34.5kv XLPE Insulated Medium Voltage Cable Tr-XLPE Insulated Cable

Substation Interconnections: The cable is widely used to connect 34.5kv substations in urban and rural networks, forming the backbone of regional power grids. Its ability to transmit large currents over medium distances reduces the need for intermediate transformers, lowering infrastructure costs. The Tr-XLPE insulation’s thermal resistance ensures reliability even in densely packed cable ducts, where ambient temperatures can rise due to adjacent cables.

Industrial Power Feeds: Large manufacturing plants, refineries, and chemical facilities rely on the cable to supply power to high-demand equipment such as furnaces, compressors, and motor control centers. The 34.5kv rating allows direct connection to on-site transformers, eliminating the need for intermediate voltage conversion, while the cable’s EMI shielding prevents interference with sensitive industrial control systems. The Tr-XLPE insulation’s resistance to oils, chemicals, and moisture makes it suitable for harsh industrial environments.

Renewable Energy Evacuation: Wind farms and solar parks utilize the cable to transmit electricity from inverters or collection substations to the main grid. The 34.5kv rating efficiently handles the power output of multiple turbines or solar arrays (typically 50–200MW), while the Tr-XLPE insulation’s thermal stability withstands temperature fluctuations in outdoor installations. The cable’s UV-resistant sheath and corrosion resistance (when armored) make it suitable for coastal wind farms or desert solar parks.

Urban Distribution Networks: In metropolitan areas, the cable serves as a main feeder for high-density residential and commercial districts. Its compact design allows installation in crowded underground ducts, while the EMI shielding prevents interference with nearby communication cables. The 240mm² and 400mm² conductors are commonly used to balance current capacity with installation flexibility, ensuring reliable power supply to hospitals, shopping malls, and high-rise buildings.

Transportation Infrastructure: Airports, railways, and seaports use the cable to power critical systems such as runway lighting, train signaling, and container handling equipment. The cable’s ability to withstand vibration, mechanical stress, and temperature extremes ensures uninterrupted operation in these high-security environments. The Tr-XLPE insulation’s fire resistance (when paired with a low-smoke zero-halogen sheath) enhances safety in enclosed spaces like airport terminals or railway tunnels.

Conductor: Constructed from stranded copper or Aluminum Wires, the conductor is designed for flexibility and conductivity. Copper Conductors undergo annealing to reduce hardness, while Aluminum Conductors are often coated with tin to improve corrosion resistance and solderability. Stranding follows a class 2 configuration (multiple layers of twisted wires), ensuring uniform current distribution and minimizing skin effect losses at high frequencies.

Tr-XLPE Insulation: The insulation layer is made from thermally treated XLPE, cross-linked using either radiation (electron beam) or chemical (peroxide) curing. This process forms a three-dimensional molecular structure, enhancing thermal stability and Chemical Resistance compared to conventional PE insulation. Tr-XLPE is infused with antioxidants and flame retardants to extend service life and reduce fire propagation risk, meeting IEC 60502-2 and IEEE 404 standards.

Semiconducting Screens: Two semiconducting layers—inner and outer—surround the insulation. The inner screen (in contact with the conductor) ensures a smooth transition between the conductive conductor and insulating XLPE, preventing electric field concentration at the interface. The outer screen (between insulation and shield) performs a similar function, reducing partial discharge activity. Both layers are extruded simultaneously with the insulation to ensure intimate contact and eliminate voids.

Metallic Shield: A copper or Aluminum Tape shield is applied over the outer semiconducting layer, providing EMI protection and a path for fault current. Copper tape offers higher conductivity (for faster fault clearing), while aluminum tape is lighter and more cost-effective. The shield is overlapped (15–20%) to ensure complete coverage and bonded to the outer screen to prevent moisture ingress.

Sheath: The outer sheath is typically made of polyvinyl chloride (PVC), polyethylene (PE), or low-smoke zero-halogen (LSZH) material. PVC Sheaths offer good mechanical strength and flame resistance, suitable for indoor or protected outdoor installations. PE sheaths provide superior water and chemical resistance, ideal for underground or submersible applications. LSZH sheaths are preferred in enclosed spaces (e.g., tunnels, buildings) as they release minimal toxic smoke during combustion, meeting EN 60332-3-24 fire safety standards.

Armor (Optional): For direct burial or harsh environments, the cable may include a Steel Tape or wire armor layer beneath the sheath. Galvanized steel armor provides crush and impact resistance, with thickness ranging from 0.8mm to 1.2mm, ensuring durability in industrial or construction zones.

Reels: Standard lengths (500m, 1000m, or custom lengths up to 2000m) are wound onto heavy-duty steel or wooden reels. Steel reels are preferred for large diameters (1.8–2.5m) due to their strength, while wooden reels are used for smaller lengths to reduce weight. Each reel features flanges to prevent cable slippage, a central hub with lifting holes, and steel reinforcement to withstand transportation stress. The cable ends are sealed with moisture-resistant caps (IP68-rated) to prevent water or debris ingress.

Coils: Short lengths (50m, 100m) are coiled and wrapped in UV-resistant polyethylene (PE) film, with an additional layer of hessian cloth for mechanical protection. Each coil is secured with steel straps (16mm width) to maintain shape, with labels indicating length, conductor size, voltage rating, and batch number.

Labeling: Every reel or coil is marked with a durable, weather-resistant label containing the cable type (34.5kv Tr-XLPE Insulated), conductor size, standards compliance (IEC 60502-2, IEEE 575), manufacturing date, and batch number. Reels include a certificate of conformity and test report, while coils feature handling instructions (e.g., "Maximum Bend Radius: 12×OD").

Export Packaging: For international shipments, reels are placed in wooden crates lined with moisture-absorbing desiccants (100g per m³) to prevent condensation. Crates are marked with international shipping symbols (e.g., "Fragile," "This Side Up") and include customs documentation, such as a commercial invoice, packing list, and material safety data sheet (MSDS).

Loading and Securing: Reels are loaded horizontally onto flatbed trucks or shipping containers using cranes with spreader bars. They are secured with steel chains (grade 80) attached to the vehicle’s anchor points, with wooden chocks placed between reels to prevent rotation during transit. Coils are stacked vertically with plywood separators, limiting stack height to 1.5m to avoid crushing.

Temperature Control: While the cable withstands -40°C to 90°C, extreme temperatures during transportation can affect handling. In hot climates (above 40°C), reels are covered with reflective tarps to prevent sheath softening, which could cause adhesion between cable layers. In cold climates (below -20°C), cables are pre-conditioned in heated warehouses for 24 hours before loading to maintain flexibility.

Handling Equipment: Only certified equipment with reel handlers or cable drums is used to move reels, with operators trained to avoid sudden impacts. Manual handling is restricted to coils ≤50m, with workers using lifting straps to prevent back injuries.

Route Planning: For oversized reels (diameter >2.5m), transportation routes are pre-planned to avoid low bridges or narrow roads. Permits are obtained for oversized loads, with escort vehicles used during transit to ensure safety.

Domestic Shipping: Within regions with well-developed infrastructure (e.g., Europe, North America), delivery is via road transport (curtain-side trucks) with transit times of 2–5 business days. Express delivery (1–2 days) is available for urgent orders, using dedicated couriers with GPS tracking.

International Shipping: For global destinations, sea freight (2–6 weeks) is cost-effective for large volumes, with shipments containerized in 40ft high-cube containers. Air freight (3–5 days) is offered for small orders, with cables packed in reinforced boxes to withstand air cargo handling.

Delivery Terms: Customers can choose from Incoterms such as EXW (Ex Works), FOB (Free On Board), CIF (Cost, Insurance, Freight), or DDP (Delivered Duty Paid). DDP includes customs clearance, import duties, and final delivery to the customer’s site, simplifying international procurement.

Tracking and Updates: Customers receive a unique tracking number upon shipment, accessible via an online portal showing real-time location, estimated delivery time, and transit milestones (e.g., "Departed Factory," "Cleared Customs"). Automated SMS/email alerts are sent for delays or delivery confirmations.

Sample Specifications: Standard samples are 2m lengths, including all layers (conductor, insulation, shield, sheath) to demonstrate construction. Custom samples (e.g., stripped ends for conductor/insulation inspection) can be provided at no extra cost.

Cost and Lead Time: Samples are free for qualified customers (utility companies, EPC contractors, distributors), with shipping costs covered for domestic orders. International sample shipping is charged at cost, with delivery in 3–5 business days via DHL or FedEx.

Testing Data: Each sample includes a test report with key parameters: conductor resistance, insulation thickness, dielectric strength, and partial discharge levels. Third-party certification (e.g., from TÜV or UL) is available upon request for an additional fee.

Warranty: The cable comes with a 15-year warranty covering defects in materials and workmanship, valid for installations by certified electricians following IEEE 575 guidelines. The warranty excludes damage from improper installation, lightning strikes, or physical abuse.

Technical Support: A team of engineers is available 24/7 via phone, email, or video conference to assist with installation guidance, termination techniques, and troubleshooting. They provide detailed drawings for cable routing, bending, and shield grounding, ensuring compliance with local electrical codes.

Repair and Replacement: For warranty claims, the manufacturer dispatches a technician to inspect the cable within 48 hours of notification. If a defect is confirmed, the cable is repaired or replaced free of charge, including labor and transportation costs. Out-of-warranty repairs are offered at a competitive rate.

Training: On-site or online training sessions are provided for installers and maintenance teams, covering topics such as proper reel handling, termination with cold-shrink sleeves, and insulation testing. Training materials include video tutorials, installation manuals, and safety checklists.

Feedback and Improvement: Customer feedback is actively solicited to enhance product design. Suggestions for improvements (e.g., new sheath materials, higher temperature ratings) are evaluated by the R&D team, with updates incorporated into future product iterations.