The optimum material solution for Low Voltage energy cables

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1 The optimum material solution for Low Voltage energy cables

2 About Borealis and Borouge Borealis is a leading provider of innovative solutions in the fields of polyolefins, base chemicals and fertilizers. With headquarters in Vienna, Austria, Borealis currently employs around 6,400 and operates in over 120 countries. It generated EUR 8.1 billion in sales revenue in The International Petroleum Investment Company (IPIC) of Abu Dhabi owns 64% of the company, with the remaining 36% owned by OMV, the leading energy group in the European growth belt. Borealis provides services and products to customers around the world in collaboration with Borouge, a joint venture with the Abu Dhabi National Oil Company (ADNOC). Building on its proprietary Borstar and Borlink technologies and 50 years of experience in polyolefins, Borealis and Borouge support key industries including infrastructure, automotive and advanced packaging. The Borouge 3 plant expansion in Abu Dhabi will be fully operational in Borouge 3 will deliver an additional 2.5 million tonnes of capacity when fully ramped up, bringing the total Borouge capacity to 4.5 million tonnes. Borealis and Borouge will then have approximately 8 million tonnes of polyolefin capacity. Borealis offers a wide range of base chemicals, including melamine, phenol, acetone, ethylene, propylene, butadiene and pygas, servicing a wide range of industries. Together with Borouge the two companies will produce approximately 6 million tonnes of Base Chemicals in Borealis also creates real value for the agricultural industry with a large portfolio of fertilizers. The company distributes approximately 2.1 million tonnes per year. This volume will increase to more than 5 million tonnes by the end of Borealis and Borouge aim to proactively benefit society by taking on real societal challenges and offering real solutions. Both companies are committed to the principles of Responsible Care, an initiative to improve safety performance within the chemical industry, and contribute to solve the world s water and sanitation challenges through product innovation and their Water for the World programme. For more information visit: Borstar is a registered trademark of the Borealis Group. Borlink and Water for the World are trademarks of the Borealis Group. The optimum material solution for Low Voltage energy cables

3 Contents 04 Meeting society s increasing energy supply needs 05 Reliability of supply the key consumer demand 06 Cost efficiency reflected in technology development 07 Installation versatility toughness reduces costs 08 Environmental performance material choice has a positive impact 09 Experience builds confidence setting a new standard Connecting to the grid 3

4 Meeting society s increasing energy supply needs Modern society is becoming more and more dependent on an ever-expanding range of electrical appliances and equipment to serve its daily needs, both in the home and at the workplace. This in turn is generating a strong global growth in demand for electric power, distribution networks and greater reliability of supply. Traditionally, power has been distributed through overhead lines as this method was for many years considered the least expensive alternative. However, the further extension of these power grids to satisfy supply requirements is raising public concern regarding their costs, environmental impact and appropriateness in their use of land. These challenges are being addressed and a solution found in underground cable systems. Over time, the advances in materials, improvements in cable manufacturing techniques and the development of efficient installation methods have significantly reduced the previously higher costs of underground cable systems. Today they present an economically and environmentally attractive alternative to overhead lines. 4 The optimum material solution for Low Voltage energy cables

5 Reliability of supply the key consumer demand With the objective of providing reliable cost effective, high quality solutions, Borealis invested in the development of its proprietary Visico /Ambicat XLPE technology for cable insulation. This material system is based on a reactor made silane crosslinkable polyethylene material VISICO: VI-nyl SI-lane CO-polymer that is mixed with a catalyst AMBICAT: AMB-ient cure CAT-alyst to facilitate crosslinking of the cable insulation in the presence of a minute amount of moisture at ambient conditions. The material system is manufactured on a large scale according to stringent specifications and, combined with its robust processing characteristics, it constitutes a solid base for consistently reliable cable quality and performance. The Visico /Ambicat XLPE technology offers clear performance and processing advantages over traditional PVC insulation. Underground cable laying along the road 5

6 Cost efficiency reflected in technology development As table 1 shows, XLPE insulated cables are rated for continuous operation at 90 C, which is 20 C higher than that of PVC. The obvious advantage for the network operator is that XLPE insulated cables give the possibility for the network to take a temporary overload without the risk of damage to the cables. Depending on the installation and requirement on maximum voltage drop, the higher temperature rating of XLPE allows for a smaller conductor and a higher electrical breakdown strength that give the opportunity to reduce insulation thickness. ranging from soft to hard can be selected depending on requirement. Moreover, the material s density is low, similar to that of XLPE insulation, which enhances the reduced weight benefit of an XLPE-based cable construction. Property Flexibility Hardness Water absorption Characteristics Range: soft stiff Range: soft stiff Low Property Temperature tolerance Abrasion resistance Chemical resistance Characteristics Rated for 90 C continuous operation Good Good Abrasion resistance Low temperature properties Stress crack resistance Table 2: Polyethylene jacketing Range: good - excellent Good Excellent Stress crack resistance Low temperature properties Water absorption Thermal ageing properties Dielectric constant Density (weight) Track resistance Table 1: XLPE insulation Excellent Good Low Excellent Low Low Good The example shown in figure 1, based on Cenelec HD603, shows an almost 50% weight reduction over PVC when XLPE insulation is used in conjunction with a PE jacket. Compared with PVC the overall weight saving, including conductor (aluminium) but excluding bedding, is 24%. XLPE has a significantly lower density and therefore a bigger volume per kg than traditional PVC insulation. This means that for a given conductor size the overall weight of XLPE cable is lower due to the combined effect of greater material volume per kg and the specification requirements that allow for reduced insulation thickness. As jacketing for low voltage cables, polyethylene (PE)- based materials (table 2) with low to high density have been found to be an attractive solution from which material Figure 1: Comparison of material needed for insulation and jacketing. Cable 4x95 mm² according to Cenelec HD603 6 The optimum material solution for Low Voltage energy cables

7 Installation versatility toughness reduces costs The installation of underground cables typically requires measures to protect the cables from physical damage, such as penetration of the jacket by sharp stones. Filling the cable trench with sand is a common but costly method of protection. However, by using High Density Polyethylene (HDPE) jacketing with a good balance of toughness and flexibility, laying costs can be significantly reduced. Trenches can be smaller and the risk of damage to cables during installation lowered. Moreover, the trenches can be backfilled with the excavated earth as opposed to soft filling with sand, giving a further cost reduction. Automatic cable laying machines, which are frequently used where conditions allow, also contribute to cost reduction. Experience gained from the installation of MV cables in Germany (figure 2) showed that costs were significantly reduced when an HDPE jacket was used instead of a traditional PVC jacket. Furthermore, as PE can be handled at temperatures as low as -20 C, it allows installation under conditions in which PVC would be stiff and prone to cracking. Cable laying in narrow trench Figure 2: Standardised cost of laying cables with different jacketing material (Source: H. Stöger, Elektrizitätswirtschaft, 83 (1984), H. 26, , updated information) 7

8 Environmental performance material choice has a positive impact A reduction of the total weight of materials used in a cable system helps to reduce the environmental burden. Using less material and offering lower weight than PVC, XLPE insulation provides an environmentally friendly solution without any compromise in cable system performance. Cable scrap and cables taken out of service at the end of their working life have to be separated into their polymeric and metal components. Different polymer types have to be segregated into those that can be recycled and those to be used for energy recovery. This requires special separation steps that can be significantly simplified if only one polymer type is used for the cable construction elements. Constructions with XLPE insulation and PE jacketing give this cost saving advantage. The need to satisfy environmental requirements for halogen-free flame retardant properties of jacketing has resulted in Borealis development of a cost effective generation of materials based on PE copolymer, chalk and silicon. This technology is known as CASICO (CA-lcium carbonate SI-licon CO-polymer). Exposed to fire the material releases only a low level of smoke in an initial stage thereby allowing people to find escape routes. Furthermore, compared to the smoke generated by burning PVC, it has low toxicity and is low in the acid by-products that cause corrosion and secondary fire damage. Fire testing of Casico technology 8 The optimum material solution for Low Voltage energy cables

9 Experience builds confidence setting a new standard Continuing growth in the global adoption of XLPE for Low Voltage cables is clear evidence of confidence in the material s excellent performance and overall cost advantages in these applications where it is progressively replacing PVC as the material of choice. And, with the Wire & Cable industry focused on optimising the balance between cost and high reliability of installed low voltage networks, the benefits of Visico/Ambicat insulation, combined with polyolefin-based jacketing materials, position them to set a new cable system standard. Cable laid in trench 9

10 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 Borlink, Visico /Ambicat, 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 50 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 Borealis largest investment in Europe to date, the new 350,000 t/y high-pressure, low-density PE plant in Stenungsund, Sweden, was inaugurated in June 2010, further strengthening Borealis capabilities to meet the needs of the growing wire and cable markets. Furthermore, Borouge s expansion of Borstar and Borlink capacity in Abu Dhabi, UAE, allows us to satisfy growing customer demand for wire and cable products in the Middle East and Asia Pacific markets and other 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 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 the Borealis Group. Borlink, Visico, Ambicat, Casico and Water for the World are trademarks of the Borealis Group. 10 The optimum material solution for Low Voltage energy cables

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12 For more information visit: Borealis AG Borouge Pte Ltd WC BROCH 138 GB BB