Cable manufacturing process for the world's major ultra-high voltage cable manufacturers

The successive development of UHV projects has led to the development of
ultra-high voltage cables.
Below, Xiaobian is represented by Nexans, Furukawa Electric, Southern Cable and other enterprises, and takes you to understand the cable manufacturing process
of the world's major ultra-high voltage cable manufacturers.

Nexans, France

French Nexans company adopts MDCV process, conductor section is 800mm2, adopts undivided conductor structure, (above 800mm2 adopts split conductor structure), insulation layer nominal thickness of 35.
6mm, metal sleeve adopts welded flat aluminum sleeve, outer sheath adopts flame retardant PE material, and the design scheme is serpentine arrangement
.

Nexans metal welding flat aluminum sleeve has the following characteristics: the metal strip is cut horizontally parallel to the cable axis, the surface is clean and the width is accurate, the aluminum strip is formed through a series of plastic molds with the same diameter as the cable, the cable is introduced by the mold without touching the aluminum strip, the shape of the aluminum strip is adjusted until his edge is close to the cable and has a certain pressure, the seam is welded with a laser beam, the weld is inspected by a camera, and the welding quality control system detects any defects with the help of eddy current, The welded tube shrinks through a series of dies, and the cable and aluminum tube are then pulled by a crawler traction device that controls the entire line speed
.

Metal welded flat aluminum sleeve has the following three advantages
.
First, the outer sheath and smooth aluminium sheath are extruded
simultaneously through a crosshead head.
Second, the sheath on the metal shield is unlikely to wrinkle
.
Third, this tightly coupled composite aluminum-PE sheath has a bend radius of up to 20 times the outer diameter
of the cable.

Nexans XLPE cable structure:

1.
Copper conductor → conductor shielding→ insulation→ insulation shielding→ expansion belt→ copper wire→ back-bound copper strip→ expansion belt→ aluminum strip→ PE sheath

2.
Copper conductor→ conductor shielding→ insulation→ insulation shielding→ semi-conductive strip→ aluminum strip→ PE outer sheath

3.
Copper conductor → shielding→ insulation→ insulation shielding→ expansion belt and copper wire shielding →expansion belt→ aluminum sleeve/(lead) belt→ PE outer sheath

SILIC (SILEC):

French Scholik company adopts VCV process, the conductor adopts split conductor, metal sleeve aluminum-plastic composite comprehensive waterproof layer and aluminum wire shielding structure, and the insulation nominal thickness is 32.
0mm
.
The outer sheath is made of flame-retardant PE material, and the design scheme is serpentine arrangement; With 500kV and 400kV class XLPE cable supply performance, mainly distributed in Europe and China
.

Bruker, Switzerland

MDCV process is adopted

Prysmian adopts MDCV process with a conductor cross-section of 1000 mm2, a four-split conductor structure, a nominal insulation thickness of 30.
2 mm, a welded flat aluminum sleeve for the metal sleeve, and flame retardant PE for the outer sheath
.

Southern German cable

German Southern Cable Company adopts MDCV process, conductor six-split conductor structure, insulation nominal thickness 34.
0mm, metal sleeve adopts copper strip and copper wire shielding structure, outer sheath adopts flame retardant PE material
.

Japanese company J-power systems

Japan J-power systems company adopts VCV process, conductor bidding section is 800mm2, adopts four-split conductor structure, insulation layer nominal thickness of 31.
4mm, metal sleeve adopts extruded wrinkle aluminum sleeve, outer sheath adopts flame retardant PVC material, and the design scheme is serpentine arrangement
.

Japanese company Viscas

Japan Vicas Company (now and Yuyu Electric Co.
, Ltd.
) adopts VCV process, the conductor bidding section is 800mm2, the five divisions are adopted, the insulation nominal thickness is 30.
0mm, and the metal sleeve adopts extruded wrinkled aluminum sleeve
.
The outer sheath is made of flame-retardant PVC material
.

Furukawa Electric of Japan

The cross-section is 800mm2, and the five-split pressed element-shaped stranded conductor is adopted
.
Buffer layer: 0.
25mm thick strap, 3 layers, 50% cover, 50% metal strip thickness 0.
25mm
.

Degassing: > 350 hours
.

Concentrate:

VCV: vertical crosslinking production line

MDCV: long-die crosslinking production line

FZCV: Crosslinking production line with silicone oil as the transmission medium