CN114068084A - Gas-free submarine cable and series synchronous production system and process thereof - Google Patents
Gas-free submarine cable and series synchronous production system and process thereof Download PDFInfo
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- H—ELECTRICITY
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- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
- H01B7/282—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
- H01B13/24—Sheathing; Armouring; Screening; Applying other protective layers by extrusion
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
- H01B13/26—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
- H01B13/2613—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping by longitudinal lapping
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/14—Submarine cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A30/00—Adapting or protecting infrastructure or their operation
- Y02A30/14—Extreme weather resilient electric power supply systems, e.g. strengthening power lines or underground power cables
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Abstract
The invention provides a gas-free submarine cable and a series synchronous production system and process thereof. According to the gas-free submarine cable, the XLPE insulating layer is made of a degassing-free cross-linked polyethylene insulating material, and is subjected to cross-linking extrusion, wherein the content of cross-linked byproducts is less than 100ppm, so that a degassing procedure of insulating byproducts which is long in time consumption in the traditional large-length XLPE submarine cable production process can be directly removed, the insulating property of a product is not affected, and meanwhile, fuel power and investment cost of drying room equipment required by the degassing procedure are reduced, and the conductor shielding layer, the XLPE insulating layer, the insulation shielding layer, the second semi-conductive water-blocking layer, the metal protective layer and the non-metal protective layer can be produced at one time through a production line, so that the intermediate production times and the circulation process are reduced, the submarine cable production period can be shortened by 30-50%, the submarine cable capacity can be improved, the manufacturing cost can be reduced, the energy consumption can be reduced, and the product competitiveness can be improved.
Description
Technical Field
The invention relates to the technical field of submarine cables, in particular to a gas-free submarine cable beneficial to a large-water-depth environment and a series synchronous production system and process thereof.
Background
Based on the gradual development of the field of marine energy transmission such as offshore wind power, the application of submarine cable products gradually develops towards green low carbon, large length, high voltage and large water depth, the market increasingly pays attention to the cost of submarine cables, and with the adjustment of national policies of offshore wind power 'fair price surfing' and the continuous increase of submarine cable manufacturers at home and abroad in the future, the construction cost of submarine cable engineering can be obviously reduced, and the market competition is more intense. In order to improve the product competitiveness, the high-voltage alternating current submarine cable product will tend to develop towards the direction of low cost, high performance and short period.
The existing high-voltage submarine cable structure of 220kV or more is mainly suitable for offshore power transmission with shallow water depth, and for submarine cables with water depth more than 500m, the related structural design and application are less, and the existing submarine cable product does not have the advantage of good water-blocking performance; meanwhile, in the aspect of production technology, the conventional equipment modification and process optimization are relatively limited, and the production efficiency improvement effect is not obvious. In terms of a cross-linking byproduct removing process, the existing large-length cross-linked polyethylene insulated high-voltage submarine cable needs to be subjected to a heating degassing process after the production of an insulated wire core, and is used for removing byproducts such as methane, acetophenone and cumyl alcohol generated in the insulation vulcanization cross-linking process, and generally after a 220kV insulated wire core exceeds more than 15km, the degassing period is as long as 1-2 months, so that the production efficiency and equipment capacity of the cross-linked polyethylene insulated submarine cable are severely restricted, and the delivery period requirement cannot be met; simultaneously, the degassing process also limits the synchronous production of the cable insulation layer and the sheath structure, and the multiple production and circulation of the cable core can also increase the risk of the occurrence of quality problems of the submarine cable. Therefore, it is necessary to design an efficient submarine cable structure and optimize the production process, so as to achieve the purpose of improving the performance and production efficiency of the submarine cable, and enhance the advantages of high-voltage submarine cable products, so as to meet more intense market competition.
Disclosure of Invention
The invention aims to provide a gas-free submarine cable and a series synchronous production system and process thereof, wherein an XLPE insulating layer adopts a degassing-free cross-linked polyethylene insulating material, a sheath wire core is formed by adopting the series synchronous production system and process, degassing procedures between a cross-linking and wrapping procedure and a sheath extrusion procedure of the traditional long XLPE submarine cable are eliminated through optimization of materials, equipment and process flows, meanwhile, series synchronous production is realized through the cross-linking procedure, the wrapping procedure and the sheath extrusion procedure, the intermediate production times and the circulation process are reduced, the production cycle of the submarine cable can be shortened by 30-50%, the productivity of the submarine cable is improved, the manufacturing cost is reduced, the energy consumption is reduced, the product competitiveness is improved, and the water blocking performance requirement of a water blocking conductor is improved through optimization of the structural design of the submarine cable, so that the problems that the existing submarine cable is suitable for shallow water depth and low in large-length degassing efficiency are solved, The production period is long.
The invention can be realized as follows:
the invention provides an air-free submarine cable, wherein a protective layer wire core of the air-free submarine cable comprises a water-blocking conductor, a first semi-conductive water-blocking layer, a conductor shielding layer, an XLPE insulating layer, an insulating shielding layer, a second semi-conductive water-blocking layer, a metal protective layer and a non-metal protective layer which are sequentially arranged from inside to outside; the XLPE insulating layer is made of a degassing-free cross-linked polyethylene insulating material, and after the XLPE insulating layer is extruded through cross-linking, the content of cross-linking byproducts is less than 100ppm, so that the insulating property requirement of a product is met, and an additional byproduct removing process is not required to be independently added.
Specifically, the degassing-free submarine cable further comprises an inner liner, a mixed armor layer and a tegument layer which are sequentially arranged on the outer side of the sheath wire core from inside to outside.
Specifically, the water-blocking conductor is formed by layering, pressing and twisting a plurality of sectional aluminum wires, the sectional aluminum wires are of a trapezoidal structure, and a seawater-proof water-blocking compound is filled and wrapped in gaps of each twisted layer, so that the applicable water depth can be increased to 2000m compared with that of a conventional water-blocking tape material, and the water-blocking performance requirement of a large-water-depth submarine cable is met.
Specifically, the compression coefficient of the aluminum wires of the section bar can reach more than 95 percent, and the resistivity of a single aluminum wire of the section bar is not more than 0.028264 omega mm at 20 DEG C2And/m. Armor metal wires and non-metal wires are distributed at intervals in the mixed armor layer, and a plurality of optical units are compounded. Compared with the conventional submarine cable adopting a copper core conductor and metal armor structure, the weight of the submarine cable can be reduced by 20-35%, and the submarine cable is beneficial to construction and installation of submarine cables in large-water-depth environments.
The invention also provides a series synchronous production system of the gas-free submarine cable, which is used for preparing a protective layer wire core of the gas-free submarine cable, and realizing series synchronous production of the cross-linking process, the wrapping process and the protective layer extrusion process.
Specifically, this synchronous production system of establishing ties includes that the level that sets up along production line direction in proper order establishes ties puts off the carousel, first reverse wheel, traction wheel, three-layer coextrusion plastic extruder, second reverse wheel, heater, around chartered plane, first tractor, lead extruding machine, pitch coating machine, plastic extruder, segmentation cooling trough, laser note rice ware, second tractor and level receive the line carousel.
Specifically, the horizontal paying-off turntable and the horizontal taking-up turntable respectively have an active paying-off function and an active taking-up function, a water-blocking conductor externally coated with a first semi-conductive water-blocking layer is paid off by the horizontal paying-off turntable, the water-blocking conductor is pulled to a three-layer co-extrusion plastic extruder through a first reversing wheel and a traction wheel to be extruded, vulcanized, crosslinked and cooled by a conductor shielding layer, an XLPE insulating layer and an insulating shielding layer, the water-blocking conductor is pulled to a heater through a second reversing wheel to be heated secondarily after being cooled, a second semi-conductive water-blocking layer lapping and covering wrapping are carried out through a wrapping machine, the water-blocking conductor is pulled to a lead extruding machine through a first traction machine to be extruded and coated by a metal protective layer after being wrapped, the water-blocking conductor is pulled to an asphalt coating machine and a plastic extruding machine to be extruded and coated by a non-metal protective layer in a thermal state, the water-cooling tank is cooled to normal temperature after the thermal state extrusion and coating, and then a laser meter-recording device is used for printing and recording rice, after printing characters and recording rice, pulling the characters and the rice into the horizontal take-up turntable through a second tractor to carry out cable arrangement and take-up.
Preferably, the first tractor and the second tractor are both crawler tractors; the heater is an annular high-frequency heater; horizontal unwrapping wire carousel and horizontal receipts line carousel all possess special cable winding displacement ware, possess the initiative and receive and release the line function, can satisfy receiving of big length high pressure submarine cable sheath sinle silk and store.
Specifically, still be provided with a plurality of guide pulleys and bearing rollers that turn to in the whole production line between horizontal unwrapping wire carousel to the horizontal receipts line carousel to accomplish long distance sinle silk circulation work.
Based on the series synchronous production system, the invention also provides a series synchronous production process for eliminating the gas submarine cable, which adopts the series synchronous production system and specifically comprises the following steps:
step 1, a horizontal paying-off turntable discharges a water-blocking conductor wrapped with a first semi-conductive water-blocking layer, the water-blocking conductor is pulled to a three-layer co-extrusion plastic extruder through a first reversing wheel and a traction wheel, the three-layer co-extrusion plastic extruder extrudes, vulcanizes and cross-links the water-blocking conductor outside the first semi-conductive water-blocking layer, cools the water-blocking conductor to form a conductor shielding layer, an XLPE insulating layer and an insulating shielding layer, and a cross-linked wire core is formed after cooling; the cooled crosslinked wire core is pulled to a heater through a second reversing wheel to be heated for the second time, so that the decomposition of byproducts in the XLPE insulating layer is accelerated;
step 2, after the crosslinked wire core is heated for the second time, lapping and wrapping the crosslinked wire core by a wrapping machine to form a second semi-conductive waterproof layer, then pulling the crosslinked wire core to a lead extruder by a first tractor to be positioned outside the second semi-conductive waterproof layer to extrude and wrap to form a metal protective layer, performing thermal extrusion and wrapping on the outer side of the metal protective layer by an asphalt coating machine and a plastic extruder to form a non-metal protective layer, and then cooling the non-metal protective layer to normal temperature by a sectional cooling water tank to form a sheath wire core;
and 3, printing and recording the rice on the non-metal protective layer through a laser meter recorder, and then pulling the sheath core into the horizontal take-up turntable through a second tractor to arrange cables and take up the cables.
Specifically, the XLPE insulating layer is made of a degassing-free crosslinked polyethylene insulating material with the material density of 0.93g/cm3After the XLPE insulating layer is formed by extrusion, the content of the crosslinking byproducts of methane, acetophenone and cumyl alcohol in the XLPE insulating layer is less than 100ppm, the product performance requirements are met, and an additional byproduct removing procedure is not required to be independently added.
Specifically, the heating temperature for secondary heating of the crosslinked wire core in the step 1 is 85-95 ℃.
The beneficial effects of the invention include:
(1) according to the air-free submarine cable, the XLPE insulating layer is made of an air-free cross-linked polyethylene insulating material, and is cross-linked and extruded, so that the content of cross-linked byproducts is less than 100ppm, the insulating property of the product is not affected, the long-time insulating byproduct degassing process in the traditional large-length XLPE submarine cable production process can be directly removed, fuel power and drying room equipment investment cost required by the degassing process are reduced, and the manufacturing cost is remarkably reduced;
(2) according to the air-free submarine cable, the structural design of the submarine cable is optimized, the water blocking performance requirement of the water blocking conductor is improved, the structural design of the aluminum core conductor and the mixed armor layer is adopted, the weight of the submarine cable can be reduced by 20-35%, the applicable water depth reaches 2000m, the engineering application of the submarine cable with large length, large water depth and high pressure can be met, and therefore the problems that the existing submarine cable is low in applicable water depth, low in degassing efficiency with large length and long in production period are solved;
(3) the series synchronous production system has a linkage control function, the production speed of each device of a cable core in the whole production line is kept synchronous and continuous production is realized, the conductor shielding layer, the XLPE insulating layer, the insulating shielding layer, the second semi-conductive waterproof layer, the metal protective layer and the non-metal protective layer are produced at one time through the production line, the intermediate production times and the circulation process are reduced, the degassing process between the traditional large-length XLPE submarine cable crosslinking and wrapping process and the protective layer extrusion process is eliminated, the submarine cable production period can be shortened by 30-50%, the submarine cable production capacity is improved, the manufacturing cost is reduced, the energy consumption is reduced, and the product competitiveness is improved.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained according to the drawings without inventive efforts.
FIG. 1 is a schematic view of the construction of the airless submarine cable according to the invention;
FIG. 2 is a schematic diagram of the structure of the tandem synchronous production system of the present invention for eliminating the gas-free submarine cable.
Icon: 1-horizontal paying-off turntable, 2-first reversing wheel, 3-traction wheel, 4-three-layer co-extrusion plastic extruder, 5-second reversing wheel, 6-heater, 7-wrapping machine, 8-first traction machine, 9-lead extruding machine, 11-asphalt coating machine, 12-plastic extruder, 13-sectional cooling water tank, 14-laser meter counter, 15-second traction machine, 16-horizontal take-up turntable, 10-water-resistant conductor, 20-first semi-conductive water-resistant layer, 30-conductor shielding layer, 40-XLPE insulating layer, 50-insulating shielding layer, 60-second semi-conductive water-resistant layer, 70-metal protective layer, 80-non-metal protective layer, 90-inner lining layer, 100-mixed armor layer, 110-outer coating layer, 101-light unit, 102-non-metal wire, 103-armoured metal wire.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. The components of embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations.
Thus, the following detailed description of the embodiments of the present invention, presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Furthermore, the appearances of the terms "first," "second," and the like, if any, are used solely to distinguish one from another and are not to be construed as indicating or implying relative importance.
Referring to fig. 1, the present invention first provides an air-free submarine cable, which specifically includes a water-blocking conductor 10, a first semiconductive water-blocking layer 20, a conductor shielding layer 30, an XLPE insulating layer 40, an insulating shielding layer 50, a second semiconductive water-blocking layer 60, a metal sheath 70, a nonmetal sheath 80, an inner liner 90, a mixed armor layer 100, and an outer sheath layer 110, which are sequentially disposed from inside to outside, wherein armor wires 103 and nonmetal wires 102 are alternately disposed in the mixed armor layer, and two optical units 101 are also compounded. The XLPE insulating layer 40 is made of a degassing-free crosslinked polyethylene insulating material, and the degassing-free crosslinked polyethylene insulating material means that after the XLPE insulating layer 40 made of the material is subjected to crosslinking extrusion, the content of crosslinking byproducts is less than 100ppm, so that an additional byproduct removing process is not required to be independently added, and the insulating property requirement of a product is met.
Specifically, the conductor shielding layer 30, the XLPE insulating layer 40 and the insulation shielding layer 50 are extruded once in a three-layer co-extrusion mode, the XLPE insulating layer 40 is made of an ultra-clean gas-free cross-linked polyethylene material, the material supplier and the model are Dow chemical HFDD-4201SC, the content of methane by-products after cross-linking extrusion is less than 100ppm, the insulation electrical performance is not influenced, therefore, the degassing process of the insulation by-product which takes a long time in the traditional production process of the large-length XLPE submarine cable can be directly removed, the sheath wire core of the degassing submarine cable can be prepared by adopting the series synchronous production process, the structures of the conductor shielding layer 30, the XLPE insulating layer 40, the insulation shielding layer 50, the second semi-conductive waterproof layer 60, the metal sheath 70 and the non-metal sheath 80 can be produced at one time through a production line, meanwhile, fuel power required by a degassing process and investment cost of drying room equipment are reduced, and the manufacturing cost is obviously reduced.
Specifically, the water-blocking conductor 10 is formed by layering, compressing and stranding a plurality of sectional aluminum wires, the sectional aluminum wires are of a trapezoidal structure, the sectional aluminum wires are filled and coated with a seawater-proof water-blocking compound in gaps, the compression coefficient of the sectional aluminum wires reaches over 95 percent, and the resistivity of the sectional aluminum wires is not more than 0.028264 omega mm at 20 DEG C2/m。
Specifically, the water-blocking conductor 10 and the insulating shielding layer 50 are respectively wrapped with a first semi-conductive water-blocking layer 20 and a second semi-conductive water-blocking layer 60, the first semi-conductive water-blocking layer 20 and the second semi-conductive water-blocking layer 60 are made of sea water-blocking type semi-conductive water-blocking tapes with high water absorption rate and expansion rate, and the thicknesses of the water-blocking tapes are 0.27mm and 1.0mm respectively.
Specifically, the second semiconductive water-blocking layer 60 is extruded with a metal sheath 70, and the metal sheath 70 is made of an alloy lead ingot. The metal sheath 70 is extruded with the non-metal sheath 80, and the non-metal sheath 80 is made of high-density polyethylene. The non-metal sheath 80 is wound with a layer of polypropylene rope as an inner liner 90, the outer side of the inner liner 90 is twisted with a layer of mixed armor layer 100, the mixed armor layer 100 is wound with two layers of polypropylene rope materials as an outer layer 110, and the twisting directions of the two layers of polypropylene ropes are opposite.
Specifically, the hybrid armor layer 100 is formed by two optical units 101, a plurality of non-metallic wires 102 and armor wires 103 which are distributed and twisted at intervals, and the outer side of the hybrid armor layer is coated with an anti-corrosion asphalt material. The non-metal wire 102 is a round bar structure extruded by a high-density polyethylene material, the armored metal wire 103 is formed by twisting a plurality of hard copper wires, 2 optical units 101 are symmetrically distributed in the mixed armor layer 100, and three non-metal wires 102 are respectively arranged on two sides of each optical unit 101. The diameter of the non-metallic wire 102 and the diameter of the metallic wire 103 are both 6.0mm, and the diameter of the light unit 101 is 5.0 mm.
According to the air-free submarine cable, the XLPE insulating layer 40 is made of an ultra-clean air-free cross-linked polyethylene material, and the content of methane byproducts is less than 100ppm after cross-linking extrusion, so that the long-time-consuming degassing procedure of the insulating byproducts in the traditional long-length XLPE submarine cable production process can be directly removed, the conductor shielding layer 30, the XLPE insulating layer 40, the insulation shielding layer 50, the second semi-conductive water-blocking layer 60, the metal sheath 70 and the non-metal sheath 80 can be produced in one step through a production line, the intermediate production times and the circulation process are reduced, the submarine cable production period can be shortened by 30-50%, the submarine cable production capacity can be improved, the manufacturing cost can be reduced, and the product competitiveness can be improved; by optimizing the structural design of the submarine cable, and by structural designs of the aluminum core conductor, the mixed armor and the like, compared with the structural design of the conventional copper core conductor and the conventional metal armor, the weight of the submarine cable can be reduced by 20-35%, the submarine cable is beneficial to construction and installation of the submarine cable in a large water depth environment, and the influence of water tension on the submarine cable is reduced; through the design of the molded water-blocking conductor, the filling coefficient of the conductor can be increased to more than 95% from 90% of that of a conventional round compressed conductor, and meanwhile, the water-blocking compound material is adopted in the conductor gap, compared with the conventional water-blocking tape material, the applicable water depth can be increased to 2000m, the water-blocking performance requirement of a submarine cable with large water depth is met, and therefore the problems that the conventional submarine cable is low in applicable water depth, low in degassing efficiency and long in production period are solved.
Referring to fig. 2, the system for synchronously producing in series a cable free from air seabed according to the present invention is used for preparing a sheath core of the cable free from air seabed, and realizes the synchronous production of the cross-linking process, the wrapping process and the sheath extrusion process, as shown in fig. 2, the air-free submarine cable comprises a water-blocking conductor 10, a first semi-conductive water-blocking layer 20, a conductor shielding layer 30, an XLPE insulating layer 40, an insulating shielding layer 50, a second semi-conductive water-blocking layer 60, a metal sheath 70, a non-metal sheath 80, an inner lining layer 90, a mixed armor layer 100 and an outer sheath layer 110 which are sequentially arranged from inside to outside, the water-blocking conductor 10, the first semiconductive water-blocking layer 20, the conductor shielding layer 30, the XLPE insulating layer 40, the insulation shielding layer 50, the second semiconductive water-blocking layer 60, the metal protection layer 70 and the nonmetal protection layer 80 form a protection layer wire core, and the XLPE insulating layer 40 is made of degassing-free cross-linked polyethylene insulating material (Dow chemical HFDD-4201 SC).
This synchronous production system of establishing ties specifically includes along the horizontal unwrapping wire carousel 1, first reverse wheel 2, traction wheel 3, three-layer coextrusion plastic extruder 4, second reverse wheel 5, heater 6, around chartered plane 7, first tractor 8, crowded lead machine 9, pitch coating machine 11, plastic extruder 12, segmentation cooling trough 13, laser meter register 14, second tractor 15 and the horizontal line carousel 16 of receiving that production line direction set up in proper order.
The horizontal paying-off turntable 1 and the horizontal take-up turntable 16 respectively have an active paying-off function and an active take-up function, in the use process, the horizontal paying-off turntable 1 puts out a water-blocking conductor 10 wrapped by a first semi-conductive water-blocking layer 20, the water-blocking conductor 10 is pulled to a three-layer co-extrusion plastic extruder 4 through a first reversing wheel 2 and a traction wheel 3 to extrude, vulcanize, crosslink and cool a conductor shielding layer 30, an XLPE insulating layer 40 and an insulating shielding layer 50, the second reversing wheel 5 is pulled to a heater 6 to carry out secondary heating after cooling, the second semi-conductive water-blocking layer 60 is lapped and wrapped by a lapping machine 7, the first traction machine 8 is pulled to a lead extruding machine 9 to extrude and wrap a metal sheath 70, and the asphalt coating machine 11 and the plastic extruder 12 carry out thermal extrusion and wrapping of a non-metal sheath 80, after hot extrusion coating, the material is cooled to normal temperature through the sectional cooling water tank 13, then the laser rice recorder 14 is used for printing characters and recording rice, and after the characters and the rice are printed, the material is pulled into the horizontal take-up turntable 16 through the second tractor 15 to be arranged in a cable and taken up.
Specifically, the first tractor 8 and the second tractor 15 are both crawler-type tractors; the heater 6 is an annular high-frequency heater; the horizontal paying-off turntable 1 and the horizontal take-up turntable 16 are both provided with cable winding displacement devices.
Specifically, a plurality of steering guide wheels and carrier rollers are arranged in the whole production line from the horizontal paying-off turntable 1 to the horizontal take-up turntable 16, so that the work of long-distance wire core circulation is guaranteed.
The series synchronous production system has a linkage control function, the production speed of cable cores in each device is kept synchronous and continuous production is realized, the degassing process between the traditional cross-linking and wrapping process and the sheath extrusion process of the large-length XLPE submarine cable is eliminated through the application of a degassing-free XLPE insulating material and the optimization of the process flow, the continuous production is completed through the production line by the structures of the conductor shielding layer 30, the XLPE insulating layer 40, the insulating shielding layer 50, the second semi-conductive water-blocking layer 60, the metal sheath 70 and the non-metal sheath 80 in one step, the repeated circulation and multiple step production in the middle process are eliminated, the whole production period can be shortened by 30-50% compared with the original sea cable production process, the energy consumption is reduced, the production efficiency is improved, and the productivity is improved and the delivery requirements of customers are met.
Based on the series synchronous production system, the invention also provides a series synchronous production process for eliminating the gas submarine cable, which adopts the series synchronous production system and specifically comprises the following steps:
step 1, the horizontal paying-off turntable 1 pays off a water-blocking conductor 10 wrapped with a first semi-conductive water-blocking layer 20, the water-blocking conductor 10 is pulled to a three-layer co-extrusion plastic extruder 4 through a first reversing wheel 2 and a traction wheel 3, and the conductor shielding layer 30, an XLPE insulating layer 40 and an insulating shielding layer 50 are formed by extrusion, vulcanization crosslinking and cooling on the outer side of the first semi-conductive water-blocking layer 20 through the three-layer co-extrusion plastic extruder 4 to form a crosslinked wire core; and the cooled crosslinked wire core is pulled to the heater 6 through the second reversing wheel 5 to be heated for the second time, so that the decomposition of byproducts in the XLPE insulating layer 40 is accelerated.
Specifically, the heating temperature of the secondary heating is 85-95 ℃, and the decomposition of byproducts in the gas insulated wire core is further accelerated to be avoided. When the insulated wire core starts to produce, a 1m wire core is sampled from the end part, and the crosslinking degree, the interface condition and the byproduct content of the gas insulated crosslinked wire core are verified to meet the requirements of relevant standards by means of a thermal extension test, a silicone oil boiling test and a gas chromatography test.
Specifically, the XLPE insulating layer 40 is made of a degassing-free cross-linked polyethylene insulating material (tao shi chemical HFDD-4201SC), for example, a submarine cable with 18km 220kV (3 × 1000 cross section), and the content of the extruded cross-linked byproducts such as methane is less than 100ppm after being tested, so that the insulating property is not affected, the degassing process of the insulating byproducts, which is time-consuming and long in the conventional production process, can be directly removed, the fuel power and investment cost of drying room equipment required by the degassing process are reduced, and the manufacturing cost is significantly reduced.
Step 2, after the crosslinked wire core is heated for the second time, the second semi-conductive waterproof layer 60 is formed by lapping and covering the crosslinked wire core on the outer side of the crosslinked wire core by the lapping machine 7, then the second semi-conductive waterproof layer is formed by extruding and coating the outer side of the second semi-conductive waterproof layer 60 through the first traction machine 8, the asphalt coating machine 11 and the plastic extrusion machine 12 are used for extruding and coating the outer side of the metal protective layer 70 in a thermal state to form the non-metal protective layer 80, and then the segmented cooling water tank 13 is cooled to normal temperature to form the sheath wire core.
And 3, printing and marking rice on the non-metal protective layer 80 through the laser rice marker 14, and then pulling the sheath wire core into the horizontal take-up turntable 16 through the second tractor 15 to perform cable arrangement and take-up.
Specifically, after the production of the sheath wire core is finished, the series resonance voltage-withstanding test equipment is adopted for carrying out an alternating voltage test, the product is not broken down, the test voltage meets the standard requirements of related products, and the product performance of the gas-insulated power wire core is verified and avoided by the alternating voltage test means.
Specifically, the XLPE insulating layer 40 is made of an ultra-clean degassing-free crosslinked polyethylene insulating material with the material density of 0.93g/cm3The content of the cross-linked by-products after cross-linking extrusion is low, the insulating electrical performance is not affected, the content of the cross-linked by-products such as methane and the like in the XLPE insulating layer 40 after extrusion is less than 100ppm, the insulating by-product degassing process which consumes a long time in the conventional production process can be directly removed, the fuel power and the investment cost of drying room equipment required by the degassing process are reduced, and the manufacturing cost is obviously reduced.
Specifically, the water-blocking conductor 10 is formed by layering, pressing and twisting a plurality of section aluminum wires which areThe profile aluminum wire has a trapezoidal structure, is filled and coated with a seawater-proof water-blocking compound, the compression coefficient of the profile aluminum wire reaches more than 95%, and the resistivity of the profile aluminum wire at 20 ℃ is not more than 0.028264 omega mm2And/m. Compared with the conventional submarine cable adopting the structural design of the copper core conductor, the submarine cable can effectively reduce the weight and is beneficial to the construction and installation of the submarine cable in the large-water-depth environment. Water-blocking compound materials are adopted in gaps of the aluminum wire conductors of the profiles, and compared with conventional water-blocking tape materials, the applicable water depth can be increased to 2000m, and the water-blocking performance requirement of the submarine cable with large water depth is met.
The series synchronous production process adopts a series synchronous production system with a linkage control function, the production speed of cable cores in each device is kept synchronous and continuous production, the structures of the conductor shielding layer 30, the XLPE insulating layer 40, the insulation shielding layer 50, the second semi-conductive waterproof layer 60, the metal protective layer 70 and the non-metal protective layer 80 are continuously produced at one time through a production line, repeated circulation and multiple step-by-step production in the middle process are eliminated, the degassing process between the traditional large-length XLPE submarine cable crosslinking and wrapping process and the protective layer extrusion process is eliminated through the application of a degassing-free XLPE insulating material, the whole production period can be shortened by 30-50% compared with the original submarine cable production process, the productivity is favorably improved, and the delivery requirements of customers are favorably met. And by optimizing the structural design of the submarine cable, the water blocking performance requirement of the water blocking conductor is improved, the weight of the submarine cable is reduced, and the engineering application of the submarine cable with large length, large water depth and high pressure is met, so that the problems of low water depth, low degassing efficiency of the large length and long production period of the conventional submarine cable are solved.
The above description is only for the specific embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the appended claims.
Claims (10)
1. An air-free submarine cable comprises a water-blocking conductor (10), a first semi-conductive water-blocking layer (20), a conductor shielding layer (30), an XLPE insulating layer (40), an insulating shielding layer (50), a second semi-conductive water-blocking layer (60), a metal protective layer (70) and a non-metal protective layer (80) which are arranged in sequence from inside to outside; the XLPE insulating layer is characterized in that the XLPE insulating layer (40) is made of a degassing-free cross-linked polyethylene insulating material, and after the XLPE insulating layer (40) is cross-linked and extruded, the content of cross-linking byproducts is less than 100 ppm.
2. The gas-free submarine cable according to claim 1, wherein the water-blocking conductor (10) is formed by layering, compacting and stranding a plurality of profile aluminum wires, wherein the profile aluminum wires are in a trapezoidal structure, the compacting coefficient of the profile aluminum wires reaches more than 95%, and the electrical resistivity of the profile aluminum wires at 20 ℃ is not more than 0.028264 Ω -mm2/m。
3. The airless submarine cable according to claim 2, wherein in the water-blocking conductor (10) the profiled aluminum wire interstitial filling is coated with a sea-water-blocking type water-blocking compound.
4. The airless submarine cable according to claim 1, further comprising an inner liner (90), a hybrid armor (100), and a jacket (110) disposed sequentially from inside to outside on the non-metallic sheath (80).
5. The airless submarine cable according to claim 4, wherein the hybrid armor (100) has armor wires (103) and non-metallic wires (102) spaced apart and combined with a plurality of optical units (101).
6. The series synchronous production system for producing the airless submarine cable according to claim 1, which comprises a horizontal pay-off turntable (1), a first reversing wheel (2), a traction wheel (3), a three-layer co-extrusion plastic extruder (4), a second reversing wheel (5), a heater (6), a wrapping machine (7), a first tractor (8), a lead extruding machine (9), an asphalt coating machine (11), a plastic extruder (12), a sectional cooling water tank (13), a laser meter recorder (14), a second tractor (15) and a horizontal take-up turntable (16) which are sequentially arranged in series along the production line direction.
7. The in-line synchronous production system according to claim 6, wherein the first tractor (8) and the second tractor (15) are both crawler-type tractors; the heater (6) is an annular high-frequency heater; horizontal unwrapping wire carousel (1) and horizontal receipts line carousel (16) possess the initiative unwrapping wire function respectively and receive the line function in the initiative, horizontal unwrapping wire carousel (1) and horizontal receipts line carousel (16) all are equipped with the cable winding displacement ware.
8. The series synchronous production system of claim 6, wherein a plurality of steering guide wheels and carrier rollers are further arranged in the whole production line between the horizontal pay-off turntable (1) and the horizontal take-up turntable (16).
9. A process for the in-line synchronous production of gas-free submarine cables, characterized in that use is made of the in-line synchronous production system according to any one of claims 6 to 8, comprising the following steps:
step 1, a water-blocking conductor (10) coated with a first semi-conductive water-blocking layer (20) is discharged by the horizontal pay-off turntable (1), the water-blocking conductor (10) is pulled to the position of a three-layer co-extrusion plastic extruder (4) through a first reversing wheel (2) and a traction wheel (3), and the conductor shielding layer (30), an XLPE insulating layer (40) and an insulating shielding layer (50) are formed by extruding, vulcanizing, crosslinking and cooling the outer side of the first semi-conductive water-blocking layer (20) through the three-layer co-extrusion plastic extruder (4) to form a crosslinked wire core; the cooled crosslinked wire core is pulled to a heater (6) through a second reversing wheel (5) to be heated for the second time, so that the decomposition of byproducts in the XLPE insulating layer (40) is accelerated;
step 2, after the crosslinked wire core is heated for the second time, lapping and wrapping the crosslinked wire core by the wrapping machine (7) to form the second semi-conductive waterproof layer (60), then pulling the crosslinked wire core to the lead extruding machine (9) by the first tractor (8) to extrude and wrap the second semi-conductive waterproof layer (60) to form the metal protective layer (70), extruding and wrapping the metal protective layer (80) at the outer side of the metal protective layer (70) in a thermal state by the asphalt coating machine (11) and the plastic extruder (12) to form the non-metal protective layer (80), and then cooling the non-metal protective layer to the normal temperature by the sectional cooling water tank (13) to form a sheath wire core;
and 3, printing words and marking rice on the non-metal protective layer (80) through the laser meter marker (14), and then pulling the sheath wire core into the horizontal take-up turntable (16) through the second tractor (15) to perform cable arrangement and take-up.
10. The tandem synchronous production process according to claim 9, wherein the heating temperature for the secondary heating of the crosslinked wire core in the step 1 is 85-95 ℃.
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