2003 2004 2004 2004 2005 2005 2005 2006 2006 2008 2010 . China Taiwan Seoul. easy installation. which permitted cable operation at even higher field strengths. As XLPE cables advanced to Extra High Voltage (220 kV) applications. South Korea London Project.000 2. Italy Istanbul.000 800 Voltage [kV] 220 245 400 400 220 220 525 345 345 400 400 400 400 220 500 380 400 380 500 Cable length [km] 168 58 108 63 40 8 7 64 66 60 90 15 12 8 2. Austria Milan.600 2.000 2. Russia Vienna.000 2. Denmark Berlin 1 & 2. minimal maintenance. Turkey Porce III Columbia Conductor size [mm²] 1.500 2.5 32 13 27. Borealis has become the leading supplier of compounds to the largest EHV projects in the world.200 1. In close co-operation with the cable industry globally. Russia Powergrid. Ireland Madrid. The Netherlands Zhengzhou City. UK Madrid Airport. Singapore Copenhagen 1 & 2. Germany Dublin.02 XLPE compounds for Extra High Voltage cables The leading supplier of XLPE compounds for EHV AC cables Crosslinked polyethylene (XLPE) was first introduced for the insulation of power cables in the 1960s. Spain Aarhus-Arlborg. As a result. Superclean™ XLPE insulation was introduced by 1973 for the first XLPE 84 kV submarine cable – 56 km long – connecting the Swedish mainland with the Finnish island of Åland. China Bureyskaya. low dielectric losses and low environmental impact of XLPE cables are the primary reasons for the continuing growth in their adoption by power generators and distributors worldwide. Working in partnership with customers and targeting developments that directly respond to their needs. Further progress came with the introduction of Supersmooth™ semicon compound LE0500 in 1984. therefore. Supersmooth LE0500 semiconductive compound and Borealis Borstar HE6062 sheathing. These XLPE materials are type tested for 500 kV cable. Germany Cable materials for EHV power supply Voltage: 500 kV Cable length: 5. Borstar HDPE delivers good long-term abrasion and stress crack resistance. Mannheim. the power cable for the Porce III project is based upon Borealis’ Superclean LE4224EHV insulation.605 GWh/year. will generate 3. when it comes on-stream in January 2011. Manufactured by Südkabel. Borealis Supersmooth compound provides a very smooth interface between shielding and insulation to minimise electrical stresses and ensure consistently stable powerflow.03 500 kV XLPE Porce III . reliable long-term performance. Reservoir Dump Dam Water collection Picture 2: XYZ Scour outlet Siding Conduit tunnel Upstream surge tank Sub-station Machine room Distributor Transformers cavern Cables and ventilation vault Access tunnel Manifold tunnel Square Downstream surge tank Discharge Tunnel Figure 1: XYZ Figure 1: XYZ Customer Application Südkabel. This gives assured high levels of cleanliness and. including a one-year pre-qualification test according to the IEC 62067 standard.Columbia As part of the planned expansion of Columbia’s interconnected electrical power system.4 km Conductor size: 800 mm² Classification: A2XS(FL)2Y1x800 RM/150 290/500kV phreatic groundwater level PE Materials used Borealis Superclean™ LE4244EHV XLPE insulation Borealis Supersmooth™ LE0500 semiconductive shielding Borealis Borstar ® HE6062 jacketing Functional Requirements Benefits Consistent Extra High Voltage performance and long-term reliability Borealis Superclean compound excludes contaminants > 100 microns and controls those < 70 microns. together with good barrier properties. When completed the power plant will have the capacity of 660 MW distributed in four units and. Table 2: XYZ . the Porce III is the latest hydroelectric project and is at an advanced stage of construction. Turkey The restructuring of the Turkish electricity Power Sector in early 2000 saw the establishment of The Turkish Electricity Transmission Corporation (TEAIŞ). At that time TEAIŞ was charged with the task of developing transmission capacity to enable the reliable bulk supply of electricity to suppliers and consumers in a timely.912 m • Weight of cable: 46. Project name Customer Contractor and Cable Producer Application TEAIŞ Davutpaşa-Yildiztepe 380 kV underground cable The Turkish Electricity Transmission Corporation (TEAIŞ) Demirer Kablo • Cable materials for EHV power supply • Insulation thickness: 27 mm • Diameter of cable: 142 mm • Conductor type: copper. semiconductive shielding compound Borstar HE6062. Known as the TEAIŞ Davutpaşa-Yildiztepe project. low shrink jacketing Functional Requirements Benefits Consistent Extra High Voltage performance and long-term reliability Superclean compound excludes contaminants >70 microns and controls those >50 microns. crosslinkable. While most of the cable route follows existing municipal roads.960 kg/km • Conductor size: 2. one 300-meter section crosses the Golden Horn estuary which separates the historical from the modern part of Istanbul. safe and environmentally friendly manner.000 mm² PE Materials used Superclean LE4201EHV. low-density polyethylene insulation compound Supersmooth LE0500. over a distance of 9. is the strengthening of the electrical transmission network between the urban centres of Istanbul and Izmit. crosslinkable. milliken • Jacketing: Borstar HE6062 • Voltage: 380 kV • Total cable length: 27. tough. This assures the high level of cleanliness necessary for reliable long-term performance Supersmooth compound provides a very smooth interface between shielding and insulation to minimise electrical stresses and ensure consistent. the network improvement Picture 2: Golden horn requires the underground installation of three 380 kV XLPE power cables between two newly constructed gas insulated substations (GIS). A key project in its overall planning to upgrade the Turkish national transmission grid.04 XLPE compounds for Extra High Voltage cables 380 kV EHV power link . one each in Istanbul and Izmit.304 meters. stable power flow Table 2: Deminer project Figure 1: Project layout for Deminer power station . 2000) Voltage 1.01.05 Dachaoshan 525 kV XLPE cable project China The Dachaoshan Dam is located on the Lancang River in China’s Yunnan Province.200 m 800 mm² Table 4: Technical data.12.7 Uo (500 kV) Load cycles > 180 Conductor temperature 90°C Switching impulse +/. the "Dachaoshan project" Technical data Length of connection Total core length Conductor 400 m 7.550 kV Table 3: Connection.1999 .1. Length 100 m Duration 1 year (16. Its six Francis turbine-generator units develop 1359 MW and this power is taken to the grid by six 525 kV and 220 kV XLPE cables.175 kV Lightning impulse +/.1. the "Dachaoshan project" Figure 2: Project layout for Dachaoshan power station Picture 3: Cables installed in the power station By courtesy of ABB. technical data. The performance of the 525 kV XLPE cables was assured by the successful completion of a stringent test programme.10. Sweden Picture 4: Cable installation . 600 mm² Figure 3: Configuration of the different elements of the BEWAG 400 kV connection in Berlin . BEWAG (Berliner Kraft und Licht AG.600 mm² Part II 4 km 24 km Cu 1. technical data. Connection technical data Length of connection Total cable core length Conductor Table 5: Connection.Berlin To ensure Berlin’s power supply.5 km 39 km Cu 1. now Vattenfall Europe) built a 400 kV connection joining the power networks in the west and east of the city.03. the "BEWAG Project" Part I 6. for pre-qualification of XLPE cables with voltages of >150 (170) and ≤400 (420) kV.06 XLPE compounds for Extra High Voltage cables BEWAG 400 kV connection . In late 1993 BEWAG started an extensive qualification programme of 400 kV XLPE insulated cables. The tests followed the recommendation of CIGRE Working Group 21. therefore. the 880 m long 500 kV XLPE High Voltage cable supplied by Südkabel GmbH of Mannheim.Russia The Bureyskaya hydroelectric power station. This gives assured high levels of cleanliness and. This is the first 500 kV XLPE cable connection to be used in Russia. Germany Cable materials for HV power supply Voltage: 500 kV Cable length: 2. Functional requirements Benefits Consistent High Voltage performance and long-term reliability Borealis Superclean compound excludes contaminants >100 microns and controls those <70 microns. has now been in continuous operation for about two years. Borealis Supersmooth compound provides a very smooth interface between shielding and insulation to minimise electrical stresses and ensure consistently stable power flow. Germany.07 500 kV XLPE power cable project . Installed as part of the Bureyskaya power stations third and fourth phases of expansion.5 km Conductor size: 800 mm² Borealis Superclean LE4244EHV. Borealis Supersmooth LE0591 crosslinkable. lies at the ‘other end of the world’ in the Amur region of Russia’s far east. Construction of its supporting steel structure took three weeks and actual cable construction and installation 12 weeks. which is operated by the Russian General Energy System (GES). Germany project” Customer Application PE materials used Südkabel. Mannheim. This location provides a highly challenging environment in which the temperatures in summer can reach 40°C and in winter drop to -57°C. crosslinkable. reliable long-term performance. low-density polyethylene insulation compound. Figure 4: “the Südkabel. semiconductive shielding compound. . the EHV concept is significantly enhanced above that used to manufacture High Voltage (HV) materials. the handling of compounds must be made with minimal risk of contamination.000 0 1994 Controlled product sequence Special cleaning High level of supervision Small batch size On line segregation Special product package Very fine filtration Project focus 1996 1998 2000 2002 2004 2006 2007 Figure 5: Additional technology elements integrated into the Borealis EHV concept Figure 6: Global experience of EHV XLPE cable systems Proven technology for clean product delivery In ensuring the safe production of EHV cables. The correct design of systems within the cable manufacturing facility (gravity unload for example) and effective. . The Octabin (1 T approx) is filled and emptied under clean room conditions thus preserving ‘as produced’ quality during transfer to the cable extrusion plant.08 XLPE compounds for Extra High Voltage cables Borealis EHV XLPE concept The experience gained from many groundbreaking projects has shown that the only way to ensure the provision of XLPE materials of consistently high standard is to employ dedicated EHV production technology.000 15.000 10. The improvements include: • Tighter control of extrusion and process parameters throughout the whole production chain • Lower likelihood (>5 times lower) of contamination occurring in the insulation • Smaller contaminants and pips being excluded and controlled • Less chance (>10 times less) of pips in the semicon • Higher chemical cleanliness and smoothness of semicons Extra training EVH manual / procedure 25. With all EHV insulations and semicons produced and packed on dedicated lines specifically designed for their manufacture.000 5. Experience with many projects (Figure 6 & Table 1) has shown that the Borealis developed “EHV Octabin System” provides a very efficient and flexible solution. regular cleaning procedures to maintain high levels of purity are a necessary complement to this system.000 EHV experience [km/yrs] 20. Campus. London Infrastructure Project. Boström. Jicable 2003 p. Miller. 24-35. Lennartson. 111-117 . Critical issues for the HV & EHV XLPE cables of today and tomorrow.Flame retardant FR4805 Table 7: Recommended material systems for EHV cables Picture 5: Routing testing confirming the good performance of EHV XLPE Sources for further information 1) D. Hampton. Wald. RN. H. ELECTRA 206 Feb 2003 p. 2) J-O.09 Recommended material systems for EHV cables Production characteristics Semiconductive Insulation Jacket Normal viscosity Supersmooth LE0500 Superclean LE4201EHV Borstar HE6062 / HE6063 High viscosity (Low sag) Supersmooth LE0500 Superclean LE4244EHV Casico™ . 61-69. Smedberg & D. A. . Large projects of EHV underground cable systems. A. 4) Bjorlow-Larsen et al. p. 3) IEC 62067 Power cables with extruded insulation and their accessories for rated voltages above 150 kV (Um=170 kV) up to 500 kV (Um=550 kV) – Test methods and requirements. Jicable 2003. 010 XLPE compounds for Extra High Voltage cables . 011 . 012 XLPE compounds for Extra High Voltage cables . Visico™/Ambicat™. conformity to samples or models. but also confirmed by ongoing investments for our customers’ continued success. Visico. building wires. they can be found in the most challenging EHV and HV cable applications. we aim to remain fully responsive to our customers’ needs throughout the world. are suitable for the customer’s particular purpose. Supercure. Putting customers’ needs at the centre of our planning is reflected in the commissioning of expanded XLPE production capacity in the second half of 2007 and Borealis’ EUR 370 million investment in a new 350. and assume no responsibility regarding the consequences of its use or for any printing errors. value creating plastics solutions for the wire and cable industry. when used together with these materials. No liability can be accepted in respect of the use of Borealis and Borouge products in conjunction with other materials. compliance with performance indicators. and Casico™.000 tonne/year LDPE plant in Stenungsund. Borcell™. The information contained herein relates exclusively to our products when not used in conjunction with any third-party materials. safe and legal use. Supersmooth. Borealis and Borouge – Dedicated to Wire & Cable Solutions Borealis and Borouge are the world’s leading providers of innovative. Superclean and Nimblicity are trademarks of Borealis A/S. installation and cable-system lifetime enhancements. Through the introduction of unique polymer technologies. as well as MV and LV energy transmission and distribution cables. scheduled to come onstream towards the end of 2009. processing and handling of our products. Consequently. SuperTR. Borealis and Borouge extend no warranties and make no representations as to the accuracy or completeness of the information contained herein. Sweden. it is the responsibility of the customer to obtain all necessary information relating to the third-party materials and ensure that Borealis and Borouge products. Nothing herein shall constitute any warranty (express or implied. nor is protection from any law or patent to be inferred.Disclaimer The information contained herein is to our knowledge accurate and reliable as of the date of publication. Furthermore. Built on more than 40 years experience. of merchantability. Ambicat. Borealis and Borouge have a well-established track record in serving customers’ needs with the consistently high quality products expected of global leaders. Borstar®. non-infringement or otherwise). The customer is also responsible for the appropriate. Casico. step-change solutions and benefit the whole wire and cable value chain. In answer to the need for production. . which include Supercure™. Borouge’s expansion of Borstar® capacity in the Middle East allows us to satisfy growing customer demand for wire and cable products in emerging markets. Borstar is a registered trademark of Borealis A/S. and communications cables. It is the customer’s responsibility to inspect and test our products in order to satisfy himself as to the suitability of the products for the customer’s particular purpose. investment in the future and a dedicated team with solid industry knowledge. Our solutions are customer-driven and designed to satisfy the industry’s continuously evolving demands for higher technical performance. fitness for a particular purpose. We are committed to extending that leadership position and our role as reliable partners for the long-term – a commitment not only supported by our forward thinking in innovative solutions. Through ongoing research and development. Insofar as products supplied by Borealis and Borouge are used in conjunction with third-party materials. we continue to pioneer the development of advanced insulation and jacketing systems for both energy and communication cables. we create the innovation links that secure world-class. com and www.com © 2010 Borealis AG © 2010 Borouge Pte Ltd Borealis AG I IZD Tower Wagramer Strasse 17-19 I A-1220 Vienna I Austria Tel +43 1 22 400 000 I Fax +43 1 22 400 333 Borouge Pte Ltd I Sales and Marketing Head Office 1 George Street 18-01 I Singapore 049145 Tel +65 6275 4100 I Fax +65 6377 1233 .borealisgroup.WC BROCH079/GB 2010 02 BB For more information : visit www.borouge.