2. What does DOW ENDURANCE™ HFDC 4202 EC
do for utilities?
Life extension
Enhanced reliability / better asset utilization
Ease of installation
Optimized costs, consistent installation
Significantly Lower (~50%) water tree growth rate
Longevity, lower probability of failures
Higher quality cables
Manufacturing consistency
MV 105 C Rating for the material
Option for higher ampacity, when needed
3. How do we create the value?
Critical performance features for enhanced
cable life…..
Higher electrical breakdown strength
Minimize electrical risks …water treeing in particular…
Improved / consistent cable installation
Eliminate accessory related risks
Improved cable quality
Robust, consistent manufacturing that minimizes insulation
related stresses due to fabrication process
4. Why develop DOW ENDURANCE™ HFDC 4202
EC?
An example of Dow Wire & Cable’s continuing
commitment to bring higher value products at the
lowest total owning cost to the industry
An improved TR-XLPE built upon over 5 years of
R&D and nearly 30 years of proven experience with
4202 technology
A differentiated MV system for longer life cable
performance
5. Chronology of Dow’s TR-XLPE Insulation
1983 – HFDA 4202 Commercialized
First commercial TR-XLPE insulation with demonstrated long life
performance
1998 – HFDB 4202 Commercialized
Maintained the excellent electrical performance of the A4202
with improved properties for more robust cable manufacturing
2010 – HFDC 4202 Validation and Customer Trials
Advancements to enhance longer life, ease of installation and
further manufacturing robustness to ensure quality and
consistency
6. DOW ENDURANCE™ HFDC 4202 EC History
2004 –wet electrical synergistic technology innovation demonstrated
standard (175 mil) and reduced wall (110 mil) cable improvement. R&D
continued
Q1 2008 – conducted utility survey to understand needed attributes of
next generation MV cables
April 2008 – survey results analyzed and top-priorities determined
Q2 2008 – lab work initiated to optimize formulation for desired
performance based on R&D work done at that time
Q3 2008 – prototype pilot plant samples made and screened
March 2009 – cables made (175 mil), tested ACLT, no failures at 485
days
November 2009 – material first introduced at dinner for AEIC CEC
representatives and invited guests
March 2010 – test cables made with Dow production HFDC 4202
April 2010 – product introduction at IEEE T&D conference
7. Historical Approaches to Extending MV Cable Life
Option 1:
• Eliminate moisture incursion into cable / insulation
Cable design options
Water block layers (polymeric, swellable tapes, metallic
tapes
Extreme case -Radial moisture barrier (Similar to HV Cable Designs)
However, typically result in higher cable costs (materials
& processing)
Option 2:
• Use polymeric materials, especially insulation, resistant to water
tree growth (path to electrical degradation / failures
Enhanced materials’ performance (shield / insulation
interface)
Water Tree Retardant insulation (TR-XLPE)
Typically more cost effective
TR-XLPE (a water tree retardant XLPE) has been the market
leading technology for MV cables in North America for nearly 30
years and gaining global acceptance as a long life insulation.
.
8. Technology of DOW ENDURANCE™ HFDC 4202 EC
Same proven “Tree-retardant” additive technology used in 4202
for nearly 30 years.
Produced in totally integrated, state-of-the art facility
− Feedstock to finished compound
− Ongoing investments in continuous improvement
Extended cable life
(enhanced formulation technology)
Improved ease of installation
(reduced insulation shield stripping force)
Enhanced quality cable manufacturing
(more robust processing)
.
10. Electrical Property Validation
Laboratory Plaque Data
Water Tree Resistance
Dissipation Factor
ACBD Retention
Cable Data
ACLT Results
MV105C
11. Water Tree Size and Shape Changed with
HFDC-4202 EC
Water Tree Comparison
ASTM D6037; 30 day Aging
0.6
0.5 4201 XLPE
0.4
0.3
0.2
B4202 TR-XLPE
W
0.1
m
h
g
n
L
T
e
a
r
)
(
t
0
XLPE TR XLPE C4202
ASTM D6097-97 Water Tree Test
Water Tree Retardance
C4202 TR-XLPE
All 80x Magnification
12. Dissipation Factor Testing on Cured Plaques
Spec Max.
HFDC 4202 has similar dissipation factor as HFDB 4202
13. Further Enhancements of ACBD Retention
with Wet Aging
Plaque Wet Aging Test Method
21d at 6kV / 1kHz in ionic solution
Retained Dielectric Strength with Wet Aging
1200
Dielectric Strength volts/mil
1000
800
Initial
600
After 21 days aging
400
200
0
E-4201 A-4202 B-4202 C-4202
14. Enhanced Wet Electrical Test Data
175 Mil Wall Cables
Prototype C4202, “Enhanced TR-XLPE 1,2” cable performances demonstrate
improved wet electrical performance and projected longer life.
15. Enhanced Wet Electrical Test Data for Higher
Stress Design
110 mil wall cables
Prototype C4202, “Enhanced TR-XLPE ” cable performances demonstrate improved
wet electrical performance and projected longer life.
16. Enhanced Wet Electrical Test Data
Actual Performance
Enhanced Dow TR-XLPE – HFDC-4202 EC – demonstrates
significant improvement over current commercial product
17. HFDC 4202 ACLT Performance
ACLT Testing under “4,4” Conditions
HFDB-4202 population at 1000 days aging - 0% remain
Prototype HFDC-4202 at 1050 days aging - 53% remain
Pilot plant HFDC-4202 at 830 days aging - 92% remain
Production Plant HFDC-4202
• No failures out to 630 days C4202 demonstrating
improved wet cable life
• Aging continues…
over B4202
17
DOW CONFIDENTIAL – Do Not Share Without Permission
20. Reduced Cable Strip Force
•Facilitates ease of installation of splices, elbows and
terminations
•Early tests have shown a reduction in strip force when
using C4202 as a part of a Dow system of materials
•Dow continues lab testing to validate the amount of
strip force reduction that can be obtained
•Dow encourages utilities to obtain trial quantities of
cables with C4202 to conduct field validation of the
reduced strip force
21. Reduced Strip Force System
Inital and Predicted after ICEA Cyclic Aging
18
16
14
12
10
8
6
o
b
p
5
0
e
S
F
"
/
c
r
t
.
,
l
i
4
2
0
B4202/0693 C4202/0693 B4202/0693LS C4202/0693LS
Initial Thermally Conditioned
Strip Force against Conditioning Temperature Strip Force Stability vs Time Aging at 100C
16
20
14
16
12
12 10
8 8
o
b
p
5
0
e
S
F
"
/
c
r
t
.
,
l
i
6
o
b
p
5
0
e
S
F
"
/
c
r
t
.
,
l
i
4
4
0 0 200 400 600 800 1000
-20 0 20 40 60 80 100 120
Time (hrs)
Conditioning Temp (deg C) for 4hrs
B4202/0693 C4202/0693 B4202/0693LS C4202/0693LS B4202/0693 C4202/0693 B4202/0693LS C4202/0693LS
Testing on 1/0 15 kV cables permission 21
DOW CONFIDENTIAL – Do Not Share Without Permission
23. Improved Extrusion and Crosslinking
HFDC 4202 Cure Technology
Cure
Mh at 182C
“Bending the rules”
TM
Superior scorch retardance that
enables improved cable quality
Scorch
Optimized cure performance to ensure ts1at 140C
consistent processing
Extrusion characteristics compatible
with existing equipment
DOW CONFIDENTIAL – Do Not Share Without Permission
24. Commercialization Timeline
Compound Production Trial 1Q10
Dow material qualification cable testing initiated => 4Q10
Cable manufacturers qualification initiated => Complete*
ICEA Qualifications completed => 120day = Data available
360day = Data Available
Commercially Available => NOW!
*Southwire and Nexans have completed 120 AWTT testing
.
25. HFDC - 4202 Qualification -Completed
Volts / mil
Industry
Requirement
380 V/mil
Source-Nexans
26. Action Steps
We recommend utilities update their MV cable specifications to
reflect the acceptance of DOW ENDURANCETM HFDC-4202
EC. Ask your cable manufacturer to provide cables with this
insulation material.
Dow welcomes dialog on specific steps to make this happen
Dow also would like to understand your experience with the new
compound:
Do your line technicians like the lower strip capability?
Do they think this makes the installation easier?
Does this capability increase the likelihood of higher quality
accessory installation?
Are there any issues with cables made from the new
,.
compound?
27. DOW ENDURANCE™ HFDC 4202 EC
Performance Summary
Excellent electrical performance,
exceeding existing TR-XLPEs
SUPERIOR VALUE !!
Enhanced strip-ability
Greater tree retardancy
XLPE
Cable Life in Wet Environments Ref. 4202 TR-XLPE
1
TRXLPE C4202
Ease of Installation 0 Water Tree Resistance
Electrical Strength Retention In Wet
Conditions
.
28. Summary
DOW ENDURANCE™ HFDC 4202 EC TR-XLPE:
Continues great tradition of high quality insulation
compounds, based on proven experience and TR technology
of the past 28 years
Confirms Dow’s commitment to continuous improvement and
bringing value added solutions to the industry
Has enhanced electrical performance (projected longer life),
higher water tree retardance, lower and consistent insulation
shield strip force and robust cable manufacturing
Provides superior performance solutions for power delivery
industry. With the ICEA qualifications complete,
installations can move forward.
32. ICEA Qualification Progress-120 Days
Material Combinations
Source-averages of data from Nexans and Southwire
ongoing cable qualifications
.
33. ICEA Qualification Progress-180 Days
AWTT Qualification Testing
Material Combinations
Source-ongoing cable qualification
.
by Southwire Company
Notes de l'éditeur
The slide shows the key value propositions for the enhanced material-presentation will provide more detail about each of these value propositions ( stress the value that the utility will receive from this compound-see next slide ) Dow W&C is continuing to examine the opportunity for new technology Current B4202 cables have been qualified with a 105 C rating-however, per ICEA requirements, each cable manufacturer has to qualify their cables for a 105 rating but our materials, both B4202 and C4202, are capable of qualification with this rating
These attributes create value for utilities in these areas.
We want to be sure that we continue to link 4202 to the proven TR technology , we must maintain this as our solid competitive advantage-length of time in the market Dow W&C is committed to providing products that provide greater value at the lowest life cycle cost-as we have shown previously in the Dow Inside presentation we have a model that shows this value and would welcome the opportunity to work with you to customize this model to reflect your utility’s specific costs Dow W&C is continuing to examine the opportunity to bring new technology to the wire and cable industry Create a balance between improvements and new product releases
These are the three key dates in the development of TR-XLPE for North America
Technology has been under development for 6 years-survey was the catalyst to bring forward the technology developed and the need identified by the survey Dow 4202 was first introduced in 1983-27 years ago-it has been a very strong performer from which utilities have benefited greatly Top technical attributes from the survey were as follows: longer life, greater tree retardancy, smaller diameter and higher temperature rating. As always to have the greatest impact on reducing costs making the product easier to install was seen as the key commercial attribute. These attributes became the desired objective of our next generation MV insulation compound C-4202 ACLT test is used as a screening test on prototype materials
Dow’s introduction of TR-XLPE was a material science breakthrough solution to a problem that plagued the industry with XLPE cables
C4202 is based on the same tree retardant technology as A4202 and B4202 Include without pick-off verbally in second value bullet in the orange block
We will now present the electrical test data developed at this time
As a part of any compound development, tests are conducted at each step to validate the material being developed Our initial process is to confirm in fundamental material tests that the material meets designed performance targets. These fundamental material tests enable screening of multiple technologies. The first step is to make plaques of the material, the plaques are 6.4 mm thick and 25.4 mm long
We will now move to compound testing on plaques-this slide and the next two all refer to plaque testing C4202 shows the results of 3 samples and has a Constrained Water Tree Shape as Expected for a Dow TR-XLPE 3 micron needle point Very often, to increase conductivity, electrolyte solutions rather than water are used. Such tests are widely used to rapidly screen insulation compounds for resistance to the growth of vented Water Trees. Typical of such test methods is the ASTM D 6097-97, a ‘Standard Test Method for Relative Resistance to Vented Water Tree Growth in Solid Dielectric Insulating Material’ After 30 days the test is terminated and each specimen is then stained with a dye, such as methylene blue and slices are cut through the conical defect. For each sample the slice corresponding to the center of the defect is identified. The slices are examined under a microscope and the length of the vented Water Tree (LWT) and the distance (L) from the tip of the conical defect to the opposite surface of the sample are measured.
Key message here is that C4202 is consistent with B4202 in dissipation factor testing
Here again testing is being done on plaques-the results shown are for testing after 21 days at 6Kv and at a much higher frequency of 1KHz than the typical 60 hz signal-there are many who believe that the higher frequency causes faster aging. This is a Dow (UCC) developed test protocol that we have used over the years for screening developmental insulations. E-4201 is XLPE insulation and is shown as a reference against the other Dow TR-XLPE’s
Now let’s move on to testing results on cables-Accelerated Cable Life Test (ACLT) You can see that the new “enhanced TR-XLPE” moves the time to failure to the right-you can see the extended time that it took for failure for two different constructions “ Enhanced TR-XLPE” are various prototypes that have been investigated for development This screening process has given us confidence to move forward with this technology Hence we developed thin wall, higher stress cables to show the impact –next slide shows these results “ 4,4” ACLT (34.6 kV); no overlap at 90% or 95% confidence level. Not all the TRXLPEs were B4202. In this slide they were A4202 and 8202 .They are all Dow TRXLPE technology. Conventional semicons, copper mesh neutral 175 mil stress max 10.8 kV/mm, avg 7.8 kV/mm 4xVg all cables = 34.6 kV 90C conduct in air, water tank uncontrolled, 175 mil 70-75C mid sample in water, 46-55C water temp
Standard TR-XLPE (blue) is B4202 4xVg all cables = 34.6 kV 90C conduct in air, water tank uncontrolled 110 mil stress max 15.5 kV/mm, avg 12.4 kV/mm, stress enhanced 1.44X over 175 mil cables 110 mil 67-72C mid sample in water, 47-53 water temp Weibell plot-63% of the samples tested will fail in the number of days on the x axis corresponding to 63% on the Y axis The curved lines on either side of the ‘curve fit’ line reflects the 90% confidence intervals
Pilot plant made HFDC-4202 already exceeds the characteristic life of Commercial HFDB-4202 EC Though there are no failures after 570 days from Commercial HFDC-4202 EC, Weibaeys analysis line is included for illustration. Commercial HFDC-4202 EC, clearly demonstrates “best in class performance” of TR-XLPE Technology
4,4 conditions refers to 4 times rated voltage (Vo) and 4 times rated temperature For discussions with customers/utilities, the earliest version of C4202 made is the prototype. Then the production was scaled up to the pilot plant and finally to the production plant.
C4202 insulation material meets the MV 105 criteria As temperature increases, typically DF increases as well DF still much lower than EPR-which is typically .3 up to 6.5 at 90 C depending on the type of EPR formulation. We do not believe the initial data point at 140C (0.4% DF) is correct; our lab plaque data shows it should be lower. However, we are sharing the data unedited from the test lab.
Let us now look at the key mechanical data
Example is for a 1/0 15 KV cable using 0693 on pilot plant C4202. More testing will be done with other size constructions as they are made. The NA strip protocol involves a 90 degree pull at a rate of 20 inches per minute. The relaxed is Dow’s internal method of aging the cable for 4 hrs at 100C and measuring strip. This correlates with the strip force after ICEA cyclic aging. The IEC strip protocol involves at 180 degree pull at a rate of 10 inches per minute. The requirement is for the strip force to be between 4 to 45 N per cm. The IEC spec requires aging for 7 days at 100C as well and to meet the required range.
Data generated in Dow labs regarding strip force with both B4202 and C4202
More consistent quality manufacturing is expected-more experience needed to fully understand implications of this material Evaluations conducted on commercial insulation extruders (120mm, 6 inch, 200mm) in limited runs have shown that C4202 is similar to B4202 in extrusion processing; this was by design. The processing improvements were for cable centering/sag resistance and scorch resistance. These features would need to be assessed in longer runs to assess scorch (planned for 2011) and heavy walled cables where centering is an issue.
Southwire and Nexans currently have cables undergoing qualification GCC has made cables with C4202 but has not yet begun qualification Hendrix has made the qualification cables and is in process for qualification
ICEA specifies the compound manufacturer to conduct a 360 day AWTT test with performance of 380 v/mil required-as a result the material is now qualified and along with the Southwire and Nexans 120 day qualification, all requirements have been met. GCC’s is forthcoming. You can see that the C-4202 insulated cables achieve over twice the industry requirement for TR-XLPE insulated cables Note that C4202 has changed only 8.5% from the 120 day value to the 360 day value while B4202 has changed 21.3 %. Much slower degradation. Both AWTT tests were done by Nexans so this is as close as possible to apples to apples.
Desire is to have utilities requesting C-4202 from their cable manufacturer Dow also desires to understand how C-4202 is working for the end user-contact Brent Richardson with answers to the questions
Spider diagram shows improved performance in 4 key areas: -Cable life in wet environments -Water tree resistance -Electric strength retention in wet conditions -Ease of installation via lower strip force
Slide contains key points This slide summarizes the presentation The next slides discusses what end users should do next
Results shown are the average of qualification data from both Nexans and Southwire As expected, the 120 day values are all well above the 660 V/mil requirement of the ICEA Results are similar to AWTT results for B4202 at the same time period and this was also expected No major difference in performance in such a short period of time-short period does not allow for differentiation between CS types 0800 can be used for copper or aluminum. 0802 is typically used for solid conductors to reduce shrink back.
Results shown are from qualification data from Southwire only As expected, the 180 day values are all well above the 580 V/mil requirement of the ICEA Results are similar to AWTT results for B4202 at the same time period and this was also expected Some difference in performance is beginning to appear between CS types 0800 can be used for copper or aluminum. 0802 is typically used for solid conductors to reduce shrink back.
