110kV XLPE Insulated 630mm² Copper Cable with Welded Corrugated Aluminum Sheath

Product Specification

110kV XLPE Insulated 630mm² Copper Cable with Welded Corrugated Aluminum Sheath

This single-core 110kV copper cable is engineered for high-voltage power transmission where overhead lines are not an option. With a 630 mm² cross-section and a welded corrugated aluminum sheath (W CAS), it provides a 100% waterproof barrier and heavy mechanical protection for underground city grids, substations, and large industrial projects.

Cable Construction 

High-voltage stability depends entirely on structural layers. This 110kV cable is built as follows:

1. Conductor: 630 mm² Compacted Stranded Plain Copper (Round or Segmented Milliken design to reduce skin effect).

2. Conductor Screen: Extruded semi-conducting layer to smooth out electrical stress.

3. Insulation: Super-clean, high-voltage Cross-linked Polyethylene (XLPE).

4. Insulation Screen: Extruded semi-conducting layer for radial electric field uniformity.

5. Water-blocking Layer: Semi-conducting waterproof tape to prevent longitudinal water migration.

6. Metallic Sheath: Welded Corrugated Aluminum Sheath (W CAS). Acts as a 100% radial water barrier and heavy grounding conductor.

7. Outer Jacket: High-Density Polyethylene (HDPE) or Flame-Retardant PVC with a conductive graphite coating for outer sheath fault testing.

Where This Cable is Used

• Substations: Connecting main transformers to the high-voltage grid.

• City Grid Undergrounding: Replacing bare overhead wires in urban areas via cable tunnels or buried ducts.

• Heavy Industry: Powering mega-scale facilities like steel mills, chemical plants, and data centers.

How It Solves Site Installation Problems

• 100% Moisture Protection: The welded corrugated aluminum sheath leaves no seams. It completely blocks underground water, stopping water-trees from growing in the XLPE insulation.

• High Earth-Fault Capacity: The thick aluminum sheath acts as a reliable grounding conductor, safely carrying high short-circuit currents during grid faults.

• Easier Bending in Tunnels: The corrugated design makes the cable more flexible than smooth aluminum or lead sheaths, meaning faster pulling through tight curves and narrow trenches.

• No Need for Concrete Conduits: The rigid aluminum structure easily withstands rock impact and soil pressure, allowing for direct burial and lower civil engineering costs.

Technical Data

• Voltage Rating: 64/110kV (Max. system voltage: 126kV)

• Conductor Size: 630 mm²

• Standards: IEC 60840, GB/T 11017

• Operating Temperature: 90°C continuous, 250°C short-circuit peak

• Laying Formation: Trefoil or Flat layout

Testing & Factory Acceptance (FAT)

We do not ship unverified cables. Every length is tested in our high-voltage laboratory before loading:

• 100% Partial Discharge (PD) Testing and AC withstand testing inside our Faraday cage.

• We welcome third-party inspectors from SGS, Bureau Veritas (BV), or Intertek for onsite or remote video FAT.

• All orders are shipped on heavy-duty, reinforced steel drums with sealed ends to keep moisture out.

FAQ

Q: Why use a corrugated aluminum sheath instead of a lead sheath?

A: Aluminum is much lighter than lead, making the cable easier to pull. It also gives you much higher mechanical strength for direct burial and better current capacity during earth faults.

Q: What is the current rating (ampacity) for this 630mm² cable?

A: It depends on your layout (trefoil or flat), burial depth, and soil temperature. Send us your trench details and we will run the exact calculation for you.

Q: Do you supply the matching 110kV joints and terminations?

A: Yes. We supply complete systems, including compatible GIS terminations, outdoor porcelain/composite terminations, and straight-through joints.

Q: What is the warranty?

A: 24 months from site commissioning or 36 months from the Bill of Lading (B/L) date. The actual design life is over 40 years.