Capabilities of New US Manufacturing
Facility for HV/EHV Solid Dielectric Cable
Fahrudin Mekic
Di
Director,
M
Marketing
k i and
dS
Sales
l
ABB Inc.
Power Systems Division North America
Overview
© ABB Group
April 18, 2012 | Slide 2

ABB cable system products

Accessories and installation

Cable project management

Project Examples
Overview
© ABB Group
April 18, 2012 | Slide 3

ABB cable system products

Accessories and installation

Cable project management

Project Examples
ABB’s production unit for HV cables
Karlskrona, Sweden – submarine cables
Huntersville, USA – land cables
High Voltage Cables

The world
world’s
s most modern cable factory

Standard cables and advanced customized products

E t d d and
Extruded
d paper insulated
i
l t d cables
bl ffor b
both
th AC and
d DC

Submarine and underground high voltage turn key projects
© ABB Group
April 18, 2012 | Slide 4
ABB’s production unit for accessories
Alingsås, Sweden – accessories
Kabeldon Cable Accessories

Joints, terminations and connections for
power cables 1 - 420 kV.

Tools and accessories.
accessories

Training programmes and supervision.
© ABB Group
April 18, 2012 | Slide 5
Background
1970s: Deliveries of extruded polymer insulated (“XLPE”)
cable
bl systems
t
for
f voltage
lt
ratings
ti
up to
t 145 kV.
kV
1980s: XLPE transmission cable systems rated 230 kV.
1990s: XLPE transmission cable systems rated 420 kV and
500 kV.
1999:
© ABB Group
April 18, 2012 | Slide 6
polymer
y
insulated cable system
y
for
The world’s first p
direct current transmission.
How much power with a pair of HVDC land cables?
Power [MW]
Aluminum
conductor
1800
1600
1400
1200
1000
800
600
400
200
00
0
Station limit
80 kVdc
© ABB Group
April 18, 2012 | Slide 7
Copper
conductor
150 kVdc
1800
1600
1400
1200
1000
800
600
400
200
0
Station limit
80 kVdc
320 kVdc
Approximate data:
depending on
installation conditions
150 kVdc
320 kVdc
… and with 1 system of HVAC land cables?
Power [[MVA]
Aluminum
conductor
Copper
conductor
1600
1600
1400
1400
1200
1200
1000
1000
800
800
600
600
400
400
200
200
0
0
72.5 kVac
© ABB Group
April 18, 2012 | Slide 8
123 kVac
245 kVac
362 kVac
420 kVac
Approximate data:
depending on
installation conditions
72.5 kVac 123 kVac
245 kVac
362 kVac
420 kVac
Typical EHV AC Cable Design (Al Laminate Sheath)
© ABB Group
April 18, 2012 | Slide 9
RATED VOLTAGE
245 - 550
kV
CONDUCTOR
segmented
Copper / round
round,
CONDUCTOR SHIELD
Conductive PE (Borealis)
INSULATION
- Type
- Material
- Supplier
Triple extruded, dry cured
XLPE
Borealis
INSULATION SHIELD
Conductive PE (Borealis)
LONGITUDINAL WATER SEALING
Swell able tape
METALLIC SCREEN
Copper wire
TEMPERATURE MONITORING
FIMT in metallic screen
RADIAL WATER SEALING
Laminate (Al ) and PE
OUTER JACKET
Polyethylene
D
Development
l
off P
Polymer
l
IInsulated
l d HVDC C
Cables
bl
1999
G
Gotland
160 kV (±80 kV)
50 MW
43 miles
2000
Direct Link
160 kV (±80 kV)
3×60 MW
3×40 miles
© ABB Group
April 18, 2012 | Slide 10
2002
Murray Link
300 kV (±150 kV), 220 MW
112 miles
2007-2009
Type and PQ
Q test
2
2500 mm Cu or Al
640 kV (±320 kV), up to 1100 MW
2002
C
Cross
S
Sound
d
300 kV (±150 kV), 330 MW
26 miles subsea
2013
D lWi 1
DolWin1
640 kV (±320 kV), 800 MW
60 miles (+47 miles subsea)
2006
E tLi k
EstLink
300 kV (±150 kV), 350 MW
20 miles (+46 miles subsea)
2015
N dB lt
NordBalt
600 kV (±300 kV), 700 MW
31 miles (+248 miles subsea)
2009
B Wi
BorWin
300 kV (±150 kV), 400 MW
47 miles (+80 miles subsea)
2015
D lWi 2
DolWin
640 kV (±320 kV), 900 MW
56 miles (+28 miles subsea)
2012
EWIP
400 kV (±200 kV), 500 MW
46 miles (+116 miles subsea)
In progress
T
Type
and
d PQ test
t t
2
2500 mm Cu or Al
1000 kV (±500 kV), up to 1700 MW
Typical HVDC Underground Cable Design
© ABB Group
April 18, 2012 | Slide 11
Conductor material
Copper or Aluminum
Conductor screen material
Conductive PE
Insulation type/material
Dry cured HVDC polymer (XLPE)
Insulation screen
Conductive PE
Bedding
g
Conductive swelling
g tapes
p
Metallic screen
Copper wires
Bedding
Conductive swelling tapes
Radial moisture barrier
Aluminum-PE laminate
Outer jacket
Polyethylene
Overview
© ABB Group
April 18, 2012 | Slide 12

ABB cable system products

Accessories and installation

Cable project management

Project Examples
ABB Power Products
Cable accessories,
accessories 12 – 420 kV
ABB AB, Kabeldon, Sweden
Full range of cable accessories from 12 to 420 kV
Extensive reference list from installations worlwide since 40 years
Standard products on pricelist
Quotations for any projects
12
24
36
Medium Voltage
© ABB Group
April 18, 2012 | Slide 13
42
52
72
84
123
High Voltage
145
170
245
300
Extra High Voltage
NB ! Pictures not in scale
362
420
kV
Well qualified according to standards – HVAC…
Prequalification tests
Qualifying the technology
and the manufacturer
Type tests
Qualifying the product and
the project
© ABB Group
April 18, 2012 | Slide 14
… as well as for HVDC Light
© ABB Group
April 18, 2012 | Slide 15
Complete supplier for cable system solutions
© ABB Group
April 18, 2012 | Slide 16

System studies and system design

Project management

Manufacturing and delivery of cables

Procurement of other components

Civil works

Installation

Supervision

Testing

Recovery of old cables

Maintenance of fluid-filled cable
systems

S i agreements
Service
t
Installation services
© ABB Group
April 18, 2012 | Slide 17

Survey

Supervision

Cable laying

Erection and jointing

Testing
g after installation

Turn-key responsibility

Fault location if a damage occur

Repair of cable faults
ABB Power Cables Service
Service Portfolio
© ABB Group
April 18, 2012 | Slide 18

Manufacturing and delivery of
spare cables & accessories

Service & Repair
preparedness agreements

On Call 24/7 Support

Maintenance of cable system

Storage and handle of strategic
spare material
t i l & equipment
i
t

As Built documentation
Overview
© ABB Group
April 18, 2012 | Slide 19

ABB cable system products

Accessories and installation

Cable project management

Project Examples
Complete project responsibility (1/3)
Planning
Route surveys

System studies

Typography

Cable optimization

Geological

Environmental study

Geothermal

D
Documentation
i
Design
g and engineering
g
g
© ABB Group
April 18, 2012 | Slide 20

Cable design

Route design
Development
p
testing
g

Type testing
Complete project responsibility (2/3)
Manufacture

Cable

Cable accessories

Installation tools


Trenching
© ABB Group
April 18, 2012 | Slide 21
Transportation and
installation
Size and weight of
cable reels
Length of cable
sections
Jointing

Drilling

Power cable

Plowing

Fiber optic cable

Rock cutting

Blasting
Complete project responsibility (3/3)
Installation of accessories





Joints
Terminations
Oil feeding system
(LPOF cables)
Surge arresters
Link boxes
Mechanical protection

Burial

Concrete slabs

Pipes
Repair preparedness
Field testing
© ABB Group
April 18, 2012 | Slide 22

HVDC test

Provide spare parts

HVAC test

Provide specialists
Overview
© ABB Group
April 18, 2012 | Slide 23

ABB cable system products

Accessories and installation

Cable project management

Project Examples
Overview of Offshore Wind Interconnection System
Offshore
wind turbines
Offshore
AC substation
platform(s)
Offshore
HVDC converter
Onshore
HVDC converter
DC cable
bl system
t
AC MV cable system
AC HV cable system
100 - 300 MW:
300 - 500 MW:
500 - 1000 MW:
© ABB Group
April 18, 2012 | Slide 24
160 kV ((±80 kV)) HVDC
300 kV - 400 kV (±150 kV - ±200 kV) HVDC
640 kV (±320 kV) HVDC
Onshore
AC network
BorWin 1 HVDC Transmission System – Cable Designs
North Sea segment (75 miles)
1200 mm2 Cu
Wadden Sea segment (5 miles)
1600 mm2 Cu
Underground segment (47 miles)
2300 mm2 Al
© ABB Group
April 18, 2012 | Slide 25
BEC Submarine Cable Project Overview
Circuit Route is approximately 6.4 miles between Bayonne, NJ d B kl NY
NJ and Brooklyn, NY
Cable route was selected based on many factors including llocation relative to numerous anchorage areas and ti
l ti t
h
d
shipping channels in New York Harbor, and permitting requirements for Army Corp and the states of New York i
t f A
C
d th t t
fN Y k
and New Jersey
Th
Three cables installed
bl i t ll d
Burial depth of 4
Burial depth of 4‐‐15 ft
Phase separation of 25‐
Ph
Phase separation of 25
ti
f 25‐33ft
Water depth up to 70ft
© ABB Group
April 18, 2012 | Slide 26