CN116487099A - 一种提高交联聚乙烯绝缘电力电缆阻水性的方法 - Google Patents
一种提高交联聚乙烯绝缘电力电缆阻水性的方法 Download PDFInfo
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Abstract
本发明属于电线电缆技术领域,尤其涉及一种提高交联聚乙烯绝缘电力电缆阻水性的方法,包括位于内部绞合的导体单元,包覆在外从里向外依次排列的阻水绕包带、聚乙烯隔离套、连锁铠装层、聚乙烯外护套,本发明综合材料阻水和结构组数的优点,大大提升电缆的使用寿命和运行可靠性,金属铠装层采用皱纹铝合金带联锁铠装而成,铠装层不仅具有保护电缆的作用,同时还具备作为径向防水层提升电缆防水性能和增加电缆弯曲性的优点;隔离层和外护层均由铝塑复合带和聚乙烯材料组合而成,一方面可显著提升电缆阻水性能,另一方面这两种材料密度低,不增加电缆本体重量便于使用,同时还具备较好的机械性能和易加工等特性。
Description
技术领域
本发明属于电线电缆技术领域,尤其涉及一种提高交联聚乙烯绝缘电力电缆阻水性的方法。
背景技术
交联聚乙烯绝缘电缆因其良好的电气和机械物理性能在电力系统中得到广泛的应用,然而电缆通常采用直埋、电缆沟、隧道等敷设方式,难免与水直接接触,甚至会短期或长期浸泡在水中,致使水分慢慢渗透到电缆内部。潮气或水分渗入电缆后,交联聚乙烯绝缘在运行电压下生成水树枝,当水树枝生长到一定程度会产生尖端放电,最终导致电缆绝缘层击穿,缩短电缆寿命,严重影响电网的安全运行。因此,电缆阻水技术对于保证交联聚乙烯绝缘电缆的运行可靠性和提升使用寿命具有非常重要的意义,进行提高交联聚乙烯绝缘电缆阻水性能的技术研究是十分必要的。
目前,市面上阻水电缆通常分为两大类:材料阻水和结构阻水。材料阻水是指绝缘料采用防水树型材料,虽然可以防止水树产生,但忽略了水分浸入电缆后引发导体氧化后电阻增大引发电缆发热、金属铠装层生锈腐蚀电缆等诸多不利影响。结构阻水一般指径向阻水,大多采用金属套,虽然效果很好,但影响电缆的弯曲性能且增加本体重量,生产成本高,不利于大面积推广。为克服现有产品和技术的不足,现通过对交联聚乙烯绝缘电力电缆阻水性能的技术研究,发明出一种可显著提高交联聚乙烯绝缘电力电缆阻水性能的全阻水技术。经工艺试制,在没有显著提升电缆成本及重量的前提下,全阻水型电力电缆的阻水性能不仅可以满足相关标准要求,同时保留了电缆优异的电气和机械性能,大大提升了电缆使用寿命,可满足排水不畅或长期浸在水中等较为苛刻的运行环境。
发明内容
本发明的目的是提供一种提高交联聚乙烯绝缘电力电缆阻水性的方法。
为达到上述目的,本发明采用的技术方案是:
一种交联聚乙烯绝缘电力电缆,包括位于内部绞合的导体单元,包覆在外从里向外依次排列的阻水绕包带、聚乙烯隔离套、连锁铠装层、聚乙烯外护套。
进一步的,所述导体单元包括位于中心的导体,依次包覆于导体外的导体屏蔽层、交联聚乙烯绝缘层、绝缘屏蔽层、半导电阻水层、铜带屏蔽层。
进一步的,所述导体单元之间阻水绕包带内部空间还填充有阻水绳。
一种提高交联聚乙烯绝缘电力电缆阻水性的方法,包括以下步骤:
S1.导体绞制:导体绞制采用分层紧压成型,紧压模为钻石涂层纳米模,紧压系数不小于0.9,绞制中导体除外层和中心线外分层绕包半导电阻水带;
S2.导体屏蔽、绝缘、绝缘屏蔽三层共挤:绝缘采用抗水树型交联聚乙烯,将绝缘偏心度控制在10%以内,绝缘屏蔽的可剥离半导电屏蔽料,剥离力不小于20N,在交联绝缘三层共挤生产过程中,加热管中的氮气纯度在99.5%以上,氮气压力为1MPa;
S3.半导电阻水带绕包:绝缘线芯外绕包一层半导电阻水带,包带重叠率在带宽的20%,半导电阻水带抗张强度≥30N/cm2,延伸率≥12%,含水率≤9%,长期稳定性90℃,瞬间稳定性230℃,膨胀速度≥8mm/1min,膨胀高度≥12mm/3min,表面电阻≥1500Ω,体积电阻≥1×105Ω·cm;
S4.加装金属屏蔽层:用一层厚度0.1mm的铜带重叠绕包,重叠率不小于带宽的15%;
S5.成缆及填充:线芯成缆时节径比在25-30,绞向为右向,缆芯中心及边缘均采用阻水绳填充密实,缆芯外绕包两层0.5mm的阻水带,阻水带重叠绕包,重叠率为带宽的15%-30%,成缆所用填充数量应以不圆度不大于10%为准;
S6.挤包隔离套:挤包隔离套前缆芯纵包一层铝塑复合带,厚度为0.15-0.25mm,搭盖宽度大于6mm,用热风枪加温对重叠处进行熔胶焊接,挤包的隔离套选用中密度聚乙烯材料,标称厚度为1.4-2.0mm,其最薄点厚度应不小于标称厚度的80%-0.2mm,挤塑螺杆转速在25r/min以内,各段温度在130-175℃;
S7.加装金属铠装层:采用0.5-0.7mm的皱纹铝合金带联锁铠装而成金属铠装层,金属铠装层外绕包两层0.5mm阻水带,阻水带重叠绕包,重叠率控制在带宽的10%-30%;
S8.挤包外护套:电缆外护套采用高密度聚乙烯材料,标称厚度为(0.03D+1.0)mm,D为护套前直径,护套最薄点厚度应不小于标称厚度的80%-0.2mm,挤塑螺杆转速控制在25r/min以内,各段温度控制在130-175℃。
进一步的,所述步骤S1中阻水带中含有阻水粉,阻水粉配比是丙烯酸钠60-80份,单体丙烯酰胺20-40份,交联剂0.1-0.8份,引发剂0.1-0.6份,去离子水200份。
本发明具有的优点是:
1.本发明综合材料阻水和结构组数的优点,大大提升电缆的使用寿命和运行可靠性;
2.金属铠装层采用皱纹铝合金带联锁铠装而成,铠装层不仅具有保护电缆的作用,同时还具备作为径向防水层提升电缆防水性能和增加电缆弯曲性的优点;
3.隔离层和外护层均由铝塑复合带和聚乙烯材料组合而成,一方面可显著提升电缆阻水性能,另一方面这两种材料密度低,不增加电缆本体重量便于使用,同时还具备较好的机械性能和易加工等特性。
附图说明
图1是本发明结构示意图。
具体实施方式
如图1所示,一种交联聚乙烯绝缘电力电缆,包括位于内部绞合的导体单元,包覆在外从里向外依次排列的阻水绕包带7、聚乙烯隔离套8、连锁铠装层9、聚乙烯外护套10;所述导体单元包括位于中心的导体1,依次包覆于导体外的导体屏蔽层2、交联聚乙烯绝缘层3、绝缘屏蔽层4、半导电阻水层5、铜带屏蔽层6;所述导体单元之间阻水绕包带内部空间还填充有阻水绳11。
一种提高交联聚乙烯绝缘电力电缆阻水性的方法,包括以下步骤:
1.导体绞合
导体为符合GB/T 3956规定的退火铜线、铝线或铝合金线绞制而成,导体绞制采用分层紧压成型,保证了导体的紧密和结构稳定。紧压模为钻石涂层纳米模,紧压系数不小于0.9,绞制后导体表面光洁、无油污,无损伤屏蔽及绝缘的毛刺、锐边,无凸起或断裂的单线。绞制中导体除外层和中心线外分层绕包半导电阻水带,且不留空隙,其目的在于有效地抑制水分纵向浸入电缆导体内,起到了很好的阻水效果。
阻水带中的阻水粉应含有丙烯酸钠、单体丙烯酰胺、交联剂、引发剂和去离子水成分,其成分的重量配比是丙烯酸钠60-80份,单体丙烯酰胺20-40份,交联剂0.1-0.8份,引发剂0.1-0.6份,去离子水200份。
2.导体屏蔽、绝缘、绝缘屏蔽三层共挤
导体屏蔽、绝缘、绝缘屏蔽采用三层共挤生产线生产,导体进入机头前用纱布除去毛刺、灰尘等杂物,使导体表面光滑,保证屏蔽包覆质量。绝缘采用抗水树型交联聚乙烯生产,同时严格按工艺配模,配备在线测偏仪,将绝缘偏心度控制在10%以内。绝缘屏蔽采用可剥离半导电屏蔽料,剥离力不小于20N。
在交联绝缘三层共挤生产过程中,应采用空气净化室加料,保证材料的清洁度。加热管中的氮气纯度应在99.5%以上,否则会导致绝缘老化变色,甚至会使绝缘表面硬化龟裂。生产中应定时排放废氮气机交联副产物,保持氮气压力在1MPa,压力过大会导致导体屏蔽内镶嵌,损伤绝缘甚至造成击穿,压力过小则不能保证绝缘表面外观质量,造成电缆不圆整。线芯生产完成后,应在自然环境内存放至少2天,在去气的同时也消除了绝缘内应力。
3.半导电阻水带绕包
绝缘线芯外绕包一层半导电阻水带,包带重叠率控制在带宽的20%左右。
半导电阻水带抗张强度≥30N/cm2,延伸率≥12%,含水率≤9%,长期稳定性90℃,瞬间稳定性230℃,膨胀速度≥8mm/1min,膨胀高度≥12mm/3min,表面电阻≥1500Ω,体积电阻≥1×105Ω·cm。
4.金属屏蔽
由于电力系统对电缆运行安全性要求很高,电缆采用消弧线圈接地时,接地故障电流较大,因此金属屏蔽也是保证电缆质量的关键之一。金属屏蔽采用一层厚度0.1mm的铜带重叠绕包,重叠率不小于带宽的15%。绕包时注意调整绕包角度和绕包张力,同时可在绕包前后加装比绝缘线芯大1.5-2.0mm的尼龙模来克服线芯摆动,避免绕包时铜带起皱或擦伤线芯。
5.成缆及填充
线芯成缆时节径比控制在25-30,绞向为右向,缆芯中心及边缘均采用阻水绳填充密实,缆芯外绕包两层0.5mm的阻水带,阻水带重叠绕包,重叠率为带宽的15%-30%。成缆所用填充数量应以保持电缆圆整为准,不圆度不大于10%。
6.隔离套
挤包隔离套前缆芯纵包一层铝塑复合带,厚度为0.15-0.25mm,搭盖宽度应大于6mm,用热风枪加温对重叠处进行熔胶焊接。挤包的隔离套选用中密度聚乙烯材料,标称厚度为1.4-2.0mm,其最薄点厚度应不小于标称厚度的80%-0.2mm。挤塑螺杆转速控制在25r/min以内,各段温度控制在130-175℃,挤塑温度以塑化良好且断面无气孔为准。铝塑复合带和聚乙烯隔离套组成综合防水层,该结构每天单位面积水分渗透量为(0.05-0.1)×10-8(g/cm2),远低于单一聚乙烯材料每天单位面积水分渗透量28×10-8(g/cm2),其径向阻水性能优异。
7.金属铠装层
金属铠装层采用0.5-0.7mm的皱纹铝合金带联锁铠装而成,联锁铠装层在整个电缆长度上是连续的,不能有任何损伤电缆铠装层下面和上面护层的毛刺、尖边、凹痕、裂缝或其他裂痕。铝合金带可以接头,接头不应显著地增大带子的宽度或厚度,也不能降低铝合金带的机械强度或对成形后的铠装层造成有害的影响,且不能有任何切口或断裂。皱纹铝合金带联锁铠装结构不仅进一步提升了电缆径向阻水的性能,而且保证了电缆的弯曲性能。
金属铠装层外绕包两层0.5mm阻水带,阻水带重叠绕包,重叠率控制在带宽的10%-30%。绕包后包带应平整,不起皱。
8.外护套
电缆外护套采用高密度聚乙烯材料,标称厚度为(0.03D+1.0)mm,D为护套前直径,护套最薄点厚度应不小于标称厚度的80%-0.2mm。挤塑螺杆转速控制在25r/min以内,各段温度控制在130-175℃,挤塑温度以塑化良好且断面无气孔为准。
9.阻水试验
电缆径向阻水试验:常温下,将电缆浸入水中,电缆两端头露出水面,72h后电缆绝缘表面应干燥无水分;电缆纵向阻水试验:取一端至少长6m的电缆,按照GB/T12706.2-2020中附录F要求进行透水试验,在整个试验期间,两端应无水分渗出。
Claims (5)
1.一种交联聚乙烯绝缘电力电缆,其特征在于:包括位于内部绞合的导体单元,包覆在外从里向外依次排列的阻水绕包带、聚乙烯隔离套、连锁铠装层、聚乙烯外护套。
2.如权利要求1所述的交联聚乙烯绝缘电力电缆,其特征在于:所述导体单元包括位于中心的导体,依次包覆于导体外的导体屏蔽层、交联聚乙烯绝缘层、绝缘屏蔽层、半导电阻水层、铜带屏蔽层。
3.如权利要求2所述的交联聚乙烯绝缘电力电缆,其特征在于:所述导体单元之间阻水绕包带内部空间还填充有阻水绳。
4.如权利要求1-3任一所述的提高交联聚乙烯绝缘电力电缆阻水性的方法,其特征在于,包括以下步骤:
S1.导体绞制:导体绞制采用分层紧压成型,紧压模为钻石涂层纳米模,紧压系数不小于0.9,绞制中导体除外层和中心线外分层绕包半导电阻水带;
S2.导体屏蔽、绝缘、绝缘屏蔽三层共挤:绝缘采用抗水树型交联聚乙烯,将绝缘偏心度控制在10%以内,绝缘屏蔽的可剥离半导电屏蔽料,剥离力不小于20N,在交联绝缘三层共挤生产过程中,加热管中的氮气纯度在99.5%以上,氮气压力为1MPa;
S3.半导电阻水带绕包:绝缘线芯外绕包一层半导电阻水带,包带重叠率在带宽的20%,半导电阻水带抗张强度≥30N/cm2,延伸率≥12%,含水率≤9%,长期稳定性90℃,瞬间稳定性230℃,膨胀速度≥8mm/1min,膨胀高度≥12mm/3min,表面电阻≥1500Ω,体积电阻≥1×105Ω·cm;
S4.加装金属屏蔽层:用一层厚度0.1mm的铜带重叠绕包,重叠率不小于带宽的15%;
S5.成缆及填充:线芯成缆时节径比在25-30,绞向为右向,缆芯中心及边缘均采用阻水绳填充密实,缆芯外绕包两层0.5mm的阻水带,阻水带重叠绕包,重叠率为带宽的15%-30%,成缆所用填充数量应以不圆度不大于10%为准;
S6.挤包隔离套:挤包隔离套前缆芯纵包一层铝塑复合带,厚度为0.15-0.25mm,搭盖宽度大于6mm,用热风枪加温对重叠处进行熔胶焊接,挤包的隔离套选用中密度聚乙烯材料,标称厚度为1.4-2.0mm,其最薄点厚度应不小于标称厚度的80%-0.2mm,挤塑螺杆转速在25r/min以内,各段温度在130-175℃;
S7.加装金属铠装层:采用0.5-0.7mm的皱纹铝合金带联锁铠装而成金属铠装层,金属铠装层外绕包两层0.5mm阻水带,阻水带重叠绕包,重叠率控制在带宽的10%-30%;
S8.挤包外护套:电缆外护套采用高密度聚乙烯材料,标称厚度为(0.03D+1.0)mm,D为护套前直径,护套最薄点厚度应不小于标称厚度的80%-0.2mm,挤塑螺杆转速控制在25r/min以内,各段温度控制在130-175℃。
5.如权利要求4所述的提高交联聚乙烯绝缘电力电缆阻水性的方法,其特征在于:所述步骤S1中阻水带中含有阻水粉,阻水粉配比是丙烯酸钠60-80份,单体丙烯酰胺20-40份,交联剂0.1-0.8份,引发剂0.1-0.6份,去离子水200份。
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