Abstract
In China, recent ablation failures of water-blocking buffer layer occurred in high voltage (HV) cross-linked polyethylene (XLPE) cables with corrugated aluminum sheath have stimulated the product development of cables with smooth aluminum bonded sheath. Despite the many advantages, bending performance is one of the few weaknesses of smooth aluminum bonded sheath. In this paper, a three-dimensional model of a cable with smooth aluminum bonded sheath in a four-point bending test was set up, where the cohesive zone model was applied to simulate the mechanical behavior of the adhesive layer (bonding interface). The influence on the bending performance of the bonded sheath by the thickness of aluminum layer, the parameters of hot melt adhesive, the thickness and material parameters of outer jacket, as well as the cable specification was investigated, together with the stress distribution and damage analysis of the adhesive layer. Based on the research, the material selection and structural design of smooth aluminum bonded sheath were recommended for HV XLPE cables, including an additional requirement for the shear strength of hot melt adhesive besides those already in IEC and IEEE standards. Finally, a 110 kV XLPE cable with smooth aluminum bonded sheath was manufactured and type tested.
Highlights
In the past few decades, high voltage (HV) cables insulated with cross-linked polyethylene (XLPE) have been widely applied in urban power grids around the world [1], [2]
For XLPE land cable, metal sheaths are mainly made of aluminum, while copper, lead, stainless steel, and other metals are only used in some special occasions, such as in the case of vibration and corrosion [3]–[5]
The only thing known is that the key procedure in the production of a combined design (CD) cable is to use a qualified adhesive to bond the metal sheath and plastic outer jacket of proper dimensions, so as to improve the bending performance [3], [4], [8]–[10]
Summary
In the past few decades, high voltage (HV) cables insulated with cross-linked polyethylene (XLPE) have been widely applied in urban power grids around the world [1], [2]. The only thing known is that the key procedure in the production of a CD cable is to use a qualified adhesive to bond the metal sheath and plastic outer jacket of proper dimensions, so as to improve the bending performance [3], [4], [8]–[10]. The effects of the bonding adhesive, the smooth aluminum, the outer jacket, and the cable specification on the bending performance were discussed, and suggestions on material selection and dimension design of the bonded sheath were proposed. B. MATERIAL PARAMETERS 1) XLPE, ALUMINUM, AND POLYETHYLENE The elastic modulus, Poisson’s ratio, and the relationship between yield stress and plastic strain for each material need to be input for the mechanical simulation of the cable [5], [11].
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