Cigre WG B1.

34:
Mechanical Forces in Large Cross Section
Cable Systems
Johannes Kaumanns, Convenor
Ron van den Thillart
Gunnar Gehlin
Brian Gregory
Jorice Samuel
Ricardo Reinoso
Morten Ahrenkiel Vilhelmsen
Marco Bacchini
Tatsuo Kurata
Janislaw Tarnowski
Detlef Wald
Dennis Johnson
Caroline Pye
Hans-Peter May
1
Scope of the work of cigre WG B1.34:

- Extruded land cables, AC and DC

- Large conductor cross sections, typically >1000mm2
- Axial thrust, cyclic movements calculation methods
- Overview of best practices for rigid, flexible, duct
installations and transition regions
- Cleats
- Measurements of mechanical cable properties and forces

Not in the scope are

- Internal forces inside accessories
- Submarine cables

2
Introduction:

Why a new WG for thermo-mechanical forces ?

- With larger conductor cross sections the

thermo-mechanical forces are increasing

- The design principles or thermo-mechanical design are

described in cigre TB 194, but need deeper background
and guidance

- The existing design principles are based on measurements

on paper insulated cables and must be confirmed for
extruded cables, which might behave differently

- Some new calculation approaches allow a better

description of transition regions between rigid and flexible
installations 3
Measured Forces on Rigidly Installed Cables

- Non linear behavior

- Relaxation effect

- Hysteresis effect
Example 1: Measured force on a 420kV/1600mm2 cable during cycling

- Forces can reach easily

several tons depending on
the rate of temperature rise

4
Example 2: Measured force on a 220kV/2500mm2 cable during rapid heating
Complex Thermo-mechanical Behavior of Cables:

- non linear behavior

- relaxation effects
- hysteresis effects
- temperature dependent cable properties

=> Measurements of cable properties are needed!

main parameter:
- conductor cross section
- sheath design (wire screen or thick metal sheath)
- geometry (diameter)
and
- cable design !
(conductor stranding, compactness, friction between layers,
etc.)
5
 Measurements of mechanical Cable Properties

• Thermal expansion coefficient α

• Axial stiffness EeffA
• Bending stiffness EI
can be measured on
full size cable samples

Example for measurement of cable bending stiffness EI

Value for α Conductor Material

20 ⋅ 10-6 /K Copper, from measurements [5]
17 – 18.5 ⋅ 10-6 /K Copper, from literature
24 ⋅ 10-6 /K Aluminium, from literature
28 ⋅ 10-6 /K Lead, from literature 6
 Forces in Rigidly Installed Cable Systems:

∆l = l ⋅ α ⋅ ∆T
F / A = E ⋅ ∆l / l
A
}F = EA ⋅ α ⋅ ∆T Thermal expansion coefficient
Axial stiffness
Compressive B
Force C A : Rigid bar
Point of
D B : Stranded conductor,
max. force
E no relaxation
C : EA simplified model
F
D : Conductor with relaxation
(1st cycle)
Tmax Temperature
E : EAeff to max. Force
Tensile F : Relaxation after
Force many load cycles
7
Flexible Installations 1
- Horizontally snaked systems
- Vertically sagged systems

- Calculation method is based on Euler-buckling theory

for small displacements/bending angles <20°
- Cable thrust is about 10 times smaller in comparison
to straight arrangement

F F
∆Lo

 ∆L 
π EI eff
2
f − f0 4 α c ∆T + 0  l 2
f0 + 
l 
F= ⋅ f =
2

l 2
f π 2

Calculation example for cable thrust considering snaked system with 8

thermal expansion and additional cable movement into snake
Experiences with
sagged systems

9
Flexible Installations 2

- Bended cable arrangement

- Calculation method is based on Arc-Castigliano theory

for bending angles >20°
 ∆ L0 
 α ∆ T +  EI
F=
L 
⋅ 4 ⋅ 108
⋅ φ −3.93

F R2
 ∆L0  L2
2Φ
δ =  α ∆T +  ( + s)
 L  4s
δ

∆Lo
F
Calculation example considering thermal expansion and 10
additional cable movement into bend
 Transition from Buried to Flexible Regions 1

- Snaked buried installation and transition to free cable arrangement

- Calculation method is based on locking wave theory F1 = F2 ⋅ eµφ

- Relevant parameter: Friction µ between cable core and sheath
Thermo-mechanical force Counter force Fo
depending on
arrangement

∆Lo
snaking angle φ = total bending angle, Σθ

buried open

11
 Duct installations
- Duct installations are semi-flexible
- Cable forms specific pattern depending on temperature,
cable properties, friction and gap to duct
- FEM calculation possible (but very complex)
- Approach on experiences and
simplified formulas is possible, too
Duct clearance

15mm

30mm

60mm

90mm

12
Some best practices (examples)

Flexible bend below outdoor

Rigid clamping in manhole by
termination reduces the force
anchor cleats
between cable and termination

13
Cable Cleats

- Cable cleats are an important

component for the thermo-
mechanical design as they have
to handle all relevant forces

- Holding forces are limited

- Rubber inlays compensate radial

Typical design of a cable cleat (clamp) expansion and increase friction

- Special anchor cleats (longer) or

a train of cleats show higher
holding forces

- Thermo-mechanical cable thrust

of a straight arrangement is
typically larger than holding force
0 2.25 4.5 6.75 9.0 kN 11.5 of a clamp !
14
Typical holding force of a cable cleat (clamp)
Simplified Model for Cable Properties
(based on measurements on cable designs from Japan)

• Model for Axial Stiffness, EeffA:

Eeff: Effective axial modulus 30kN/mm2
A: Conductor cross section

• Model for Bending Stiffness, EI:

E I = Ec･Ic + Ei･Ii + Em･Im (kN･mm2)
Where:
•Ec: Conductor Effective Young’s Modulus 7.5 kN/mm2
•Ei : XLPE Effective Young’s Modulus 0.4 kN/mm2
•Em: Metallic sheath Effective Young’s Modulus
Corrugated aluminum: 11 kN/mm2
Corrugated stainless steel: 12 kN/mm2
•Ic: π･dc4/ 64 dc: Conductor diameter [mm]
•Ii: π･(di4 – dc4)/64 di: Insulation screen diameter [mm]
•Im: π･dm4･t / 8 dm: Mean outer sheath diameter [mm]
t: Metallic sheath thickness [mm]

15
 Summary

- The new Technical Brochure is a guidance for the thermo-mechanical

design of extruded land cable systems

- The design methods of TB 194 are explained in detail and additional

design approaches are introduced

- The thermo-mechanical behavior of extruded cable is very complex

and depend on individual cable designs,
⇒ Therefore measurements of cable properties are needed

- Flexible/semi flexible design approaches can reduce the high forces at

large conductor cable systems very efficiently

- Several examples are explained in detail for a better understanding

- Best practices of the different design approaches are presented

- For comparison a wide overview of measured cable properties and

measured forces are given 16
Summary

Many thanks to all members of

WG B1.34 for active support and
discussions !

Any questions ?

17
 Appendix A: Arc-Castiliagno theory

- Mechanical structures shaped

by circular curvature

- Application of basic mechanical formula set:

- Mathematical solution depends on

geometry and cable properties:

- Introduction of an approximated angel function f(φ):

18
Appendix B: Euler-Buckling theory
- Mechanically straight structures with small deflections
- Application of basic mathematical formulas and solution
of differential equation

π 2 EI eff f − f0
With a = f0: N = ⋅
l2 f 19