1. INTRODUCING HIGH-PERFORMANCE POLYPROPYLENE THERMOPLASTIC ELASTOMER (HPTE) INSULATION FOR MV CABLES IN THE NETHERLANDS
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2. 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.
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3. 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
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4. 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
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5. 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.
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Pignataro production

6. 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
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7. 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
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8. 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.
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Pignataro production

9. History (cont.) Year Production Core facilities 2011
More than 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.
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10. Pignataro production line layout
Single line process
Insulation
+sc screens
Core cooling
conductor
Continuity
device
Metallic
screen
Protection
layers
Water blocking tapes
Finished cable
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11. Pignataro single line process
conductor
Finished cable
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12. 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
IEC add.
Cable finishing: elsewhere
HPTE insulated 6/10kV 1x240Solid Al
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13. 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
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14. 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
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15. 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
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16. 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
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17. THANK YOU FOR YOUR ATTENTION
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