XLPE INSULATED CABLES MV-90
Designed for Medium Voltage (MV) Applications Ranging from 5kV to 46kV, Playing a Critical Role in Distributing Electrical Power
XLPE INSULATED CABLES MV-90
Application and Description
The single core cables are designed for distribution of electrical power with nominal voltage Uo/U ranging from 5KV to 46KV and frequency 50Hz. Single core cables are made of stranded copper or aluminium conductor, triple extruding insulating system consisting of thermosetting semi-conducting conductor shield, XLPE/TR-XLPE/EPR insulation and thermosetting semiconducting insulation shield. There are a number of designs of metallic shields including the copper tape helically applied with overlap, copper wire shield, concentric neutral, longitudinally applied corrugated copper tape and metal sheath available, which are surrounded with fillers and grounding conductor, overall binder tape and overall PVC, LSZH or PE jacket.
Standards
National Fire Protection Standard (NEPA 70): National Electric Code
AEIC CS8
ICEA S-93-639 (NEMA WC74), Standard for shielded power cable 5KV-46KV
ICEA S-97-682
IEEE 1202 – Flame Testing of cables for use in cable tray
ICEA T29-520 Vertical
UL 1072 for medium voltage cables.
Construction
Conductor
The conductor consists of uncoated Class B compressed concentric stranded aluminium alloy 1350 or soft drawn annealed copper meeting the requirement of ASTM B3. Unless otherwise specified, the conductor shall be supplied class B as per ASTM B496.
Conductor Shield
Conductor shield consists of extruded thermosetting semi conducting compound which is free stripping from conductor and bonded to the insulation.
Insulation
The insulation is either XLPE or EPR extruded concentrically over the conductor. High dielectric strength tree retardant XLPE (TR-XLPE) can be offered as option to provide an optimum balance of mechanical and electrical properties, insuring resistance to treeing.
100% or 133% insulation level is available upon request. The insulation meets or exceeds electrical and physical requirements of ICEA S-96-659/NEMA WC71, and UL 1072.
Insulation Shield
Insulation shield consists of extruded thermosetting semi-conducting compound with controlled adhesion to the insulation, providing required balance between electrical integrity and ease of stripping.
Metallic Shielding
1) Copper Tape
For Copper tape shield, helically bare 5 mil copper tape shield over the insulation shield with minimum overlap of 20%. There are grounding conductor made of bare stranded copper conductor per each interstices, per UL, ICEA and AST
2) Wire Shield
Bare copper wire shield is evenly spaced with 5000 circular mils minimum per inch of core diameter. The shield insures a reliable shield that can be easily terminated.
3) Concentric Neutral
Either bare or tinned copper wire (#6 to #9AWG) is helically applied around the cores.
Assembly
Cables are cabled together with a left hand lay and suitable filler to make the cable round. A binder tape is applied to maintain core geometry and mechanical stability. Fillers may be PP yarn, ramie yarn, plastics or other filler material.
Armour (optional)
For armouring options, inner PVC jacket is applied over the binder type. Corrugated aluminium interlocking armour (AIA) is applied over the inner jacket.
Jacket
A protective sunlight and ozone resistant jacket of PVC is extruded for a tight fit over the welded armour or the core assembly.
Options
-TR-XLPE insulation.
-Compact stranded conductor.
-Super smooth conductor shield.
-Zero or one grounding conductor.
-CPE, LLLPE, LSOH or low temperature PVC jacket.
-Oil resistant jacket.
What Are XLPE Insulated Cables MV-90?
XLPE Insulated Cables MV-90 are single-core cables engineered for medium-voltage power distribution, operating at nominal voltages from 5kV to 46kV with a frequency of 50Hz. The term "XLPE" refers to cross-linked polyethylene, a thermosetting material that offers superior electrical and mechanical properties compared to traditional insulation materials like PVC. The "MV-90" designation indicates that these cables are rated for operation at a maximum conductor temperature of 90°C, making them suitable for demanding environments.
These cables are designed to carry electrical power efficiently over long distances, with applications in underground ducts, direct burial, and aerial installations. Their robust construction ensures durability, resistance to environmental stressors, and reliable performance in both urban and industrial settings.
Standards and Compliance
XLPE Insulated Cables MV-90 are manufactured to meet rigorous industry standards, ensuring safety, reliability, and performance. Key standards include:
NFPA 70 (National Electrical Code): Ensures compliance with safety regulations for electrical installations.
AEIC CS8: Specifies requirements for extruded dielectric shielded power cables.
ICEA S-93-639 (NEMA WC74): Governs shielded power cables rated 5kV to 46kV.
ICEA S-97-682: Addresses utility-shielded power cables.
IEEE 1202: Tests flame propagation for cables used in cable trays.
UL 1072: Certifies medium-voltage cables for safety and performance.
These standards ensure that XLPE Insulated Cables MV-90 meet the electrical, mechanical, and environmental requirements for medium-voltage applications.
Applications of XLPE Insulated Cables MV-90
XLPE Insulated Cables MV-90 are versatile, supporting a wide range of applications in power distribution:
Utility Networks: Used in underground ducts or direct burial for distributing power in urban and rural grids.
Industrial Facilities: Power heavy machinery and equipment in factories, refineries, and mines.
Renewable Energy: Connect wind turbines and solar panels to the grid, handling medium-voltage outputs.
Commercial Buildings: Supply power to large office complexes, hospitals, and data centers.
Aerial Installations: Used in overhead power lines where lightweight aluminum conductors are preferred.
The cables’ ability to operate at 90°C in ducts or air, combined with their resistance to moisture and thermal stress, makes them ideal for these diverse applications.
Technical Specifications and Performance
The technical specifications of XLPE Insulated Cables MV-90 vary depending on voltage rating, conductor size, and shielding type. Below is a summary of key specifications for wire-shielded and tape-shielded cables at 5kV, 15kV, 25kV, and 35kV, based on ICEA standards:
Wire-Shielded Cables (5kV, 100% Insulation Level)
4 AWG: Insulation thickness 2.29 mm (90 mils), overall diameter 17.5 mm, weight 430 kg/km (CU) or 289 kg/km (AL), ampacity 110A (CU, in duct) or 145A (CU, in air).
1000 MCM: Insulation thickness 2.29 mm, overall diameter 42.4 mm, weight 5426 kg/km (CU), ampacity 1075A (CU, in air).
Tape-Shielded Cables (15kV, 100% Insulation Level)
2 AWG: Insulation thickness 4.45 mm (175 mils), overall diameter 23.4 mm, weight 820 kg/km (CU), ampacity 195A (CU, in air).
1000 MCM: Insulation thickness 4.45 mm, overall diameter 47.5 mm, weight 6027 kg/km (CU), ampacity 1060A (CU, in air).
Concentric Neutral Cables (25kV, 133% Insulation Level)
1/0 AWG: Insulation thickness 8.76 mm (345 mils), overall diameter 35.1 mm, weight 1827 kg/km (CU), ampacity 279A (CU, direct buried).
1000 MCM: Insulation thickness 8.76 mm, overall diameter 56.1 mm, weight 6761 kg/km (CU), ampacity 1040A (CU, in air).
These specifications highlight the cables’ ability to handle high currents while maintaining compact dimensions and manageable weights, especially when using aluminum conductors.
Advantages of XLPE Insulated Cables MV-90
XLPE Insulated Cables MV-90 offer several advantages over other cable types:
High Dielectric Strength: XLPE insulation provides excellent resistance to electrical breakdown, ensuring reliable performance at medium voltages.
Thermal Stability: Rated for 90°C operation, these cables can handle high temperatures without degrading.
Moisture Resistance: TR-XLPE insulation prevents water tree formation, extending cable lifespan in wet environments.
Flexibility: Stranded conductors and flexible shielding options make installation easier, even in complex layouts.
Versatility: Multiple shielding and jacketing options allow customization for specific applications.
Environmental Resistance: PVC, LSZH, or PE jackets protect against UV radiation, ozone, and chemical exposure.
Conclusion
XLPE Insulated Cables MV-90 represent a pinnacle of cable technology, combining advanced materials, precise engineering, and compliance with rigorous standards to deliver reliable power distribution. Their robust construction, featuring XLPE insulation, versatile shielding options, and durable jackets, makes them ideal for a wide range of medium-voltage applications. As the world transitions to smarter, more sustainable energy systems, these cables will continue to play a vital role in powering the future. Whether in utility networks, industrial facilities, or renewable energy projects, XLPE Insulated Cables MV-90 are a testament to the ingenuity driving modern electrical infrastructure.
