Over the past ten years power and communication cables have been converging. This manual treats in detail the various aspects of both fields, from traditional power cables to the latest fibre optic communication cables, constituting a one-stop guide for cable engineers.
Preface xix Acknowledgments xxi Cables: A Chronological Perspective 1(75) R. Bartnikas Preliminary Remarks 1(2) Power Cables 3(32) Oil-Impregnated Paper Power Cables 4(1) Oil-Pressurized Power Transmission Cables 5(6) Solid-Dielectric-Extruded Power Transmission Cables 11(3) Solid Extruded Dielectric Power Distribution Cables 14(5) Underwater or Submarine Cables 19(4) Low-Loss Power Transmission Cable Systems 23(1) Compressed SF6 Gas Power Transmission Cables 24(5) Superconducting Power Transmission Cables 29(6) Communication Cables 35(41) Introduction 35(3) Twisted-Pair Communication Cables 38(5) Coaxial Cables 43(10) Optical Fiber Cables 53(17) References 70(6) Characteristics of Cable Materials 76(95) R. Bartnikas Introduction 76(1) Metallic Conductors 76(6) Conductor and Insulation Semiconducting Shields 82(10) Insulation 92(66) Dielectric Characteristics of Solid and Solid-Liquid Systems 93(13) Oil-Impregnated Paper 106(16) Extruded Solid Dielectrics 122(1) Natural Rubber 122(1) Butyl Rubber 123(2) Ethylene-Propylene-Rubber 125(2) Silicone Rubber 127(1) Polyethylene 128(6) Crosslinked Polyethylene 134(3) Comparison of EPR and XLPE Insulation 137(10) Tree-Retardant XLPE 147(4) Synthetic Solid-Liquid Insulations 151(4) Gas-Solid Spacer Insulating Systems 155(3) Materials for Protective Coverings 158(4) Nonmetallic Sheaths 158(3) Metallic Sheaths 161(1) Armoring Materials 162(1) Coverings for Corrosion Protection 163(1) Conclusion 164(1) Glossary of Cable Materials Technology 165(6) References 165(6) Design and Manufacture of Extruded Solid-Dielectric Power Distribution Cables 171(37) H. D. Campbell L. J. Hiivala Introduction 171(1) Design Fundamentals 171(11) Inductance 176(3) Capacitance 179(1) Electric Stress 180(1) Insulation Resistance 180(1) Dissipation Factor 181(1) Design Considerations 182(5) Ampacity 183(1) Shield Circulating Currents 183(1) Proximity, Skin Effect, and Eddy Currents 183(1) Emergency Overload Rating 184(1) Earth Interface Temperatures 184(1) Short-Circuit Currents 184(1) Electric Stress 185(1) Cable Insulation Levels 186(1) Dielectric Loss 186(1) Design Objectives 187(8) Partial Discharge 187(2) Temperature Ratings 189(1) Conductor Constructions 189(1) Shields and Jackets 190(2) Portable Cables 192(1) Aging of Underground Cables 192(3) Solid-Dielectric Insulation Techniques 195(6) Compounding 196(1) Extrusion 197(1) Vulcanization 198(2) Recent Developments 200(1) Related Tests 201(7) References 204(4) Extruded Solid-Dielectric Power Transmission Cables 208(35) L. J. Hiivala Introduction 208(1) Historical Overview 208(1) Development Trends 209(1) Design and Construction 209(1) Conductors 210(1) Semiconducting Conductor and Insulation Shields 211(1) Insulations 212(1) Thermoplastic Polyethylene 213(1) Crosslinked Polyethylene 214(3) Ethylene-Propylene-Rubber 217(1) Metallic Shields and Sheaths 218(1) Tapes and Wires 218(1) Laminate Shield 219(1) Lead Alloy Sheaths 219(1) Corrugated Sheaths 220(1) Protective Coverings 221(1) Polyvinyl Chloride 221(1) Polyethylenes 222(1) Manufacturing Methods 222(4) Compounding 222(1) Extrusion 223(1) Crosslinking (Curing) Methods 223(3) Testing 226(6) Development Tests 226(1) Prequalification Tests 227(1) Type Tests 228(3) Sample Tests 231(1) Routine Tests 231(1) Electrical Tests after Installation 232(1) Accessories 232(8) Preparations for Installation 232(2) Extruded Cable Terminations 234(2) Extruded Cable Joints (Splices) 236(1) Tape Wrapped Joints 236(1) Field-Molded Joints 236(1) Prefabricated/Premolded Joints 237(1) Extrusion-Molded Joints 238(2) Transition Joints 240(1) Concluding Remarks 240(3) References 240(3) Design and Manufacture of Oil-Impregnated Paper Insulated Power Distribution Cables 243(33) W. K. Rybczynski Brief History of Development 243(1) Elements of Solid-Type Oil-Paper Cable Design 244(21) Voltage Rating 245(1) Insulation Levels 245(3) Selection of Conductor Size 248(4) Selection of Conductor Material and Construction 252(2) Selection of Insulation Thickness 254(3) Cable Impregnation 257(1) Metallic Sheaths 258(5) Protective Coverings 263(1) Extruded Nonmetallic Coverings 263(1) Fibrous Nonmetallic Coverings 264(1) Metallic Coverings 264(1) Cable Manufacture 265(6) Hot Rolling of Copper Wire Bars 265(1) Cold Drawing of Wires 266(1) Annealing 266(1) Conductor Stranding 266(1) Insulating and Shielding 267(1) Laying-Up Operation 267(1) Impregnation 268(1) Application of Lead Sheath 268(2) Application of Protective Coverings and Armor 270(1) Tests 271(1) Electrical Characteristics 271(3) Conclusion 274(2) References 274(2) Low-Pressure Oil-Filled Power Transmission Cables 276(20) W. K. Rybczynski Introduction 276(1) Elements of Oil-Filled Cable Design 277(6) Voltage Ratings 277(1) Insulation Levels 278(1) Selection of Conductor Sizes 278(1) Selection of Conductor Material and Construction 278(1) Selection of Insulation Thickness and Electrostatic Shields 279(1) Dielectric Liquid Impregnants 280(1) Metallic Sheaths 280(1) Reinforcement of Lead-Alloy-Sheathed Cables 281(1) Protective Coverings 282(1) Cable Manufacture 283(1) Self-Supporting Conductor 283(1) Insulation and Shielding 283(1) Tests 284(2) Routine Tests 285(1) Tests on Specimens 285(1) Electrical Characteristics 286(2) Dielectric Power Factor 286(1) Ionization Factor 287(1) Alternating-Current Withstand Voltage Level 287(1) Impulse Withstand Voltage Level 287(1) Principles of Oil Feeding 288(3) Notes on Sheath Bonding 291(1) Limitations of LPOF Cables 292(1) Self-Contained High-Pressure Oil-Filled Cables 292(1) Self Contained Oil-Filled Cables for dc Application 293(3) References 294(2) High-Pressure Oil-Filled Pipe-Type Power Transmission Cables 296(17) W. K. Rybczynski Introduction 296(1) Principles of Operation 297(1) Elements of Cable Design 297(4) Voltage Rating 297(1) Insulation Levels 297(1) Selection of Conductor Sizes 298(1) Selection of Conductor Material and Construction 298(1) Selection of Insulation Thickness and Electrostatic Shield 298(1) Impregnating Oil 299(1) Moisture Seal and Skid Wires 299(1) Carrier Pipe and Pipe Coating 299(1) Coordination of Pipe and Cable Sizes 300(1) Pipe Filling Oil 301(1) Cable Manufacture 301(1) Tests 302(2) Routine Tests 303(1) Tests on Specimens 303(1) Electrical Characteristics 304(2) Dielectric Power Factor 304(1) Ionization Factor 305(1) Alternating-Current Withstand Voltage Level 305(1) Impulse Withstand Voltage Levels 306(1) Principles of Oil Feeding 306(1) Cathodic Protection 306(1) Limitations of HPOFPT Cables 307(1) Development of HPOFPT Cable for Higher Voltages in the United States 307(1) Gas-Type Cables 308(2) Gas-Filled EHV Cable 308(1) Beaver and Davy Gas-Filled Cables 309(1) Hunter and Brazier Impregnated Pressure Cables 309(1) Pirelli Gas-Filled Cable 309(1) High-Viscosity, High-Pressure, Gas-Filled Pipe-Type Cable 310(1) Gas Compression EHV Cables 310(1) Concluding Remarks 311(2) References 311(2) Voltage Breakdown and Other Electrical Tests On Power Cables 313(18) H. D. Campbell Introduction 313(1) Alternating-Current Overvoltage Test 313(2) Direct-Current Overvoltage Test 315(1) Voltage Testing of Production Lengths 315(5) Test Sets for Routine Measurements 316(1) Routine Test Terminations 317(3) Tests on Specimens 320(2) Impulse Tests 322(9) Necessity of Impulse Tests 322(2) Lightning Impulse Waveform 324(1) Impulse Generator 324(3) Test Specimens 327(1) Test Specimen Preparation 328(1) Calibration Procedures 328(1) Polarization Effects 329(1) Impulse Testing as a Development Tool 329(1) References 330(1) Dissipation Factor, Partial-Discharge, and Electrical Aging Tests on Power Cables 331(96) R. Bartnikas Introduction 331(1) Dissipation Factor of a Cable 332(3) Bridge Techniques for the Measurement of tan δ 335(13) Partial-Discharge Characteristics 348(9) Partial-Discharge Measurements 357(18) Partial-Discharge Site Location 375(12) Discharge Pulse Pattern Studies 387(6) Electrical Aging Mechanisms 393(8) Accelerated Electrical Aging Tests 401(26) References 418(9) Field Tests and Accessories for Polymeric Power Distribution Cables 427(22) H. H. Campbell W. T. Starr Introduction 427(1) Alternating-Current Overvoltage Test 428(1) Dissipation Factor (Power Factor) Test 429(1) Insulation Resistance Test 430(1) Partial-Discharge Test 431(1) Direct-Current Overvoltage Test 431(1) Direct-Current Test Procedures 432(1) Interpretation of Test Results 432(1) Question of Test Levels 433(1) Direct Stress versus Alternating Stress Considerations 434(1) Practical Test Levels 435(1) Joints and Terminations 436(3) Some Current Practices 439(10) Taped Designs 439(1) Shrink Back 440(1) Modular Designs 440(6) Tests 446(1) Separable Connectors 446(1) References 446(3) Power Cable Systems 449(102) G. Ludasi Introduction 449(1) Comparison of Overhead Lines and Cables 449(2) Resistance 449(1) Inductance 450(1) Capacitance 450(1) Overall Parameter Effects 450(1) Radial Power Systems 451(2) Radial Branches for Underground Residential Distribution 451(2) Secondaries 453(1) Looped Systems 453(3) Open Loop 453(1) Closed Loop 454(2) Current-Carrying Capacity: Rating Equations 456(3) Direct-Current Cables 459(1) Calculation of Losses 459(12) Resistance of the Conductor 459(1) Skin Effect 460(1) Proximity Effect 461(1) Skin and Proximity Effects in Pipe-Type and SL Cables 462(1) Dielectric Loss 462(2) Losses in Cable Screens, Shields, and Sheaths 464(1) Circulating Current Losses 464(2) Losses in the Sheaths or Shields of Specially Bonded Systems 466(1) Eddy Current Losses in Sheaths or Shields 467(1) Calculation of Losses in Nonmagnetic Armor or Sheath Reinforcement 468(1) Losses in Magnetic Armor 469(1) Concentric Neutral Cable 469(1) Pipe-Type Cable Losses and Losses in the Sheaths of SL Cables 470(1) Losses in Steel Pipes 470(1) Thermal Resistance of Cables 471(17) Thermal Resistance of Insulation 472(1) Single-Core Cables 472(1) Three-Conductor Cables 473(2) Thermal Resistance of Coverings over Sheaths, Shields, Armor, and Pipe (Oversheaths, Jackets, Bedding, Outer Serving) 475(1) Pipe-Type Cables, Cables in Metallic Ducts 476(1) External Thermal Resistance 476(1) Thermal Resistance between Cable and Duct or Pipe (T4) 477(1) Cables, Ducts, or Pipes Laid in Free Air 478(2) Thermal Resistance of a Single Buried Cable or Pipe 480(1) Influence of Soil Conditions on the Design of Underground Lines 480(1) Thermal Resistance of Groups of Buried Cables (Not Touching) 481(2) Groups of Buried Cables (Identical) Equally Loaded and Touching 483(1) Thermal Resistance of Duct or Pipe (T4) 484(1) External Thermal Resistance of Ducts or Pipes (T4) 485(1) Cables or Ducts (Pipes) Embedded in Special Backfill, Duct Banks 485(2) Cables in Buried Troughs 487(1) Cyclic Loading 488(4) External Thermal Resistance of a Single Buried Cable, Duct, or Pipe 490(1) External Thermal Resistance of Groups of Equally Loaded Identical Cables 490(1) Cables, Ducts, or Pipes Embedded in Special Backfill, Duct Banks 491(1) Comparison of the Neher-McGrath and IEC Methods 491(1) Short-Term Overloading 492(17) Representation of the Dielectric: Long-Duration Transients (> 1/3 of TQ, Also for cyclic rating) 494(1) Single-Core Cables 494(1) Three-Core Cables 494(1) Representation of the Cable: Long-Duration Transients (Also for cyclic rating) 495(1) Self-Contained Cables with Impregnated, Laminated (Taped), or Extruded Insulation, Unarmored, and Thermally Similar Constructions 495(1) Oil-Filled (Liquid-Filled) Pipe-Type Cables (High Pressure) 496(1) Gas Pressure Pipe-Type Cables (No Filling Material or Armor) Also Three Single-Conductor Cables in Metallic Duct 497(1) Cables in Ducts (Nonmetallic) 497(1) Other Types of Cables and Installations 498(1) Long-Duration Partial Transient of the Cable (Also cyclic loading) 498(1) Long-Duration Partial Transient of the Cable Environment (Also cyclic loading) 499(1) Buried Cables (Directly or in Ducts) 499(3) Cables (Ducts) in Air 502(1) Short-Duration Transients (Duration < 1/3 of TQ) 503(1) Calculation of the Complete Temperature Transient 503(1) Buried Cables (Directly or in Ducts) 503(1) Cables (Ducts) in Air 503(1) Correction to Transient Temperature Response for Variation in Conductor Losses with Temperature 504(1) Dielectric Loss 504(1) Dielectric Losses in Cables at Voltages Up to and Including 275kV 505(1) Dielectric Losses in EHV Cables, Higher than 275kV 505(1) Emergency Ratings 505(1) General Remarks about Overloads and Emergency Ratings 506(2) Other Methods for the Calculation of Short-Term Overloading 508(1) Fault Currents 509(8) Calculation of the Thermally Permissible Short-Circuit Current 512(1) Adiabatic Method 512(2) Comparison of the Adiabatic and Nonadiabatic Methods 514(1) Nonadiabatic Method 515(2) Cable System Economics 517(8) Calculating Procedure 519(1) Calculating Cost of Joule Losses 520(2) Total Cost 522(1) Determination of Economic Current Range for Given Conductor Size 522(1) Economic Conductor Size for Given Load 522(2) Dielectric Loss and Losses Due to Charging Current 524(1) Design Considerations 524(1) Choice of System Voltage 525(1) Cable Selection and Installation Methods 526(6) Directly Buried Cables 526(2) Cables Installed in Ducts 528(1) Pipe-Type Cables 529(3) Cable Pulling 532(9) Clearance between Cable and Duct or Pipe 533(1) Jam Ratio and Configuration in Duct or Pipe 533(1) Choice of Lubricant 534(1) Pulling Forces in Pipe-Type Cables and Ducts 534(1) Allowable Pulling Force 535(1) Pulling Force in Bends and on Slopes 536(1) Composite Curves and Angular Offsets 537(1) Sidewall Pressure 538(1) Bending Radii 538(3) Cable Training in Manholes and at Terminations 541(1) Curves on the Cable Route 541(1) Choice of Cable Route and Manhole Location 541(10) Manhole Design for Duct Installations 542(4) References 546(5) Cryogenic And Compressed Gas Insulated Power Cables 551(31) K. D. Srivastava Introduction 551(2) Compressed Gas Insulated Transmission Line System 553(12) Conductor and Sheath 554(1) Insulating Gas 555(4) Solid Spacers 559(3) Power Rating 562(2) Field Experience 564(1) Cryoresistive Cables 565(3) Taped Insulation Cables 565(3) Vacuum Insulated Cryocable 568(1) Superconductive Cables 568(8) Union Carbide Design 571(1) Brookhaven Design 571(2) General Comments on Low-Temperature Superconducting Cables 573(1) High-Temperature Superconducting Power Cables 574(2) Economic Considerations 576(6) References 578(4) Underwater Power Cables 582(42) R. T. Traut Introduction 582(1) Underwater Power Cable Design 583(13) Configuration 583(1) Single-Conductor Cables 583(3) Three-Conductor Cables 586(1) Mode as Related to Configuration 587(1) Alternating-Current Systems 587(1) Direct-Current Systems 588(1) Electrical Core Design 588(1) Conductor 589(1) Insulation and Shields 590(2) Sheath Design 592(2) Reinforcement and Jacket Design 594(2) Power Transmission Requirements 596(5) System Power Transfer Requirements 596(1) Selection of Voltage and Mode 596(1) Ampacity and Electrical Losses 597(2) Additional Shield and Sheath Design Consideration 599(1) Additional Factors Regarding Cable Sizing and Losses 600(1) Armor and External Protection Design 601(9) Design Considerations 601(4) Armor Size and Specification 605(2) Armor Material 607(1) Armor as Protection 607(3) Special Application Designs 610(1) Underwater Power Cable Manufacture 610(2) Splicing 611(1) Jacketing 611(1) Armoring 611(1) Handling 611(1) Testing 612(1) Cable Transport 612(1) Underwater Power Cable Installation 613(11) References 616(8) High-Voltage Direct-Current Cables 624(28) C. Doench K. D. Srivastava Introduction 624(2) Electrical Behavior of DC Cables 626(12) Stress Distribution and Maximum Current 627(8) Direct-Current Cable Design: Numerical Example 635(3) Transient Electric Stresses on HVDC Cables 638(1) Design of HVDC Cables 639(3) Parameter Contraints 641(1) Outline of Design Procedure 641(1) Selection of Materials 642(1) Direct-Current Cable Accessories 643(2) Background 643(1) Hydraulic Systems 644(1) Testing of DC Cables 645(2) Load Cycling and Polarity Reversal Test 646(1) Combined DC and Impulse Voltage Test 646(1) Emerging Trends in HVDC Cable Technology 647(5) References 648(4) Telephone Cables 652(130) R. Bartnikas Historical Background 652(2) Transmission Parameters of Copper Conductor Telephone Cables 654(3) Digital Transmission 657(6) Characteristics of Metallic Conductor Telephone Cables 663(20) Twisted-Wire Multipair Cables 663(20) Electrical Characteristics of Coaxial Cables 683(9) Metallic Conductor Telephone Cable Design and Manufacture 692(16) Twisted-Wire Multipair Telephone Cables 692(1) Paper Ribbon Twisted-Wire Multipair Telephone Cables 692(5) Paper Pulp Twisted-Wire Multipair Telephone Cables 697(1) Plastic Insulated Cables 698(7) Electrical Tests of Twisted-Wire Multipair Telephone Cables 705(2) Outside Plant and Station Connection Wires and Cables 707(1) Coaxial Cable Design and Construction 708(7) Video Pair Cable Design and Construction 715(1) Optical Fiber Telephone Cables 716(66) Optical Fiber Manufacture 718(5) Transmission Parameters of Optical Fibers 723(20) Construction and Design of Optical Fiber Cables 743(6) Fiber Cable Installation: Splices and Connectors 749(10) Optical Fiber Transmission Systems 759(13) References 772(10) Undersea Coaxial Communication Cables 782(36) R. T. Traut Introduction 782(1) Undersea Cable Telecommunications 783(14) History of Undersea Telecommunications Via Cable 783(1) Technical Challenges 783(4) First Undersea Telegraph Cables 787(1) First Undersea Telephone Cables 788(6) Installed Transoceanic Cable Systems 794(3) Undersea Coaxial Cable Design 797(21) Design Requirements: Electrical 797(1) Power Supply to System Repeaters 797(5) Transmission Signal Multiplexing 802(1) Undersea Coaxial Cable Design for Communications Transmission 802(7) System Requirements versus Practical Design Limitations 809(2) Design Requirements: Mechanical 811(1) Fundamental Mechanical Requirements 811(2) Evolution from External to Center Strength Designs 813(1) Protection from Damage 813(1) Practical Considerations Regarding Manufacturing. Installation, and Recovery 814(1) Influence on Design of Undersea Digital Fiber-Optic Cables 815(1) References 815(3) Terrestrial and Underwater Optical Fiber Cables 818(28) W. F. Wright Introduction 818(2) Low-Signal Loss and High Bandwidth 819(1) Immunity to Electromagnetic Interference 819(1) Small Size and Low Weight 819(1) Security 819(1) Safety 819(1) Historical Perspective 820(1) Optical Fiber Characteristics 821(6) Physical Description 821(1) Refractive Index and Total Internal Reflection 822(1) Mechanical Characteristics 823(1) Basic Optical Performance Characteristics 824(3) Introduction to Fiber-Optic Cables 827(11) Fiber-Optic Cable Design Criteria 828(1) Terrestrial Outside Plant Fiber-Optic Cable 829(1) Submarine Fiber-Optic Cable 830(4) Specialized Fiber-Optic Cable Designs 834(1) Optical Ground Wire Cable 834(1) All-Dielectric Self-Supporting Cable 835(1) Flame-Retardant Fiber-Optic Cable 836(1) Hostile Environment Fiber-Optic Cable 837(1) Introduction to Undersea Fiber-Optic Communication Systems 838(5) Repeatered Undersea Fiber-Optic Communication System Technology 839(1) Optical Amplifier Undersea Fiber-Optic Communication System Technology 840(3) Concluding Remarks 843(3) References 843(3) Author Index 846(1) Subject Index 847(10) About the Editors 857
