advanced stabilization for medium to extra high voltage cable applications ronald becker, irfaan...

Advanced Stabilization for Medium to Extra High Voltage Cable Applications

Ronald Becker, Irfaan Foster, Andrea Landuzzi, and Thomas Schmutz

Chemtura Corporation

© Copyright 2012, Chemtura Corporation

© Copyright 2012, Chemtura Corporation 2

Content

Background

Power Cables

Requirements for power cables

Cable Failures

Total Cost of Ownership

Choice of Suitable Antioxidant

Summary

Background


BackgroundPower Cables – Industry Trends


• Continued rapid expansion of energy needs globally, especially in developing world

- Population growth- Rapid urbanisation- Creation of middle class- Greater demand by consumers (digital) & industry- Ave. US household has 26 consumer electronic products

• Expect energy demand in Asia to increase 100% by 2025

• Huge investments in new infrastructure & upgrades to meet surging demand

• Significant investments in Renewable Energy require greater capex & will increase transmission distances

4

Power Cables ― Requirements for Power cables

― Cable Failures― Total Cost of Ownership



• Technically demanding

• Excellent reliability- Lifetime expectancy > 50 years- Digital world – momentary loss of supply is

catastrophic

• Total cost of ownership – cable failure or replacement is catastrophic and expensive

• Growing demands for higher capacity leading to higher service temperatures

• Minimized environmental impact

6

Requirements for Power Cables

Power CABLES – Total Cost of Ownership


• Over 40 year lifetime, cost of cable is $118 /m

• Largest potential for savings is to reduce energy losses

• Initial cable cost is only 8% of total cost

• Cable cost is only $10 /m• Metal conductor is largest cost element• TR-XLPE is 2nd largest cost element

• AO represents only $0.04 /m of cable cost but is CRITICAL FOR PERFORMANCE

Installation Cost, 28%

Replacement Cost, 13%

Initital Cable Cost, 8%

O&M cost, 27%

Energy loss, 24%

Metal, 43%

TR-XLPE, 22%

Cable Profit, 7%

Other Costs, 15%

Other Raw Materials,

13%

7Chemtura estimation for

Western Market


Cable Failures – The Costs

• Estimated* annual costs of power outages in USA is $ 80 B• Majority of outage costs are borne by commercial & industrial sectors

• Power outages can be due to:• Insulation failure

• Connection

• Pollution

• Overloads

• Workmanship

• Water Ingress

* Uni. Berkeley 2004 report for US Dept. Of Energy


Cable Failures – In XLPE Insulation

• XLPE cables tend to age progressively & unavoidably so failures become common

• In-situ replacement of cables is expensive - $350/m

• One major factor for cable failure is due to inception & growth of trees in insulation layer


Cable Failures – In XLPE Insulation

• Two types of trees occur:

Electrical Trees

Water Trees

• Electrical Trees grow quickly (hours, weeks) & are direct cause of final cable failure (flashover)

• Water Trees – more complicated, grow for years, disruptive event occurs as water tree converted into electrical tree due to impulses or surges

Water and electrical trees may lead to catastrophic failure


Cable Failures – Causes of Trees

Two theories for the creation of trees

1. Electro-Mechanic Forces• Local stresses are created near

defects in insulation, which break the polymer chain and lead to formation of voids

2. Electrochemical Oxidation• Oxidation of PE creates cavities• Oxidation products can further

degrade PE creating other defects

Electrical trees (ET) are linking two contaminantsM. S. Mashikian and A. Szatkowski, IEEE Electrical

Insulation Magazine, July-Aug. 2006


Cable Failures – Causes of Trees

Prevention of Trees requires:

• Highest cleanliness (free of impurities)

• Antioxidants to prevent polymer degradation

Water and electrical trees may lead to catastrophic failure

Electrical trees (ET) are linking two contaminantsM. S. Mashikian and A. Szatkowski, IEEE Electrical

Insulation Magazine, July-Aug. 2006

Increasing Service Life of Power Cables


Requirements for TR-XLPE cables:

Highest cleanliness Free from defects Service T of 90oC and an emergency T of

130oC for a maximum of 1,500 hours (ICEA S-97-682-1997)

Water and Electrical Tree resistant formulations

Scorch protection during cross-linking Extended polymer protection during

production & in service

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Requirements for TR-XLPE cables:• Prevent auto-oxidation of polyethylene during

processing and cable manufacture, without inhibiting the cross linking

• Provide scorch resistance, LTTS, and OIT to meet specifications

• Be compatible in the resin compound and resist extraction or blooming under elevated temperatures

• Cleanliness – avoid impurities transfer into polymer

• Easy handling and dispersion into polymer

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Choice of Suitable AntioxidantMV, HV & EHV Power Cables

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LOWINOX® TBM-6 stabilizer offers best performance

LOWINOX® TBM-6 stabilizer interacts less with the peroxide allowing higher degree of cross-linking which provides:

• Improved polymer protection during processing• Improved polymer durability in-service• Optimized dosage level of peroxides & AO

Providing better long-term performance and fewer failures

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Deg

ree

of

XL

(Δto

rque

Nm

)


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LOWINOX® TBM-6 stabilizer offers better scorch protection which provides:

• Improved polymer protection during processing• Improved polymer durability in-service• Wider operating window for cable producers• Improved productivity due to higher lines speeds

Providing better long-term performance and fewer failures

LOWINOX® TBM-6 stabilizer offers best performance17

Sco

rch

Tim

e at

120

C(m

in)

.2 % LOWINOX® TBM-6 .3 % (ANOX® 70 + NAUGARD® DSTDP

0

1

2

3

4

5

6

0

1

2

3

Scorch resistance

Interaction with Peroxides

LTT/Processing stability

Cleanliness

Compatibility

ANOX 70 + NAUGARD DSTDP

LOWINOX TBM-6


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3 Optimal 2 Good 1 Sufficient 0 Inadequate

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LOWINOX® TBM-6 stabilizer provides best scorch resistance for longer service life

LOWINOX® TBM-6 Stabilizer Characteristics

Features of LOWINOX® TBM-6 stabilizer

• Reacts with polymer backbone so more permanent and compatible with polymer

• No negative interactions with the peroxide

• Provides the best scorch resistance

• Offers best processing stability & long term heat protection

• Highest purity material

• Excellent cleanliness


LOWINOX® TBM-6 stabilizer reduces cable failures

Why Chemtura’s LOWINOX® TBM-6 Stabilizer is the only SOLUTION?

Two critical criteria for AO used in power cables Cleanliness Purity

These factors determine:• Protection provided to polymer during processing• Long term performance of polymer• Creation of water and/or electrical trees • Potential points of failure


A cleaner & purer AO will extend the service life of the power cable

Cleanliness of AntioxidantsWhy is it Important?

Two critical criteria for antioxidants used in power cables

• Cleanliness•Amount of insolubles /particulates

• Purity•The % purity is an indication of suitability


Particulates can cause failure via electrical trees

21

22

Competitive Product

Where we stand compared to our competitors

Chemtura LOWINOX® TBM-6

CLEANLINESS: Filtered acetone solutions

Impurities lead to premature cable failure

• Competitive material has many impurities • Chemtura LOWINOX® TBM-6 stabilizer – has no impurities


LOWINOX® TBM-6 stabilizer has decades of proven track record on purity and cleanliness

We deliver a highly pure product without external contaminants:•Back integration on raw materials allows control on cleanliness and consistency

•Process and plant designed to minimize contaminants, especially metals

•Direct packaging in a fully enclosed controlled environment system

•Continuous investment in improvement

•Strict specifications and quality control processes

2323

Clean & pure AO extend the service life of the power cable

23© Copyright 2012, Chemtura Corporation

Summary


Chemtura … your preferred supplier to the W&C Industry

• The CLEANEST SOLUTIONS

• PROVEN TRACK RECORD > 40 YEARS

• We supply the market leaders in the Industry

• New higher performance and cleaner products under development


Your benefits when working with Chemtura

• The widest range of specialty stabilizers• True innovation and partnership in

development• Local service, worldwide, including strategic

investments in emerging markets• Technical expertise and applications knowledge

that adds value• Regulatory compliance and corporate

responsibility

• A commitment to future growth


South America

North America

Middle East

Europe

Asia

Your Benefits When Using Chemtura Stabilizers

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Global regulatory, environmental & food contact compliance

Safer addition of additives and improved productivity using different product forms

Protecting polymer architecture and preventing discoloration using antioxidants

Maintaining the color & appeal of plastic products.Extending product life

http://www.specialchem4polymers.com/tc/antioxidant/index.aspx


advanced stabilization for medium to extra high voltage cable applications ronald becker, irfaan...

Documents

cost of cable

energy copyright

power cables copyright

total cost cable cost

background copyright

surges copyright

catastrophic failure

insulation layer copyright