INTRODUCING HIGH-PERFORMANCE POLYPROPYLENE THERMOPLASTIC ELASTOMER (HPTE) INSULATION FOR MV CABLES IN THE NETHERLANDS ROSSUM-NL-S1-0345

Development alternative for XLPE is favorable insulation material for MV nowadays. has outstanding overall characteristics and performances (electrical, thermo-mechanical and installation). has well-proven track record at all voltages. However, XLPE requires cross-linking which leads to by-products with carbon footprint as a consequence. requires cross-linking thus leading to interrupted production process. is non re-usable. ROSSUM-NL-S1-0345

Development alternative for XLPE Prysmian objective: development thermoplastic insulation material with equivalent, or even better characteristics as XLPE. Material found in HPTE: High-performance Polypropylene Thermoplastic Elastomer, also called P-Laser© granulate Polypropylene chemical symbol ROSSUM-NL-S1-0345

Development alternative for XLPE Qualification Prysmian HPTE insulation ‘P-laser’ after development test: Production XLPE P-laser (HPTE) Operating temperature 90oC 90oC (up to 110oC) Emergency temperature 105oC 130oC Dielectric strength Excellent Electrical breakdown strength Very good Thermo-plastic resistance Handeling characteristics Good ROSSUM-NL-S1-0345

History Year Production Core facilities 2002/ 2003 HPTE insulated cables prototype production, evaluation of physical, chemical and electrical parameters. Prysmian R&D laboratories, Milan, Italy 2004 Erection of HPTE production location at Pignataro, Italy. ROSSUM-NL-S1-0345 Pignataro production

History (cont.) Year Production Core facilities 2005 12/20kV HPTE 1x185mm2, produced for ENEL, Italy. 6/10kV HPTE core 1x240mm2, solidAl, produced for Alliander, Netherlands 30 km 9 km Cores produced in Pignataro, core finishing elsewhere. 2006 12/20kV HPTE 3x1x185mm2, produced for ENEL, Italy. 10 km Completion of Pignataro line with cable screening (overlapped Al tape), water blocking tape application and multi layer jacket extrusion ROSSUM-NL-S1-0345

History (cont.) Year Production Core facilities 2007 12/20kV HPTE 1x185mm2, produced for ENEL, Italy. 300 km Cores produced in Pignataro, core finishing elsewhere 2008 150 km Cores produced in Pignataro, core finishing in other plants. 2009 12/20kV HPTE, different conductor sizes, produced for ENEL and ACEA. 6/10kV HPTE core 1x240mm2, solidAl, produced for Alliander, Netherlands, second field test. 2400 km 9 km ROSSUM-NL-S1-0345

History (cont.) Year Production Core facilities 2010 Industrialization of 12/20kV HPTE production with 70mm2, 95mm2 and 240mm2 conductor sizes. Industrialization of 18/30kV HPTE 1x240mm2 core production. 4000 km Pignataro single step production line industrialized: 7 production steps in one single process. ROSSUM-NL-S1-0345 Pignataro production

History (cont.) Year Production Core facilities 2011 More than 10.000 km of HPTE insulated core (10-30kV range) have been successfully produced in Pignataro factory, demonstrating the maturity of this insulation technology for MV cables. Based on this experience, HPTE insulated core production was implemented in the Prysmian Delft factory, the Netherlands. Pilot Production 18/30kV 1x800 SolidAl and 6/10kV 1x240 Solid Al 3 km 5 km Core production at modified existing horizontal insulation line for MV cables at Prysmian Delft Factory, the Netherlands. ROSSUM-NL-S1-0345

Pignataro production line layout Single line process Insulation +sc screens Core cooling conductor Continuity device Metallic screen Protection layers Water blocking tapes Finished cable ROSSUM-NL-S1-0345

Pignataro single line process conductor Finished cable ROSSUM-NL-S1-0345

Performed (type-)tests Year Test object Standard Production location 2005 HPTE insulated 12/20kV 1x150 HD620 S2, part 10, section J, appendix G: long duration test, 500Hz, 3000 h. Core production: Pignataro 2006 HPTE insulated 12/20kV 3x1x185 IEC60502-2 + add. Cable finishing: elsewhere HPTE insulated 6/10kV 1x240Solid Al ROSSUM-NL-S1-0345

Performed (type-)tests Year Test object Standard Production location 2007 HPTE insulated 6/10kV 3x240 SolidAl cable HD620S1, part 6 section J, including accessories compatibility test Core production: Pignataro Cable finishing: Delft Test set-up compatibility test HPTE cable with XLPE cable ROSSUM-NL-S1-0345

Performed (type-)tests Year Test object Standard Production location 2010 HPTE insulated 6/10 kV 1x240Alrm HD620 S2, part 10, section J, appendix G: long duration test, 500Hz, 3000 h. Core production: Pignataro 2011 HPTE insulated 18/30kV 1x800Alrm HD620S1, part 6 section J, including accessories compatibility test. Test voltages based on Uo=20.5kV Core production and cable finishing: Prysmian Delft, the Netherlands ROSSUM-NL-S1-0345

Eco-sustainable 100% recyclable product >25-50% reduction of carbon footprint (Delft plant) >75% saving on water and energy during production (Delft plant) zero-gas technology Pallet, produced with recycled HPTE insulation ROSSUM-NL-S1-0345

Summary and conclusion Prysmian HPTE insulated cable, also known as Prysmian is 100% recyclable, has reduced energy consumption and greenhouse gas emissions is fully compatible with existing XLPE insulated cables and accessories can be used at higher operating temperatures compared to XLPE production time is reduced from days to hours has outstanding overall characteristics and performances (electrical, thermo-mechanical and installation) has well-proven track record up to 30kV voltage class. is type tested in full accordance with present standards for XLPE ROSSUM-NL-S1-0345

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