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Electric Power Distribution Handbook
the cross-linking that sets when the insulation cools. XLPE has about the
same insulation strengths as polyethylene, is more rigid, and resists water
treeing better than polyethylene. Although not as bad as HMWPE, pre-1980s
XLPE has proven susceptible to premature failures because of water treeing.
XLPE has higher temperature ratings than HWMPE; cables are rated to 90
∞
C
under normal conditions and 130
∞
C for emergency conditions.
Tree-Retardant Cross-Linked Polyethylene (TR-XLPE).
This has adders to
XLPE that slow the growth of water trees. Tree-retardant versions of XLPE
have almost totally displaced XLPE in medium-voltage cables. Various com-
pounds when added to XLPE reduce its tendency to grow water trees under
voltage. These additives tend to slightly reduce XLPE’s electrical properties,
slightly increase dielectric losses, and slightly lower initial insulation
strength (but much better insulation strength when aged). While there is no
standard industry definition of TR-XLPE, different manufacturers offer XLPE
compounds with various adders that reduce tree growth. The oldest and
most widely used formulation was developed by Union Carbide (now Dow);
their HFDA 4202 tree-retardant XLPE maintains its insulation strength better
in accelerated aging tests (EPRI TR-108405-V1, 1997) and in field service
(Katz and Walker, 1998) than standard XLPE.
Ethylene-Propylene Rubber (EPR).
EPR compounds are polymers made from
ethylene and propylene. Manufacturers offer different ethylene-propylene
formulations, which collectively are referred to as EPR. EPR compounds are
thermoset, normally with a high-temperature steam curing process that sets
cross-linking agents. EPR compounds have high concentrations of clay fillers
that provide its stiffness. EPR is very flexible and rubbery. When new, EPR
only has half of the insulation strength as XLPE, but as it ages, its insulation
strength does not decrease nearly as much as that of XLPE. EPR is naturally
quite resistant to water trees, and EPR has a proven reliable record in the
field. EPR has very good high-temperature performance. Although soft, it
deforms less at high temperature than XLPE and maintains its insulation
strength well at high temperature (Brown, 1983). Most new EPR cables are
rated to 105
∞
C under normal conditions and to 140
∞
C for emergency condi-
tions, the MV-105 designation per UL Standard 1072. (Historically, both XLPE
and EPR cables were rated to 90
∞
C normal and 130
∞
C emergency.) In addition
to its use as cable insulation, most splices and joints are made of EPR com-
pounds. EPR has higher dielectric losses than XLPE; depending on the par-
ticular formulation, EPR can have two to three times the losses of XLPE to
over ten times the losses of XLPE. These losses increase the cost of operation
over its lifetime. While not as common or as widely used as XLPE in the
utility market, EPR dominates for medium-voltage industrial applications.
TR-XLPE vs. EPR: which to use? Of the largest investor-owned utilities
56% specify TR-XLPE cables, 24% specify EPR, and the remainder specify a
mix (Dudas and Cochran, 1999). Trends are similar at rural cooperatives. In
a survey of the co-ops with the largest installed base of underground cable,
42% specify TR-XLPE, 34% specify EPR, and the rest specify both (Dudas
and Rodgers, 1999). When utilities specify both EPR and TR-XLPE, com-
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