pilc operating experiences & practices7921 89593 40 3-1x250 roeb. 8/1/50 89593 7921 40 3-1x250...
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PILC OPERATING EXPERIENCES & PRACTICES
STAN HEYER PECO ENERGY CO.
APRIL 30, 2003
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Wooden Duct
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Secondary Tap of “Edison Tube” Conductor
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OXFORD 63FROM MH #
TO MH# LENGTH CONDUCTOR SUPPLIER
INSTALL DATE
90743 7918 22 3x115 SUC 10/1/007918 6995 40 3x115 SUC 10/1/006995 90742 84 3x115 SUC 12--9990742 32870 52 3x115 SUC 12--9932870 7919 54 3x115 SUC 12--997919 32871 89 3x115 SUC 12--9932871 7920 132 3x115 SUC 12--997920 5387 35 3x115 SUC 10/1/005387 32872 88 3x115 SUC 10/1/0032872 7921 106 3x115 10/1/007921 89593 40 3-1x250 Roeb. 8/1/5089593 7921 40 3-1x250 Roeb. 8/1/507921 32878 93 3x115 10/1/0032878 7922 124 3x115 ASW 10/1/007922 7923 79 3x250 Okon. 06/06/297923 5390 200 3x250 ASW 12/01/04
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OXFORD 63FROM MH #
TO MH# LENGTH CONDUCTOR SUPPLIER
INSTALL DATE
90743 7918 22 3x115 SUC 10/1/007918 6995 40 3x115 SUC 10/1/006995 90742 84 3x115 SUC 12--9990742 32870 52 3x115 SUC 12--9932870 7919 54 3x115 SUC 12--997919 32871 89 3x115 SUC 12--9932871 7920 132 3x115 SUC 12--997920 5387 35 3x115 SUC 10/1/005387 32872 88 3x115 SUC 10/1/0032872 7921 106 3x115 10/1/007921 89593 40 3-1x250 Roeb. 8/1/5089593 7921 40 3-1x250 Roeb. 8/1/507921 32878 93 3x115 10/1/0032878 7922 124 3x115 ASW 10/1/007922 7923 79 3x250 Okon. 06/06/297923 5390 200 3x250 ASW 12/01/04
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Affect of Overloads on PILC Cable Performance
• 12 year study of 3 conductor sector cable performance (1930-1941)
• 13 kV belted cable design• 6 generating station tie lines included in
study• 22 miles of cable in study
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Conductor Temperatures
• AEIC Normal Operating Conductor Temperature - of 80oC (calculated to be 77oC)
• Overload Conductor Temperature –calculated to be 109oC
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13 kV 3-Conductor Belted Cable Overload Test Data
Test Group
Entire System
6 Years Operation at AEIC Rating 18.1 6
2 Years Overload of Test Group 67.8 9
4 Years Operation at AEIC Rating Subsequent to Overload 43.8 7.3
Failures per 100 miles of cable per year
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Causes of Failure Data During Two Years of Overload
Test Group
Entire System
Lead Sheath Cracks 52 3.4Insulation Breakdown 4.5 0.6Electrolysis & Corrosion 4.5 3.6Miscellaneous 6.8 1.4
Total 67.8 9.0
Failures per 100 miles of cable per year
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Causes of Failure During Four Years Subsequent to Overload
Test Group
Entire System
Lead Sheath Cracks 31.7 2.4Insulation Breakdown 5.4 0.7Electrolysis & Corrosion 4.5 2.5Miscellaneous 2.2 1.7
Total 43.8 7.3
Failures per 100 miles of cable per year
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Major PILC Design Change
• Increasing failure rates due to longitudinal movement of 3 conductor cable.
• Added a 500 kcmil single conductor triplexed cable in 1946.
• Triplexed cable reduced longitudinal cable movement during load cycling between 1/5 and 1/12 from 3 conductor cables.
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3-Conductor versus 1-Conductor Triplexed Cable Failure Rates
• Industry Average - 9.5• PECO 3- Conductor Cable - 8.6• PECO Triplexed Cable - 6.2
Failures per 100 miles of cable per year
Industry Average Data from Joint EEI-AEIC Cable Operating Report 1960-63
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Single Phase Splice
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3 Phase Splice
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Close Up 3 Phase Splice
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Completed Insulated 3 Phase Splice
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Four Way Splice
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Single Phase Live End Seal
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3 Phase Test Cap
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Seven Way Splice
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Close up of 7 Way Splice
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PRODUCTS NEEDED TO TRANSITION FROM PILC TO
EXTRUDED CABLES• REPLACEMENT FOR SECTOR CABLE• REPLACEMENT FOR 1 PHASE CABLE• TRIFURCATING TRANSITION SPLICE• TRANSITION SPLICE FOR SINGLE
PHASE• WYE SPLICE
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LIMITATIONS OF THE NEW EXTRUDED CABLE SYSTEM
• SPLICES ARE LARGER• TAPS CANNOT BE MADE IN TRANSITON
MANHOLES DUE TO MH SIZE LIMITATIONS
• REPAIRS SOMETIMES REQUIRE PULLING AN EXTRA STRETCH OF CABLE DUE TO INADEQUATE SPACE TO SLIDE TUBES FOR COLD OR HEAT SHRINK PRODUCTS
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BENEFITS OF EXTRUDED CABLE SYSTEM OVER PILC
• LESS SKILL REQUIRED FOR INSTALLATION
• CABLE IS LESS EXPENSIVE• FASTER INSTALLATION OF SPLICES
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TRANSITION MILESTONES
• FIRST EPR FLAT STRAP INSTALLATION AUGUST 2000
• JANUARY TO DECEMBER 2001 – LESS THAN 500 FEET OF PILC CABLE INSTALLED ( REDUCED FROM AN ANNUAL USAGE OF 12000 FEET )
• JANUARY 2002 ELIMINATED ALL USE OF PILC CABLE