2.5mm2 – 300mm2 XLPE Insulated Power Cable Applications

XLPE insulated power cables, known as cross-linked polyethylene insulated power cables, are a type of cable widely used in the field of power transmission. It uses cross-linked polyethylene as the core insulating material of the cable. Compared with the traditional polyvinyl chloride (PVC) insulated cables and non-cross-linked polyethylene (PE) cables, XLPE cable have significant improvements in electrical, thermal and mechanical properties. TST CABLES will introduce XLPE insulated power cables in detail:

  1. XLPE cable material characteristics
    Cross-linking reaction: XLPE is chemically or physically (e.g. irradiation or silane cross-linking) to cross-link the molecular chains of polyethylene to form a three-dimensional mesh structure. This process significantly improves the heat resistance, chemical resistance and mechanical strength of the material.
    Electrical properties: XLPE insulated cables have very low dielectric losses and excellent electrical insulation properties, even at high temperatures, but also maintain good electrical properties, the operating temperature range is usually up to -40 ° C to 90 ° C, some special designs even up to 125 ° C and above.
    Heat resistance and aging resistance: the heat resistance level of the material is increased after cross-linking, the long-term working temperature is higher than that of ordinary PE cables, and it is not easy to be aged under high temperature environment, which prolongs the service life of the cable.
    Mechanical strength: the cross-linked structure increases the mechanical strength and abrasion resistance of the material, so that it can withstand greater external forces in installation and operation without damage.
  2. XLPE cable structure composition
    The basic structure of XLPE cable usually includes:
  • Conductor: Copper or aluminum conductor, which can be solid or stranded conductor according to the design and usage requirements of the cable.
  • Insulation: composed of cross-linked polyethylene (XLPE), which provides the main electrical insulation.
  • Shield: Internal and external semiconductor shields for uniform electric field distribution, reducing electromagnetic interference and improving partial discharge characteristics.
  • Sheath: According to the environment where the cable is used, PVC, polyethylene or other materials can be used to provide mechanical protection and environmental protection.
  • Armor layer (optional): For cables requiring additional mechanical protection, steel tape or steel wire armor layer can be added.

3.XLPE cable product characteristics

  1. The maximum working temperature of the conductor of XLPE cable is 90℃.
  2. When short-circuit (maximum duration of not more than 5S) cable conductor maximum operating temperature of 250 ℃, the overload temperature does not exceed 130 ℃.
  3. Laying ambient temperature of not less than 0 ℃.
  4. Voltage level, medium and low voltage power cables

4.XLPE cable industrial standards
International: IEC60502, IEC60228, (IEC60332-3 only applies to FR cables) China: GB/T12706, (GB/T18380-3 only applies to FR cables), and other standards, such as BS, DIN and lCEA, upon request.

  1. What are the advantages of XLPE (cross-linked polyethylene) cables over ordinary cables?
    Excellent electrical performance: XLPE insulation has very low dielectric loss and excellent insulating properties, even at high temperatures can maintain stable electrical characteristics, to ensure efficient and safe power transmission.
    Enhanced thermal stability: The cross-linking process changes the molecular structure of the polyethylene to form a three-dimensional network structure, which greatly improves heat resistance and aging resistance, enabling the cable to operate stably over a wider range of operating temperatures.
    Long service life: Due to its excellent heat and chemical resistance, the service life of XLPE cables far exceeds that of ordinary PVC cables, usually up to 40 years or more, which reduces the replacement cost and maintenance frequency.
    Lightweight and flexible: XLPE cables have no bulky metal sheaths, small bending radii and low mass, which makes them easier to install and lay, especially in space-constrained environments.
    Environmentally friendly: XLPE cables do not contain toxic halogen elements and produce less smoke and low toxicity when burned, which is in line with modern environmental requirements, especially for places with strict environmental requirements.
    Low operating costs: no need for complex maintenance of the oil-filled system, reducing the cost of inspection and maintenance in operation, and in the long run, can significantly reduce the overall operating costs.
    High current-carrying capacity and overload capacity: Compared with PVC cables of the same cross-section, XLPE cables have a higher current-carrying capacity and stronger overload capacity, which is suitable for high power transmission requirements.
    High adaptability: XLPE cables are suitable for a wide range of environments, including underground direct burial, pipe laying, installation in tunnels, and even submarine laying, with good corrosion resistance and waterproof performance.
    Fire resistance: Some XLPE cables are designed to be fire resistant, maintaining circuit integrity for a period of time in the event of a fire, ensuring the proper functioning of critical systems such as firefighting equipment.
    Customizability: XLPE cables can be customized with different voltage levels, cross-section sizes, and jacket materials (e.g. LSZH) to meet specific installation and usage conditions.
  2. XLPE cable application fields
    XLPE cables have a wide range of applications, laid indoors and outdoors, can withstand a certain amount of traction when laid, but can not withstand external mechanical force. Single-core cables are not allowed to be laid in magnetic pipes.
    Power transmission: suitable for power lines of various voltage levels, including low-voltage, medium-voltage and high-voltage power transmission.
    Industrial applications: chemical industry, petroleum, natural gas, mining and other industrial settings with harsh environments, due to its good corrosion and temperature resistance.
    Building wiring: for internal power supply in buildings, especially in places with high fire prevention requirements, such as hospitals, schools, large buildings, exhibition halls and museums.
    Transportation infrastructure: public transportation systems such as subways, airports, railroads, etc., due to its fire-resistant, flame-retardant, low smoke and halogen-free characteristics.
  3. XLPE cable installation and maintenance
    When installing XLPE cables, it is necessary to pay attention to the minimum bending radius of the cable to avoid excessive bending resulting in damage to the insulation layer.
    XLPE cable joints need to be treated with specialized processes and materials to ensure electrical continuity and sealing.
    Regularly check the appearance of XLPE cables and the state of joints, and repair and replace them in time to ensure safe operation.
  4. Environmental protection and sustainability of XLPE cables
    Although XLPE cable may not be as environmentally friendly as low-smoke halogen-free cables in the manufacturing process, their long life and high performance characteristics reduce the frequency of cable replacement and resource consumption as a whole, which is in line with the concept of sustainable development. As technology advances, TST CABLES is also exploring more environmentally friendly cross-linking agents and recycling methods.

China’s No. 1 XLPE cable manufacturer TST cables
XLPE cable manufacturer
TST cables newly developed XLPE insulated power cable with advanced cross-linking technology to ensure efficient and stable power transmission. Excellent heat and corrosion resistance, achieving reliable companionship for decades. Halogen-free and low-smoke, making power equipment safer and energy flow greener. tst cables relies on a strong R&D team, and each inch of cable carries the persistent pursuit of high quality. We not only manufacture cables, but also build safe and long-lasting electric power for you, connecting you to a smarter and more environmentally friendly tomorrow.

If you are looking for stable and high standard high temperature cable, XLPE cable suppliers and manufacturers, please feel free to email or call to chat with our engineers about your project and get free samples.

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