220kV Cable – XLPE Cable Manufacturer

Introduction

The 220kV cable is one of the most important components in modern electrical energy transmission networks.. Thanks to its high transport capacity, excellent dielectric behavior and long life, This type of cable is widely used in GIS substations, power plants, renewable energy projects, regional interconnection systems and urban underground networks.

The growing demand for electricity, along with the expansion of wind farms, solar plants and energy infrastructure projects, has driven the development of more efficient and reliable high voltage transmission solutions. In this context, XLPE insulated 220kV cables have become a dominant technology due to their technical and economic advantages.

Technical characteristics of the 220kV cable

220kV cables generally have a rated voltage of:

• Uo = 127 kV
• U = 220 kV
• One = 245 kV

The most used international standards for its manufacturing include:

• IEC 60840
• IEC 62067
• IEC 60228
• IEC 60811
• IEC 60502
• IEEE 48
• IEEE 404

The maximum operating temperature is usually:

• Continuous service: 90°C
• emergency overload: 105°C
• Short circuit: 250°C

The conductive materials available are:

• compact copper
• Segmented copper
• Compact aluminum
• Aluminum Milliken
• Longitudinally sealed conductor

Construction of 220kV cable

Conductor

The conductor is the element responsible for transporting the electric current.

Copper offers:

• higher conductivity
• lower electrical resistance
• high short circuit capacity

Aluminum provides:

• lower weight
• total cost reduction
• ease of handling during installation

The most used sizes in 220kV projects are:

• 630 mm²
• 800 mm²
• 1000 mm²
• 1200 mm²
• 1600 mm²
• 2000 mm²
• 2500 mm²

Internal semiconductor screen

Its main function is to homogenize the electric field around the conductor and minimize partial discharges..

It is generally manufactured by simultaneous extrusion with the main insulation.

XLPE insulation

XLPE cross-linked polyethylene is currently the predominant insulating system for high voltage cables..

Among its advantages are:

• high dielectric strength
• excellent thermal stability
• low electrical losses
• long lifespan
• high resistance to aging

For 220kV cables the typical insulation thickness ranges from 25 mm y 28 mm.

Metal screen

Metal shield allows fault currents to be conducted and ensure operational safety.

It can be formed by:

• copper threads
• copper tape
• corrugated aluminum deck
• lead cover

Moisture barrier

Its objective is to prevent longitudinal or radial penetration of water.

The most used solutions are:

• aluminum foil
• aluminum extruded cover
• aluminum welded cover
• lead sheath

External cover

Cover materials include:

• PE
• HDPE
• LSZH
• PVC
• MDPE

The main features are:

• UV resistance
• chemical resistance
• mechanical protection
• high durability

220kV cable types

XLPE Cable with Aluminum Jacket

This design is widely used in underground transmission systems.

Its advantages include:

• underweight
• excellent tightness
• ease of installation

Lead Sheathed XLPE Cable

It is recommended for harsh environments.

Typical applications:

• petrochemical industry
• power plants
• coastal areas
• refineries

armored cable

It incorporates additional mechanical protection through:

• galvanized steel wire
• steel strap
• aluminum armor

It is mainly used in:

• road crossings
• buried facilities
• tunnels
• mining

Table of available sections of 50 mm² a 3000 mm²

Cable current capacity 220kV

Ampacity depends on various parameters:

• room temperature
• soil thermal resistivity
• burial depth
• phase arrangement
• installation system
• grounding method

Approximate values:

Installation methods

Directly buried

It is the most economical and widely used method.

Benefits:

• lower initial cost
• quick construction
• minimal visual impact

Installation in ducts

Recommended for:

• cities
• airports
• financial centers
• urban runners

Installation in tunnels

Allows:

• simple maintenance
• permanent inspection
• future expansion

underwater installation

Used in:

• offshore wind farms
• islands
• international interconnections
• industrial ports

Accessories for 220kV cables

High voltage accessories are critically important in system reliability.

Among them stand out:

Straight splices

They connect two sections of cable maintaining electrical continuity.

GIS Terminals

Designed for substations encapsulated in SF6 gas.

Advantages:

• less space required
• high reliability
• reduced maintenance

AIS terminals

Used in conventional outdoor substations.

Grounding systems

Include:

• link boxes
• sistemas cross-bonding
• surge limiters
• induced current monitoring

220kV cable tests

The main tests include:

Routine tests

• electrical resistance
• dimensional measurement
• partial downloads
• applied voltage

Sample tests

• tangent delta
• thermal aging
• thermal cycles

Type tests

• atmospheric impulse
• maneuver impulse
• water penetration test
• short circuit test
• cyclic loading test

220kV cable applications

220kV cables are widely used in:

• hydroelectric plants
• thermal plants
• wind farms
• solar installations
• metropolitan networks
• data centers
• industrial complexes
• mining
• regional interconnections
• offshore projects

Global market trends

The global energy transition is driving the expansion of the high-voltage cables market.

Major trends include:

• digitization of electrical networks
• integration of renewable energy
• increase in HVDC projects
• smart grid development
• real time monitoring
• DTS systems using fiber optics
• predictive maintenance based on artificial intelligence

Various studies indicate that the demand for 220kV cables will continue to grow significantly over the coming decades due to the increase in global energy consumption..

Conclusion

The 220kV cable represents an essential solution for the efficient transmission of electrical energy in modern high voltage systems. The combination of high capacity conductors, XLPE insulation, Advanced metal screens and cutting-edge accessories allow high levels of reliability and operational safety to be achieved..

Proper selection of cross section, from 50 mm² up to 3000 mm², ensures optimal performance, Long life and lower operating costs. With the development of renewable energies and new electrical infrastructures, The 220kV cable will continue to play a fundamental role in the evolution of the global energy system.

Cable manufacturer 220 kV

As a specialized manufacturer of high voltage cables, Dosense Cable is dedicated to design, development and manufacturing of power cable systems 220 kV with XLPE insulation. Our product range includes high voltage cables with copper or aluminum conductor, GIS terminals, outer terminals, straight splices, link boxes, grounding systems and complete accessories for electrical transmission networks.

Dosense Cable supplies reliable solutions for electrical companies, EPC contractors, renewable energy projects, substations and underground transmission networks in North America, South America, Middle East and Asia. Thanks to our advanced production facilities, Rigorous quality controls and compliance with international standards such as IEC, IEEE, ASTM e ICEA, We offer cable systems 220 safe kV, efficient and long life.

cable systems 220 kV constitute one of our main strengths. Dosense Cable Provides Custom Engineering Solutions, Professional technical support and competitive prices for high voltage transmission projects around the world.

Dosense cable is a leading manufacturer of cables 220 kV in china, specialized in the supply of complete extra high voltage cable systems for substations, transmission networks, renewable energy projects and industrial facilities internationally.